1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

La gestion d'une opération de traitement de l'or nécessite d'équilibrer le débit, taux de récupération, et les coûts opérationnels. Inconsistent or inefficient comminution directly impacts your bottom line. Êtes-vous confronté à ces défis persistants?

Temps d'arrêt opérationnel élevé: Changements fréquents de doublure, défaillances de roulements, and unplanned maintenance in your crushing circuit halt production. Industry averages indicate that unplanned downtime can cost between $10,000 à $50,000 par heure de perte de production et de main d'œuvre.
Libération d’or sous-optimale: Inadequate or inconsistent particle size reduction from primary crushing leads to poor gold exposure for leaching or concentration. This can leave a significant percentage of your resource unrecovered, réduisant directement les revenus.
Consommation d'énergie excessive: Older or poorly configured crushing equipment operates at low energy efficiency, making power one of your largest and most volatile cost centers.
Complexité de maintenance élevée & Coût: Equipment requiring specialized tools or extended shutdowns for servicing increases labor costs and extends periods of nonproduction.
Limites d'évolutivité: Inflexible equipment that cannot handle variable feed grades or increased throughput targets constrains your operation’s growth and adaptability.

The foundation of efficient mineral processing is reliable, highperformance primary crushing. The right equipment addresses these pain points directly.

2. APERÇU DU PRODUIT

The FDA Approved Stamp Mill is a specialized primary crushing unit engineered for the initial size reduction of goldbearing ore. Il est conçu comme un robuste, mechanical crusher where heavy stamps are lifted and dropped onto ore fed into a mortar box, fracturing the material through repeated impact.

Flux de travail opérationnel:
1. Présentation du flux: Runofmine (ROM) ore is fed into the sealed mortar box of the stamp mill.
2. Concassage mécanique: Camdriven stamps are sequentially lifted and dropped under gravity, pulvériser le minerai contre une matrice durcie.
3. Classement des tailles & Décharge: Crushed material passes through a screen grate at the base of the mortar box. Oversize material remains for further impact, while correctly sized material is discharged for subsequent processing (par ex., ball milling, lessivage).

Champ d'application & Limites:
Portée: Ideal for small to mediumscale gold mining operations, usines pilotes, and processing centers where simplicity, durabilité, and ease of maintenance are prioritized over ultrafine grinding. Effective on quartzrich and hard rock ores.
Limites: Non conçu comme une solution de broyage fin; output typically requires secondary milling. Throughput is generally lower than highcapacity jaw or gyratory crushers, making it less suitable for very largescale, opérations à fort tonnage.

3. CARACTÉRISTIQUES PRINCIPALES

HeavyDuty Cast Iron Frame | Base technique: Highcompression strength and vibration damping | Avantage opérationnel: Fournit une stabilité exceptionnelle sous charge cyclique, minimizing stress fractures and misalignment | Impact sur le retour sur investissement: Prolonge la durée de vie structurelle de plusieurs décennies, eliminating capital replacement costs

Interchangeable Hardened Steel Stamps & Meurt | Base technique: Use of highchrome alloy steel for abrasion resistance | Avantage opérationnel: Key wear components can be replaced individually without dismantling the entire mill head | Impact sur le retour sur investissement: Reduces part costs by 40% compared to full assembly replacement and cuts changeout downtime by over 60%

FDACompliant Sealed Mortar Box | Base technique: Contained crushing chamber with FDAapproved sealing gaskets and coatings | Avantage opérationnel: Prevents contamination of the ore product and contains dust particulates within the system | Impact sur le retour sur investissement: Ensures exportgrade material purity for direct shipping meets international standards

Modular Camshaft Design | Base technique: Independently mounted cam lobes for each stamp | Avantage opérationnel: Allows for individual stamp adjustment or removal without stopping adjacent units; simplifies maintenance | Impact sur le retour sur investissement: Increases overall plant availability; maintenance tasks can be performed by a twoperson crew

Système d'injection de graisse automatisé | Base technique: Centralized lubrication points with timerbased injection | Avantage opérationnel: Ensures consistent lubrication of camshaft bearings and lifters under highload conditions | Impact sur le retour sur investissement: Prouvé pour prolonger la durée de vie des roulements de plus de 200%, preventing catastrophic failure and associated downtime

Simplified Drive Train with VBelt Guarding | Base technique: Direct electric motor to flywheel coupling with industrial Vbelts | Avantage opérationnel: Easy tension adjustment; common spare parts; fully guarded for operator safety (OSHA/CE compliant) | Impact sur le retour sur investissement: Lowers maintenance skill requirements; reduces drive system repair costs by an average of 35%

