1. PEMBUKAAN PAINPOINT DRIVEN

Menskalakan operasi pemulihan emas kepada 500 Tph membentangkan cabaran berbeza yang memberi kesan langsung kepada keuntungan. Kadar suapan yang tidak konsisten, penggunaan air yang tinggi, and excessive downtime for maintenance can erode margins. Are you facing these issues?
Kesesakan throughput: Can your washing and scrubbing plant maintain a consistent 500 Tph feed without becoming a processing bottleneck, leading to pileup and lost production time?
Kos Operasi yang Tinggi: Are you managing escalating costs from water procurement, recycling system complexity, and highenergy consumption in your material handling and separation processes?
Kerugian Pemulihan: Is inefficient scrubbing or claybound material causing precious gold fines to be lost to tailings, secara langsung mengurangkan hasil keseluruhan anda?
Masa Henti Tidak Berjadual: Are frequent mechanical failures in scrubbers, skrin, or pumps causing unpredictable stoppages, making production targets unreliable?

Yang mantap 500 Tph gold mining washing plant is engineered to address these exact operational challenges.

2. GAMBARAN KESELURUHAN PRODUK

This product is a highcapacity, modular washing plant designed for alluvial and eluvial gold deposits. Its primary function is to liberate gold from claybound gravels and efficiently separate valuable material from waste through scrubbing, pemeriksaan, dan kepekatan graviti.

Aliran Kerja Operasi:
1. Suapan Utama & Menggosok: Runofmine (ROM) material is fed into a heavyduty trommel or scrubber, where intense agitation breaks down clays and cemented aggregates.
2. Saiz & Pengelasan: The disaggregated material passes over vibrating screens, separating +2mm to +10mm (khusus tapak) bersaiz besar (waste rock) from the valuable undersize fraction.
3. Konsentrasi & Pemulihan: The undersize slurry is routed to primary gravity concentrators (mis., pintu air, jig) for initial gold recovery. Tailings may pass through secondary scavenging units.
4. Pengurusan Air & Tailings: Process water is clarified in a settling system for recirculation, minimizing fresh water intake. Waste streams are managed for responsible disposal.

Skop Permohonan & Batasan:
Skop: Ideal for largescale alluvial/eluvial operations, placer deposits, and weathered conglomerates where clay removal is essential prior to cyanidation or further processing.
Batasan: Not suitable for hard rock lode deposits without prior crushing. Performance is highly dependent on feed material characteristics (kandungan tanah liat, plasticity, rock size).

3. CIRI TERAS

Modul Scrubber Tugas Berat | Asas Teknikal: Drum tork tinggi dengan pengangkat dalaman | Faedah Operasi: Ensures complete disintegration of clay agglomerates and cemented gravels at full 500 Tph feed rate | Kesan ROI: Maximizes gold liberation from the start, reducing losses to tailings and improving overall recovery rate.

Dek Skrin Bergetar Modular | Asas Teknikal: Multistage screening with replaceable polyurethane panels | Faedah Operasi: Provides precise size classification under high load; panels resist blinding and wear | Kesan ROI: Reduces screen replacement frequency by up to 40% versus standard rubber panels, mengurangkan kos inventori alat ganti dan masa henti penyelenggaraan.

Sistem Kitar Semula Air Bersepadu | Asas Teknikal: Multicompartment settling tanks with flocculant dosing | Faedah Operasi: Pulih sehingga 85% air proses untuk digunakan semula segera | Kesan ROI: Cuts freshwater procurement and pumping costs significantly; reduces environmental footprint and licensing complexity.

gris berpusat & Sistem Pelincir | Asas Teknikal: Automated manifold delivering grease to all critical bearings | Faedah Operasi: Ensures optimal bearing life on scrubber trommel rollers screen vibrators under highload conditions | Kesan ROI: Prevents catastrophic bearing failures extends component service intervals by approximately 30% reducing unscheduled stoppages.

Kawalan Berasaskan PLC & Panel Pemantauan | Asas Teknikal: Programmable Logic Controller with touchscreen HMI displaying motor loads feed rates amp draws | Faedah Operasi: Gives operators realtime visibility into plant performance enabling quick adjustments fault diagnosis | Kesan ROI: Optimizes power consumption allows predictive maintenance scheduling improves overall operational efficiency.

