1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing a highgrade gold operation where conventional crushing and grinding methods are eroding your profit margins? The challenges of processing hard rock gold ore are significant: inconsistent particle size distribution from primary crushers leading to poor liberation, excessive wear on grinding components from abrasive quartz, and high energy consumption per ton of ore milled. These factors directly impact your bottom line through increased downtime for liner changes, higher operational costs, and potential gold losses in coarse tailings. Bagaimana anda mencapai konsisten, highrecovery milling for premium ore bodies while controlling operational expenditure and maximizing the value of every ton? The solution requires a robust, precisionengineered approach to comminution.

2. GAMBARAN KESELURUHAN PRODUK

The Luxury Stamp Mill is a modern reinterpretation of the classic gravityimpact crushing principle, engineered for selective operations processing highvalue goldquartz veins and sulfide ores. It is designed for operations where preserving coarse free gold and minimizing overgrinding are critical to profitability.

Aliran Kerja Operasi:
1. Penyediaan Makanan: Bijih bersaiz (biasanya 2" ke 1/2") from a primary jaw crusher is fed into a regulated feed hopper.
2. Penghancuran Kesan Graviti: Camdriven heavyduty stamps (berat) are lifted and dropped onto the ore bed contained within a durable mortar box.
3. Pengurangan Saiz Zarah & Amalgamation: The repeated impact fractures the ore along grain boundaries, liberating gold particles which can be captured via integrated amalgamation plates or direct collection.
4. Pelepasan & Pengelasan: Crushed material passes through a grated screen at the mortar box discharge, with oversize recycled and fines reporting to downstream concentration processes (mis., pintu air, menggoncang meja).

Skop Permohonan & Batasan:
Sesuai Untuk: Small to mediumscale operations with hard rock lode deposits, perlombongan artisanal dan berskala kecil (ASM) projek formalisasi, custom milling facilities for highgrade ore, and historical site reprocessing.
Batasan: Not suitable for hightonnage, bulk mining operations (>200 TPD). Less effective for soft, bijih tanah liat yang menyebabkan pembungkusan. Requires consistent feed sizing from primary crushing.

3. CIRI TERAS

Modular HeavyDuty Frame | Asas Teknikal: Prefabricated hightensile steel truss system with vibrationdampening mounts | Faedah Operasi: Rapid onsite assembly with perfect alignment; absorbs dynamic loads for stable operation and prolonged structural integrity | Kesan ROI: Mengurangkan masa pemasangan sehingga 60% versus fieldwelded designs, lowering total project capital outlay.

PrecisionCast Camshaft & setem | Asas Teknikal: Alloy steel castings with normalized heat treatment for uniform grain structure | Faedah Operasi: Provides consistent lift and drop geometry; minimizes cam wear and stamp wobble for uniform impact energy transfer | Kesan ROI: Data lapangan menunjukkan a 40% increase in service life for wearing components, secara langsung mengurangkan kos inventori alat ganti.

Pelapik Kotak Mortar Boleh Tukar | Asas Teknikal: Segmented manganese steel or optional chromium carbide liners secured with boltin design | Faedah Operasi: Allows for quick replacement of worn sections without full mortar box dismantling; material choice can be matched to ore abrasiveness | Kesan ROI: Cuts liner change downtime by over 50%, meningkatkan ketersediaan tumbuhan.

Sistem Parut Pelepasan Boleh Laras | Asas Teknikal: Perforated screen plates with variable aperture sizes (mesh) and tensioning clamps | Faedah Operasi: Operators can control product fineness in realtime to optimize downstream recovery based on ore type | Kesan ROI: Enables processing flexibility, maximizing recovery rates across varying ore blends by an average of 515%.

Manifold Penindasan Habuk Bersepadu | Asas Teknikal: Lowpressure water spray bars mounted in the feed hopper and mortar box enclosure | Faedah Operasi: Berkesan mengawal habuk silika pada sumber; maintains optimal moisture content in the ore bed for efficient crushing | Kesan ROI: Mitigates health/safety compliance risks and reduces dustrelated maintenance on auxiliary equipment.

Sistem Pelinciran Grease Berpusat | Asas Teknikal: Manifold automatik menghantar gris ke semua galas utama (camshaft, pengangkat) from a single point | Faedah Operasi: Ensures critical points are lubricated consistently during operation; eliminates manual greasing hazards | Kesan ROI: Ujian industri menunjukkan a 30% reduction in bearing failures, menghalang pemberhentian yang tidak dirancang.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Kilang Setem Asas) | Luxury Stamp Mill Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Masa Henti Perubahan Pelapik| 812 jam (full weld/repair) | 50% lebih pantas |
| Kecekapan tenaga| ~3.5 kWj/tan (unoptimized drive systems)| ~2.8 kWj/tan (highefficiency motors & balanced flywheel) | 20% pengurangan |
| Stamp Alignment Consistency| Manual shimming required weekly| Laseraligned at factory; maintained via rigid frame design| Reduces uneven wear by ~70% |
| Operational Noise Level| Selalunya melebihi 95 dBA at source| Enclosed design with dampening mounts maintains <87 dBA| Significant reduction in noise exposure risk |
| Throughput per Stamp Weight| Varies significantly with feed control| Optimized cam profile & feed system delivers consistent tonnage| +15% throughput per unit of energy input |

