1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you facing escalating operational costs and unpredictable recovery rates in your highvolume gold mining operation? Gérer un 500 Le débit TPH présente des défis distincts qui ont un impact direct sur vos résultats. Les points douloureux courants incluent:

Inconsistent Recovery in Variable Feed: Fluctuations de la teneur en argile, distribution granulométrique, and gold particle liberation can cause significant gold losses in standard scrubber and screen setups, leading to unrecoverable revenue.
Eau excessive & Consommation d'énergie: Traditional highcapacity washing plants often operate inefficiently, consuming millions of liters of water and substantial megawatthours annually, creating both environmental and cost burdens.
Temps d'arrêt pour maintenance élevé: Abrasive feed materials lead to rapid wear on critical components, resulting in unplanned shutdowns that halt 500 tons of production every hour they persist.
Difficulté à respecter la conformité environnementale: Managing slimes and process water for a plant of this scale is a complex operational hurdle, with potential for costly regulatory issues.

La question centrale pour les directeurs d'usine est: Comment pouvez-vous obtenir des résultats cohérents, high recovery rates at a 500 TPH scale while controlling operational expenditure and minimizing downtime? The solution requires a purposeengineered system, not just scaledup components.

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, classification, and concentration of alluvial or hard rock gold ores at mass scale. Its core function is to liberate gold from host material and concentrate it into a manageable stream for final recovery.

Flux de travail opérationnel:
1. Alimentation principale & Lavage: Runofmine (ROM) material is fed into a robust trommel or scrubber barrel, where it is aggressively agitated to break down clays and cemented aggregates.
2. Classification & Dimensionnement: The discharged material is screened into multiple fractions (par ex., oversize waste, midsize gravels for secondary concentration, et sables fins/limes).
3. Concentration gravitationnelle: The goldbearing midsize fraction is routed to highcapacity centrifugal concentrators (par ex., Knelson or Falcon type) pour séparer les minéraux lourds.
4. Gestion des résidus & Gestion de l'eau: Fine tailings (boues) are managed through a dedicated system, avec de l'eau de traitement clarifiée et recirculée pour minimiser la demande en eau douce.

Champ d'application & Limites:
Idéal pour: Largescale alluvial/elluvial deposits, freemilling ores where gold is liberated via scrubbing, and hightonnage contract mining operations.
Limites: Not suitable for refractory ores requiring chemical leaching or very fine (100 micron) gold without specialized downstream circuit additions. Feed size typically limited to <200mm.

3. CARACTÉRISTIQUES PRINCIPALES

Module d'épurateur robuste | Base technique: Système d'entraînement à couple élevé avec élévateurs internes | Avantage opérationnel: Ensures complete disintegration of claybound conglomerates and thorough ore washing. | Impact sur le retour sur investissement: Maximizes gold liberation at the front end, réduire les pertes dans les résidus; les données de terrain montrent un 515% improvement in overall recovery compared to undersized scrubbers.

MultiStage Vibrating Classification Deck | Base technique: Tiered screening surfaces with adjustable mesh panels | Avantage opérationnel: Precise separation of +10mm waste rock, 10mm2mm concentration feed, and 2mm slimes. | Impact sur le retour sur investissement: Optimizes feed to concentrators, reduces wear on downstream equipment, and improves water handling efficiency.

HighGForce Centrifugal Concentrator Array | Base technique: Batch or continuous discharge centrifuges generating up to 300 G | Avantage opérationnel: Capture les fines particules d'or jusqu'à 30 microns from the highvolume sand fraction with exceptional efficiency. | Impact sur le retour sur investissement: Delivers a primary concentrate significantly upgraded (souvent >1000:1), drastically reducing the volume for final cleaning stages.

Intelligent Process Water Recirculation System | Base technique: Settling ponds or clarifier tanks with automated pump controls | Avantage opérationnel: Recycle jusqu'à 90% d'eau de procédé; manages slime settling for stable operation. | Impact sur le retour sur investissement: Cuts fresh water consumption by millions of liters per day and reduces environmental licensing complexity.

Conception modulaire BoltTogether | Base technique: Preengineered skidmounted modules with standardized connections | Avantage opérationnel: Enables rapid onsite assembly and future plant reconfiguration or relocation. | Impact sur le retour sur investissement: Réduit le temps d'installation jusqu'à 40% compared to weldedsite builds, getting your operation to revenue faster.

