1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you scaling your alluvial or eluvial gold operation and finding that your washing and recovery processes are the bottleneck? Gérer un 500 Le débit TPH présente des défis distincts qui ont un impact direct sur vos résultats. Les obstacles opérationnels courants comprennent:
Flux incohérent & Teneur élevée en argile: Variable material composition leads to screen blinding, reduced scrubbing efficiency, and significant downtime for manual cleaning, coûtant des centaines d'heures de production par an.
Inefficient Fines Gold Recovery: Standard sluices or jigs struggle with fine gold particles in a highvolume slurry, resulting in measurable metal losses that accumulate over thousands of tons processed.
Hautes eaux & Consommation d'énergie: Legacy washing plants are not optimized for specific energy consumption per ton, leading to unsustainable operational costs and limiting viable deposit locations.
Usure rapide & Charge d'entretien: Aggressive, hightonnage processing accelerates wear on scrubber drums, ponts d'écran, and pump systems, creating unpredictable maintenance cycles and spare parts costs.
Évolutivité limitée & Mobilité: Fixed plant designs cannot adapt to shifting pit faces or new site locations without major capital expenditure and commissioning delays.

Is your current setup causing you to lose gold to tailings or constraining your expansion plans? The solution requires a system engineered not just for volume, but for optimal recovery and operational cost control at an industrial 500 Échelle TPH.

2. APERÇU DU PRODUIT

The Industrial 500 L'usine de lavage de TPH Gold Mining est une installation complète, système de traitement modulaire conçu pour le lavage primaire, lavage, dépistage, and gravity concentration of goldbearing alluvial or hard rock feed material. Il se transforme brut, unclassified ore into concentrated heavy mineral product for final extraction.

Flux de travail opérationnel:
1. Alimentation principale & Lavage: Runofmine (ROM) le matériau est introduit dans un épurateur à trommel robuste ou un épurateur rotatif, where it is aggressively cleaned and clay matrices are broken apart.
2. Dimensionnement & Classification: Le matériau lavé est tamisé (typically via trommel screen or vibrating screen) to separate oversize waste rock. The undersize slurry reports to the primary concentration stage.
3. Concentration gravitationnelle primaire: Highcapacity centrifugal concentrators (par ex., Knelson or Falcon type) or optimized sluice systems capture fine and coarse gold from the screened slurry with high efficiency.
4. Gestion des résidus & Gestion de l'eau: Waste tailings are conveyed to a settling area or further processing, while process water is recirculated via a clarified water pond system to minimize fresh water requirements.

Champ d'application & Limites:
Portée: Idéal pour les dépôts alluviaux/placeurs, eluvial materials, and weathered hard rock ores where liberation occurs through washing and attrition. Suited for largescale mining operations requiring high availability.
Limites: Not designed for primary crushing of hard rock lode deposits or chemical leaching processes. Performance is contingent on proper feed size distribution (<150mm typique) and requires a consistent water source.

3. CARACTÉRISTIQUES PRINCIPALES

Conception de patins modulaires | Base technique: Preengineered structural steel skids with integrated wiring and piping | Avantage opérationnel: Réduit le temps d'installation sur site jusqu'à 60%, allows for phased deployment or relocation | Impact sur le retour sur investissement: Lower capital installation costs and future redeployment value protect investment.

Épurateur à trommel robuste | Base technique: Highinertia design with internal lifters and optimized water spray bars | Avantage opérationnel: Effectively disintegrates claybound aggregates with minimal screen blinding, assurer une cohérence 500 Débit TPH | Impact sur le retour sur investissement: Maximizes uptime by reducing stoppages for cleaning; improves overall recovery by fully liberating gold particles.

Advanced Centrifugal Concentration Circuit | Base technique: Multiunit array of continuousdischarge centrifugal concentrators for highvolume feed | Avantage opérationnel: Réalise +95% recovery rates on fine gold (100 engrener) from primary feed in a single pass | Impact sur le retour sur investissement: Directly increases revenue by capturing gold previously lost to tailings; reduces need for secondary scavenging plants.

Intelligent Process Water Management | Base technique: Integrated cyclones and settling tanks with variablespeed pump drives | Avantage opérationnel: Recircule jusqu'à 85% d'eau de procédé; maintains optimal slurry density for concentration equipment | Impact sur le retour sur investissement: Drastically reduces freshwater consumption and associated pumping costs; minimise l’empreinte environnementale.

Système de contrôle PLC centralisé | Base technique: Programmable Logic Controller with HMI touchscreen monitoring motor loads, taux d'avance, et pressions de pompe | Avantage opérationnel: Enables precise control of the entire plant by a single operator; provides realtime diagnostics and fault alerts | Impact sur le retour sur investissement: Lowers labor costs per ton processed; enables predictive maintenance to avoid catastrophic failures.

