1. PEMBUKAAN PAINPOINT DRIVEN

Are you scaling up your gold recovery operations and facing the critical bottlenecks of a 500 Daya pengeluaran TPH? Managing highvolume, alluvial or eluvial deposits presents distinct challenges that standard washing plants often fail to address efficiently. Halangan operasi biasa termasuk:

Kadar Pemulihan Tidak Konsisten: Variable feed material leads to gold losses in fines or coarse tailings, memberi kesan langsung kepada pendapatan.
Masa Henti Berlebihan untuk Penyelenggaraan: Poorly designed scrubbers and screens require frequent stoppages for wear part replacement and unclogging, crippling your planned availability.
High Operational Water & Penggunaan kuasa: Inefficient pump systems and material handling directly inflate your site’s most variable costs.
Kesukaran Mengendalikan Bahan ClayBound: Agglomeration and blinding within the scrubbing circuit reduce effective capacity and increase manual labor.
Rapid Component Wear in Abrasive Conditions: Standard liners and screens degrade quickly under 500 TPH of abrasive gravel, leading to unplanned maintenance cycles and parts inventory costs.

Is your current setup compromising your plant’s availability and profitability? Penyelesaiannya memerlukan sistem yang direka bentuk bukan hanya untuk kapasiti, but for continuous, efficient operation under demanding conditions.

2. GAMBARAN KESELURUHAN PRODUK

The OEM 500 TPH Gold Mining Washing Plant adalah lengkap, modular processing system designed for highvolume extraction of gold from alluvial, peletakan, dan mendapan eluvial. Fungsi terasnya ialah menggosok, mengelaskan, and concentrate feed material to produce a rich heavy mineral concentrate for downstream gold recovery (mis., via sluices, emparan, or shaking tables).

Aliran Kerja Operasi:
1. Suapan & PraSkrining: Runofmine material is fed via loader or conveyor into a robust grizzly or primary screen to remove oversize rocks (+75mm).
2. Menggosok Agresif & Pembebasan: Material reports to a largediameter, longlength scrubber where intense attrition breaks down clay matrices and liberates gold particles from the host gravel.
3. Precise Particle Classification: The scrubbed slurry is processed through vibrating screens (typically double or tripledeck) to separate material into key size fractions (mis., +10mm waste, 10mm+2mm gravels, 2mm sands).
4. Efficient Concentration: The goldbearing sand fraction is routed through a series of highcapacity spiral concentrators or jigs to separate heavy minerals (termasuk emas) daripada bahan gangue yang lebih ringan.
5. Pengurusan Tailing & Pengendalian Air: Waste streams are managed via slurry pumps and pipelines; process water is often recirculated from settling ponds to reduce fresh water demand.

Skop Permohonan & Batasan:
Sesuai Untuk: Largescale alluvial mining operations, projek mengorek sungai, and extensive eluvial deposits with consistent high feed rates.
Sesuai Untuk: Materials with significant clay content requiring intensive liberation.
Batasan: Tidak direka untuk hard rock (lode) pemprosesan bijih. Prestasi optimum memerlukan bekalan air yang mencukupi (recirculation mitigates this) and relatively consistent feed size distribution. Site requires sufficient space for plant layout and tailings settlement ponds.

3. CIRI TERAS

Modul Scrubber Tugas Berat | Asas Teknikal: Oversized drum with internal lifters and hightorque drive system | Faedah Operasi: Ensures complete breakdown of claybound aggregates without bogging down, maintaining design throughput even with difficult feed | Kesan ROI: Maximizes gold liberation from day one, reducing losses to tailings due to inadequate scrubbing.

Modular Vibrating Screen Decks | Asas Teknikal: Interchangeable screen panels with varied aperture sizes on independent vibration mechanisms | Faedah Operasi: Allows precise classification for optimal concentration; panels can be replaced individually during scheduled maintenance | Kesan ROI: Redunscreen downtime by up to 50% compared to fulldeck replacement systems.

HighCapacity Spiral Concentrator Battery | Asas Teknikal: Bank of specially profiled fiberglass spirals optimized for specific gravity separation at high feed rates | Faedah Operasi: Provides consistent grade concentration across the entire 500 TPH sand fraction with minimal operator intervention | Kesan ROI: Delivers stable concentrate grade for downstream processes, improving final recovery efficiency.

gris berpusat & Sistem Pelincir | Asas Teknikal: Automated manifold delivering lubricant to all critical bearing points on scrubber, skrin, dan penghantar | Faedah Operasi: Eliminates manual greasing requirements during operation, enhancing safety and ensuring optimal bearing life | Kesan ROI: Reduces lubrication labor costs by approximately 80% dan menghalang kegagalan galas yang mahal.

kakisan & Pelapik Tahan Lelasan | Asas Teknikal: Bolton liners manufactured from AR400 steel or specialized polyurethane in highwear areas (scrubber feed chute, pencuci buburan) | Faedah Operasi: Significantly extends service life in highly abrasive environments between changeouts | Kesan ROI: Mengurangkan kosperton untuk bahagian haus dengan purata 35% berdasarkan perbandingan data lapangan.

Integrated Process Water Pump Array | Asas Teknikal: Centrifugal pumps sized with calculated system head loss and configured with duty/standby capability | Faedah Operasi: Guarantees consistent water pressure and volume to all plant sections; standby pump enables immediate switchover without production halt | Kesan ROI: Prevents entire plant stoppage due to singlepump failure, protecting revenue during critical operating periods.