Ensemble de doublure résistante à l'abrasion | Base technique: Highchrome cast iron or replaceable rubber liners in highwear zones | Avantage opérationnel: Extends service life in critical flow areas subject to abrasive sands and gravels. | Impact sur le retour sur investissement: Lowers spare parts consumption and extends maintenance intervals by 3050%, directly reducing operating cost per ton.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme industrielle pour 500 Usines TPH | Our Industrial Washing Plant Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Taux global de récupération de l’or| 8592% (variable feed) | Cohérent 9397% (with optimized feed) | +5% augmentation moyenne |
| Consommation d'eau douce| ~1500 m³/operating hour | <300 m³/operating hour (with recirc.)| Jusqu'à 80% réduction |
| Temps moyen entre les pannes (Pièces d'usure critique)| ~500750 hours| 10001200 heures| +60% amélioration |
| Installation sur site & Temps de mise en service| 812 semaines| 57 semaines| ~40% de réduction |
| Efficacité énergétique (kWh par tonne traitée)| Varie considérablement; souvent non optimisé| Engineered drive systems reduce draw by ~15%| Jusqu'à 15% amélioration |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de conception: 500 tonnes métriques par heure (base d'alimentation sèche).
Taille de l'alimentation: Accepts material up to 200mm; optimal feed <150mm.
Exigences d'alimentation: Environ. 8501100 kVA charge totale connectée, dépend de la configuration (scrubber drive, concentrateurs, pompes).
Besoins en eau: Initial fill of approx. 250 m³; makeup water typically <300 m³/hr with closedcircuit recycling.
Spécifications matérielles:
Tambour de récurage: Mild steel shell with AR400 liners.
Chutes & Blanchisseurs: AR400 steel or HDPE.
Plateformes de criblage: Panneaux modulaires en polyuréthane ou en caoutchouc.
Concentrateurs: Stainless steel/Ceramic wear parts.
Dimensions physiques (Modulaire): Surface au sol typique d'environ 40 m de longueur x 20 m de largeur x 12 m de hauteur; exact layout is configurable.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +50°C; enceintes anti-poussière et anti-bruit disponibles.

6. SCÉNARIOS D'APPLICATION

LargeScale Alluvial Mining Operation in West Africa

Défi: A contract miner needed consistent throughput on a highly variable saprolitic clay ore with nuggety gold distribution. Their existing plant experienced frequent blockages and inconsistent concentration performance.
Solution: Implementation of our Industrial Washing Plant featuring an extralong scrubber module for maximum clay breakdown followed by precise screening onto two parallel banks of centrifugal concentrators.
Résultats: A atteint un débit soutenu de 480 TPH with overall plant availability exceeding 92%. Recovery rates stabilized at 95%, yielding an estimated additional 18kg of gold recovered per month versus the prior setup.

HighVolume Eluvial Deposit Processing in Mongolia

Défi: An operator faced severe water scarcity constraints while processing 400 TPH of gravels from an ancient river terrace.
Solution: Deployment of our plant configured with an oversized water recirculation system including deep cone thickeners for maximum water recovery.
Résultats: Freshwater consumption was reduced from an estimated 600 m³/hr requirement to less than 80 m³/hr makeup water (87% réduction). This allowed the project license requirements while maintaining target throughput.

7. CONSIDÉRATIONS COMMERCIALES

Our Industrial Washing Plants are offered under three primary tiers:

1. Paquet de configuration standard ($X.XM – $X.XM): Includes core modules—feed hopper/scrubber/screen deck/concentrator array/tailings handling—for turnkey operation on standard ore types.
2 Customized Configuration Package (+15–30%): Modifications for specific ore characteristics (par ex., higher clay content requiring log washers), extreme climates (30°C arctic packages), or specific regulatory requirements.
3 Fonctionnalités facultatives:
Contrôle automatisé & Monitoring SCADA System
Ensembles de production d'énergie embarqués
Secondary security concentrate handling systems

Forfaits de services:
Mise en service & Formation des opérateurs
Annual Preventative Maintenance Plans
Guaranteed Spare Parts Availability Programs

Options de financement:
We work with international export credit agencies as well as project finance partners who understand capital equipment needs within the mining sector offering leasetopurchase structures over typical terms ranging from three years upwards depending upon project specifics

FAQ

Q1 Is this plant compatible with my existing crushing circuit?
A Yes The plant is designed as either standalone unit receiving ROM material via frontend loader or integrated into existing circuits It accepts conveyorfed material typically requiring only simple chute modifications

Q2 What kind operational staff required run this facility?
A Efficient operation requires one control room operator two field technicians performing routine checks per shift plus maintenance crew Mechanical complexity similar conventional plants same capacity but automation reduces manual intervention

Q3 How does handle particularly sticky highclay feeds?
A For extreme clays we recommend optional heavyduty paddle mixer or log washer module preceding main scrubber This additional attrition stage ensures complete breakage preventing downstream blockages compromising throughput

Q4 What typical delivery timeline from order commissioning?
A For standard configuration lead time ranges between months depending current manufacturing schedule Site preparation civil works should proceed concurrently Modular design allows commissioning within weeks after modules arrive site

Q5 Are performance guarantees provided?
A Yes We offer performance guarantees based jointly agreed upon feed characteristics covering minimum throughput capacity maximum power consumption key component wear rates These backed comprehensive test work proposal stage

Q6 Can plant relocated once current deposit exhausted?
A Absolutely Modular bolttogether construction specifically facilitates relocation Minimal cutting welding required allowing efficient dismantling transport reassembly new site significantly protecting your capital investment

Q7 What aftersales technical support available globally?
A We provide remote diagnostics via installed monitoring systems plus global network certified service engineers Additionally maintain strategic inventory critical spare parts ensure minimal downtime support