5. SPESIFIKASI TEKNIKAL

Kapasiti Julat Model: 5 – 50 Tan Sehari (TPD), bergantung pada kekerasan bijih dan saiz kisar sasaran.
Keperluan kuasa: Motor elektrik dipandu; konfigurasi daripada 15 kW kepada 75 kW per mill unit. Direka untuk kuasa tiga fasa industri standard.
Spesifikasi Bahan:
Bingkai & Struktur: ASTM A36 Keluli
setem & Cams: Keluli Aloi Tempa (4140/4340)
Pelapik Kotak Mortar: ASTM A128 Manganese Steel or HighCarbon Chromium Steel
Pakai Kasut: Besi Putih HighChrome
Dimensi Fizikal (tipikal 20 TPD Unit): ~4m L x 3m W x 3m H (tidak termasuk corong suapan).
Julat Operasi Persekitaran: Direka untuk operasi dalam suhu dari 10°C hingga +45°C. All electrical components rated IP54 for dust/moisture protection.

6. SENARIO APLIKASI

HighGrade Vein Mining Operation – West Africa

Cabaran: A midtier miner was experiencing >15% gold loss in coarse tailings from their hammer mill circuit when processing extremely hard quartz veins. Overgrinding also created slimes that hampered cyanidation efficiency.
Penyelesaian: Installation of two parallel Luxury Stamp Mills configured with coarse discharge grates after primary jaw crushing.
Keputusan: Coarse free gold recovery via direct trapping improved by 22%. Pemulihan tumbuhan keseluruhan meningkat sebanyak 9% due to improved particle liberation characteristics for the leach circuit. Energy costs per ton milled fell by an estimated 18%.

Historical Tailings Reprocessing Facility – North America

Cabaran: Retreating historical tailings required gentle but effective size reduction of slaglike material to liberate encapsulated gold without creating excessive ultrafines.
Penyelesaian: A single lowspeed Luxury Stamp Mill was deployed as the primary grinder, replacing a small ball mill.
Keputusan: The impact crushing action proved more effective than tumbling abrasion on the brittle material. Gold liberation yield improved while reducing fines generation (35% dalam 200 pecahan mesh), enhancing downstream flotation kinetics. Maintenance costs were lower due to less abrasive wear compared to ball mill liners.

7. PERTIMBANGAN KOMERSIL

Our Luxury Stamp Mills are offered in three tiers:
1. Kewajipan Standard: For consistent oxide ores (<7 Mohs hardness). Includes core features like modular frame and adjustable discharge.
2. Tugas Berat: For abrasive quartz/sulfide ores (>7 Mohs hardness). Upgraded with chromium carbide liners, heavier stamp weights, and premium bearing packages.
3. Unit Loji Modular: A complete skidmounted system including integrated jaw crusher, conveyor feed system, kilang setem, and security housing.

Optional features include automated lubrication monitoring systems advanced amalgamation chambers mercury retort systems safety interlocks remote operation panels

Service packages range from basic commissioning spare parts kits comprehensive annual maintenance contracts including liner inspection replacement

Financing options include capital purchase leasetoown agreements tailored project financing solutions

8.Soalan Lazim

Q1 What primary crusher size is compatible with your stamp mills?
A Our mills are designed to accept feed optimally sized from minus two inches half inch typically produced by small jaw or cone crusher Proper feed sizing is critical achieving rated throughput preventing packing mortar box

Q2 How does this solution compare operating cost ball mill similar capacity?
A While dependent specific application key differentiator energy efficiency impact crushing typically consumes less kWh ton than tumbling grinding abrasive ores Furthermore maintenance focused few major wearing components potentially lowering long term servicing costs despite higher initial investment

Q3 Can these mills configured mercuryfree gold recovery?
A Absolutely The mills can operate dry wet configured discharge directly onto shaking tables centrifugal concentrators other physical separation equipment eliminating need mercury amalgamation

Q4 What typical delivery lead time standard model?
A Lead times vary based configuration current demand Standard models typically available within weeks confirmation order Custom modular plant units require longer fabrication period detailed project planning recommended

Q5 Are training operational manuals provided?
A Yes comprehensive digital hard copy operation maintenance manuals provided along hands training during commissioning covering safe operation routine maintenance troubleshooting procedures

Q6 What warranty coverage offered?
A We offer month warranty manufacturing defects materials workmanship Wear parts liners stamps shoes subject normal degradation covered under separate performance guarantee terms based documented application data

Q7 Do you provide engineering support plant layout integration?
A Our technical team can provide basic layout drawings interface points specifications facilitate integration your existing circuit For complex greenfield projects recommend engaging qualified engineering contractor whom we will collaborate directly