Kawalan Berasaskan PLC & Panel Pemantauan | Asas Teknikal: Centralized control system with motor amperage readouts, feed rate monitoring, and fault alarm indicators | Faedah Operasi: Gives operators realtime visibility into plant load and immediate identification of circuit bottlenecks or failures | Kesan ROI: Enables proactive adjustments to feed rate optimization reduces energy waste during partial loads by up to 20%.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (500 Kelas TPH) | OEM 500 Penyelesaian Loji Basuh TPH | Kelebihan (% Penambahbaikan) |
|||||
| Ketersediaan Loji | 8085% (downtime for wear changes & tersumbat) | disasarkan 92%+ (design focus on maintainability & redundansi) >7% Bertambah |
| Gold Recovery Efficiency ~8792% on 2mm fraction ~9396% on 2mm fraction Upto4% Increase |
| Penggunaan Air Tertentu 810 m³ per ton of feed 67 m³ per ton of feed ~25% Reduction |
| Scrubber Liner Life 600800 jam 10001200 hours ~50% Extension |
| Total Installed Power ~450 kW ~400 kW ~11% Reduction |

5. SPESIFIKASI TEKNIKAL

Kapasiti Pemprosesan Nominal: 500 Ton metrik sejam (asas makanan kering).
Saiz Suapan Maksimum: Sehingga 250mm (subject to grizzly configuration).
Keperluan kuasa: Jumlah beban yang disambungkan lebih kurang 400 kw. Typical supply: 440V / 60Hz / 3 Phase or customizable.
Spesifikasi Bahan Utama:
Scrubbler Shell / Jatuh / Pencuci pakaian : Mild steel with AR400 abrasionresistant liners.
Dek Skrin : Hightensile steel frames with interchangeable polyurethane or rubber panels.
Struktur Sokongan : Heavyduty hotdip galvanized steel beams.
Penumpu : Fiberglassreinforced polyester spiral assemblies.
Dimensi Fizikal (Modular): Approximate footprint of main processing modules is 30m L x 15m W x 12m H. Exact dimensions vary with configuration.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +50°C. Sistem penindasan habuk disertakan; kandang tersedia untuk iklim yang melampau.

6. SENARIO APLIKASI

Alluvial Gold Project Expansion West Africa Challenge A mine needed scale its operation from tph while dealing highly variable clay content was causing frequent plugging existing scrubber reducing effective below tph Solution Installation modular including heavy duty extended residence time secondary rinsing screen prevent blinding Results achieved consistent throughput target within weeks commissioning liner life increased hours reduced non scheduled stoppages

Large Scale River Dredging Operation Southeast Asia Challenge Dredge feeding required continuous classification efficient removal oversize + waste rocks minimize handling concentrate grade fluctuated due inconsistent feed distribution spirals Solution implemented integrated scalping deck ahead scrubbing module installed distributor ensure even across entire bank Results rock rejection efficiency reached stable reported downstream improved allowing reduction tabling circuit

Eluvial Deposit Processing Australia Challenge arid region limited fresh made water conservation critical also faced extremely abrasive causing weekly replacements key components Solution was specified closed loop water circuit thickeners advanced polyurethane wear components strategic areas slurry pumps Results freshwater consumption dropped recycled process component life extended average weeks between changes

7 PERTIMBANGAN KOMERSIL

Equipment pricing tiers are typically structured around the level of modularity ancillaries
Base Plant Package Includes core modules feeder primary secondary concentration battery basic controls
Premium Package Adds automated dosing standby pumps enhanced dust thicker packages
Custom Engineering For specific challenges like extreme climate pre concentration via

Ciri Pilihan
Oversized sump pump capacity future expansion
On skid diesel generator power remote locations
Full containerization sea shipment rapid deployment
Advanced samplers tails streams

Pakej Perkhidmatan
Commissioning Supervision weeks onsite support startup training
Annual Inspection Parts Kitting pre scheduled maintenance parts bundle discount
Remote Diagnostics Support subscription connectivity control system troubleshooting

Financing Options available through partners include leasing structures milestone payment linked project finance export credit agency backed loans suitable international buyers

8 Soalan Lazim

What upstream equipment needed operate this washing plant effectively require consistent feed front end such apron feeder truck receiving hopper ensure smooth prevents surges can damage scrubbing module recommended pair capable handling variations

How does plant handle variations content specifically designed difficult materials oversized long length provides adequate retention time break down clays optional high pressure spray bars inside further assist dispersion preventing blockages

What typical installation commissioning timeline experienced team modular design allows parallel site foundation work delivery From arrival site first production days achievable assuming civil works prepared advance supervised included package

Are spare parts readily available internationally maintains global network certified warehouses hold inventory critical wear items liners screen panels pump impellers Furthermore drawings provided facilitate local machining non items reducing lead times

Can system be later expanded capacity beyond tph engineering incorporates certain margins key pumping piping infrastructure However increasing beyond may require upsizing components like primary consultation recommended planning phase future expansion

What operator skill level required run effectively control simplified intuitive interface requires basic training routine checks maintenance tasks more complex procedures outlined detailed manuals supported remote assistance

Do you offer performance guarantees subject agreed upon feedstock characteristics specifications offer guaranteed recovery efficiency range within specified particle size consumption metrics outlined contract based pilot test data sample