QuickDisconnect Module Couplings | Asas Teknikal: Standardized flanges pipe connections between scrubber screen pump modules | Faedah Operasi: Enables rapid reconfiguration or module replacement during planned maintenance or site relocation | Kesan ROI: Reduces plant recommissioning time by days during moves directly increasing productive uptime.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri untuk 500 Tumbuhan Tph | Our Washing Plant Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Penggunaan Air (m³/tan) | 3.0 4.0 m³/tonne processed| ≤ 2.5 m³/tonne processed| Up to ~38% reduction |
| Target Availability (Masa Jalan yang Dijadualkan) |>90% |>95% |>5 mata peratusan |
| Kecekapan Penyeraian Tanah Liat (for medium plasticity) |>85% |>95% |>10 mata peratusan |
| Penempatan semula & Reassembly Time (for modular plants)| ~1421 days| ~710 days| ~50% lebih pantas |
| Penggunaan Tenaga Khusus (kWj/tan)| Berbeza secara meluas; optimized design can reduce by ~1520% versus nonintegrated systems.| |

5. SPESIFIKASI TEKNIKAL

Kapasiti Nominal: 500 tan sejam (Tph), design allows for peak feeds of up to 550 Tph.
Keperluan kuasa: Jumlah beban yang disambungkan lebih kurang 650800 kW dependent on configuration voltage supplied at client specification (mis., 11kV /50Hz).
Spesifikasi Bahan: Keluli tahan lelasan (AR400) in chutes hoppers; Highdensity polyurethane on screen decks launders; Certified wearresistant piping.
Dimensi Fizikal (Modular): Modul Scrubber (~12m L x 4m W x 4m H); Modul Saringan (~10m L x 4m W x 4m H). Overall footprint varies with layout.
Julat Operasi Persekitaran: Designed for ambient temperatures from 20°C to +50°C dust suppression systems standard can be configured for highaltitude operation.

6. SENARIO APLIKASI

Operasi Emas Alluvial Afrika Barat

Challenge A major operation faced severe claybinding in its deposit causing existing rotary scrubbers to “log” frequently reducing effective throughput below 96%. Plant sustained consistent >480 Tph throughput annual gold recovery increased by an estimated >8% due to improved liberation reduced oversize losses.

Southeast Asian LargeScale Placer Mine

Challenge Extremely high freshwater costs remote location required minimal water usage frequent cyclone blockages caused excessive maintenance downtime.
Solution A complete washing plant featuring an advanced multistage settling system with automated flocculant dosing highly accessible cyclone cluster design.
Results Freshwater consumption reduced by over >70%. Cyclone maintenance intervals extended from weekly monthly availability of the washing section increased >92%.

7. PERTIMBANGAN KOMERSIL

Peringkat Harga: Capital cost varies based on scope:
Base Tier Includes core scrubber screening deck primary recovery sluices basic control system
Enhanced Tier Adds secondary gravity scavenging advanced PLC control automated lubrication
FullCircuit Tier Includes complete water recycling/tailings management system turnkey commissioning support

Ciri Pilihan: Diesel power modules remote monitoring telemetry dust encapsulation covers specific oretesting package

Service Packages Annual inspection parts kitting programs guaranteed critical parts availability (<48hr dispatch) onsite technician support contracts

Financing Options Equipment leasing structures operating lease agreements project financing facilitation through partner institutions

8. Soalan Lazim

What feed size can the plant handle? The standard configuration accepts ROM material up to approximately <250mm optimal feed size is <150mm For larger material a grizzly or primary scalping unit is recommended

How does the plant handle variations in clay content? The scrubber module’s drive system is designed with variable speed control allowing operators adjust retention time drum speed based realtime feed characteristics maintain optimal breakdown

What are the typical installation requirements? A level prepared pad adequate foundations utilities connections The modular design allows phased installation We provide detailed foundation general arrangement drawings part of engineering package

Adakah alat ganti sedia ada? Yes Critical wear parts common mechanical components are standardized held global stock Strategic partners maintain regional warehouses ensure supply chain reliability

Can this plant be integrated with existing downstream processes? Yes The plant designed as standalone circuit can be configured discharge concentrated slurry directly into your existing cyanidation circuit leach tanks simply pass upgraded concentrate further processing