Ensemble de doublure résistante à l'abrasion | Base technique: Wear plates lined with chromium carbide or replaceable rubber modules in highimpact zones | Avantage opérationnel: Extends service life of critical components like scrubber drums, blanchisseurs, and pump volutes in abrasive environments | Impact sur le retour sur investissement: Réduit les dépenses annuelles en pièces de rechange d’environ 3040% versus standard mild steel.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (500 Usine TPH) | Notre 500 Solution pour usine de lavage TPH | Avantage (% Amélioration) |
| : | : | : | : |
| Taux de récupération de l'or fin (100 engrener) | 7585% (traditional sluices) | >95% (centrifugal circuit) | +1020% Récupération |
| Total Installed Power Consumption (kW) ~9001100 kW ~750850 kW 1520% Consommation d'énergie |
| Average Water Consumption (m³/hour) ~8001000 m³/hr ~600700 m³/hr 2530% Water Use |
| Planned Downtime for Wear Part Replacement (heures/mois) ~4060 hours ~2436 hours 40% Temps d'entretien |
| Assemblage sur site & Commissioning Time ~1216 weeks ~68 weeks 50% Installation Period |

5. SPÉCIFICATIONS TECHNIQUES

Capacité nominale de traitement: 500 tonnes métriques par heure (base d'alimentation sèche).
Feed Size Specification: Accepts ROM material up to 150mm; optimal performance with feed <100mm.
Exigences d'alimentation: Charge totale connectée environ 750850 kW. Alimentation primaire recommandée à 1000 kVA, 400/690V et.
Besoins en eau: Circuit conçu pour la recirculation; fresh water topup typically requires 600700 m³/hour at head pressure >3 bar.
Spécifications des matériaux clés:
Coque de tambour d'épurateur: 20mm thick mild steel with bolton chromium carbide liners.
Structural Skids: Fabricated from highgrade S355JR steel.
Pompes à lisier: Heavyduty rubberlined or hard metal pumps with adjustable speed drives.
Dimensions physiques (Modulaire): Typical layout spans approx. 60m L x 25m W x 15m H. Each major skid module is transportable within standard road freight limits.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +50°C. Les systèmes de suppression de poussière sont standard; les niveaux de bruit sont conformes aux réglementations typiques des sites miniers (<85 dB at operator stations).

6. SCÉNARIOS D'APPLICATION

LargeScale Alluvial Gold Operation in West Africa

Défi: A major operator was experiencing severe clay blinding in their existing trommel screens at +400 Capacité TPH, provoquant des temps d'arrêt quotidiens. En outre, their tabling circuit was losing an estimated 15% of fine gold (<150 micron).
Solution: Implementation of our Industrial 500 TPH plant featuring an aggressive clay scrubber module followed by screening via polyurethane panels resistant to blinding. Primary recovery was handled by an array of continuous centrifugal concentrators.
Résultats: Screenrelated downtime was eliminated. Plant throughput consistently achieved design capacity of 500 TPH. Overall gold recovery increased by an audited +18%, paying back the capital investment in under 14 months based on incremental metal capture.

Eluvial Deposit Development in South America

Défi: A new project required a mobile processing solution capable of following the pit face across difficult terrain while maintaining strict environmental controls on water usage due to permit limitations.
Solution: Deployment of our modular skidmounted plant configured with an enhanced closedloop water clarification system using flocculant dosing units alongside the standard modules.
Résultats: The plant was relocated twice within the first year using heavy haul trucks without requiring disassembly beyond module separation—recommissioning took less than one week each time.The closedloop system reduced permitted freshwater draw from a projected >800 m³/hr down to <200 m³/hr total topup requirement

Considérations commerciales

Equipment pricing is structured around core configuration packages:

1\. Base Package ($2M$2M): Includes primary feeding hopper heavyduty trommel scrubber vibrating screen basic sluice run concentrate collection system essential walkways

2\. Package de récupération amélioré ($M$M): Upgrades Base Package replacing basic sluices with full centrifugal concentrator circuit includes necessary surge tanks distribution headers

3\. Complete Turnkey Plant ($M$M): Includes Enhanced Recovery Package plus integrated water management system PLC automation package all interconnecting conveyors electrical substation commissioning services

Fonctionnalités facultatives:
HighG Intensity Magnetic Separator module final concentrate upgrade
Ensemble de production d'énergie diesel embarqué
Remote monitoring satellite data uplink
Kit de démarrage de pièces de rechange

Forfaits de services:
Standard warranty months covering defects materials workmanship
Extended Service Plan years covering scheduled maintenance inspections priority technical support
Full Maintenance Contract fixed annual fee covering all labor parts excluding consumable wear liners

Options de financement:
Equipment leasing structures through partner financial institutions
Progress payment plans aligned manufacturing milestones
Rentalto own agreements available minimum month term

FAQ

What type deposit suitable this plant?
Designed primarily unconsolidated alluvial placer eluvial deposits where liberation occurs physical washing Effective weathered oxidized hard rock ores require minimal crushing Not suitable competent lode ore requiring extensive primary grinding

How handle variation feed grade clay content?
PLC control system allows operators adjust scrubber rotation speed water addition rates realtime maintain optimal slurry density Centrifugal concentrators feature automated concentrate flushing sequences prevent overload varying grade conditions

What typical workforce required operate plant?
Designed efficient operation central control station Single operator can manage entire process from feed discharge supported two general assistants ground inspections routine tasks Total personnel per shift typically three four individuals

Are components standardized sourcing spare parts?
Yes Critical wear components pumps motors bearings instrumentation use globally available ISO standard brands Structural fabrication adheres international design codes CAD drawings provided every part ensuring longterm supportability anywhere world

What lead time delivery commissioning?
Following order confirmation engineering lead time typically weeks Manufacturing assembly require months Shipping depends destination Final site commissioning supervised our engineers requires approximately weeks assuming site preparation complete