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Anciennes usines de timbres) | FDA Approved Stamp Mill Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Temps moyen entre les pannes (MTBF)| ~500 operating hours on key bearings| 1,500+ operating hours on key bearings| +200% |
| Tolérance au métal clochard| High risk of die cracking or shaft damage| Integrated shearpin protection system activates on uncrushable objects| Réduit le risque de défaillance catastrophique d'un montant estimé 90% |
| Temps de changement de doublure| 1624 heures (équipage complet)| 68 heures (2personne équipage)| Downtime reduced by ~65% |
| Efficacité énergétique (kWh/tonne)| Varie considérablement; often undocumented| Field data shows consistent operation at ≤ 2.8 kWh/ton for 2" produit| Provides auditable baseline for up to 15% power cost savings |
| Dust Emission Containment| Open mortar boxes common leading to dust escape| Fully sealed chamber with negative pressure extraction port|< 5 mg/m³ at emission point |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de la gamme de modèles: 5 – 50 Tonnes par heure (TPH), en fonction de la dureté du minerai et de la taille du produit cible.
Exigences d'alimentation: 30 – 150 Entraînement par moteur électrique kW (400Norme V/50Hz ou 480V/60Hz). Configurations personnalisées disponibles.
Spécifications matérielles:
Cadre: Grade 25 Fonte
Timbres & Meurt: AISI 4140 Acier, HeatTreated to 4852 CRH
Revêtements de boîtes de mortier: HighCarbon Manganese Steel
Scellés & Gaskets: FDAapproved Nitrile Rubber
Dimensions physiques (Typique 20 Unité TPH): Longueur: 4.2m / Largeur: 2.8m / Hauteur: 3.1m / Environ. Poids: 12,000 kilos.
Plage de fonctionnement environnementale: Température ambiante: 10°C à +45°C / Humidity Tolerance Up to >95% sans condensation.

6. SCÉNARIOS D'APPLICATION

SmallScale Mining Cooperative in West Africa

Défi:: Need for a simpletooperate yet durable primary crusher capable of processing hard rock quartz veins without reliance on complex hydraulics or grid power.
Solution:: Installation of two modular FDA Approved Stamp Mills powered by dedicated diesel generators in a parallel configuration.
Résultats:: A atteint un débit constant de 18 TPH à 80% passage 2 engrener. La coopérative a signalé un 22% increase in overall gold recovery due to improved liberation from reliable primary crush size.

Usine pilote & Bulk Sampling Operation

Défi:: Required flexible crushing circuit capable of handling varied ore types from multiple test pits while producing uncontaminated samples for export assay analysis.
Solution:: Implementation of a single FDA Approved Stamp Mill as the primary crusher with integrated dust collection.
Résultats:: Enabled rapid switching between ore bodies with <4 hour washdown procedures between batches.
Exported samples consistently met stringent international assay lab purity requirements.

7 CONSIDÉRATIONS COMMERCIALES

Equipment pricing tiers are structured based on capacity and configuration:
Unité de base (<15 TPH): For pilot plants or auxiliary crushing.
Standard Production Unit (<1535 TPH): Includes automated lubrication and sealed mortar box.
HighCapacity Unit (<3550 TPH): Features enhanced discharge systems and premiumgrade bearings.

Fonctionnalités facultatives:
Variateur de fréquence ()for softstart capability
Integrated water spray system
Capteurs avancés de surveillance des vibrations
Stainless steel contact parts upgrade

Forfaits de services:
1) Garantie de base:
12 months parts coverage.
2) Extended Support Plan:
Includes annual inspection
, priority spare parts dispatch
,
3) Installation clé en main:
Supervised installation
, mise en service
,

Options de financement:
Capital expenditure can be structured through equipment leasing agreements
,

FAQ:

Q1 How does this integrate with my existing ball mill circuit?
A The stamp mill serves as your primary crusher
,

Q2 What is the lead time on wear parts like stamps?
A Due to standardized design
,

Q3 Are operators required?
A Operation is straightforward but does require trained personnel familiar with basic mechanical systems.

Q4 Can this process wet?
A The standard model handles nominal moisture but not slurry For sticky ores we recommend an optional scraper conveyor discharge

Q5 What does mean?
A This certification pertains specifically to materials contacting the crushed product ensuring they meet US Food Drug Administration standards This is critical when exporting concentrate

Q6 Is onsite installation support provided?
A Yes supervised installation commissioning are available under our service packages ensuring correct alignment foundation setup

Q7 What is expected energy consumption per ton?
A Based on silica quartz ore achieving minus mesh product typical specific energy consumption ranges from