1. PEMBUKAAN PAINPOINT DRIVEN

Are your gold recovery operations constrained by inconsistent throughput, excessive energy consumption per ton, or unplanned maintenance halting your entire milling circuit? Legacy stamp mill configurations often lead to three critical challenges:

Suboptimal Liberation & Pemulihan: Inefficient crushing and grinding can fail to fully liberate gold from complex ores, leaving measurable value in your tailings and directly impacting your bottomline recovery rate.
High Operational Expenditure: Aging stamp mills with manual controls consume disproportionate power for their output. Unoptimized wear part cycles lead to frequent, costly replacements and associated labor downtime.
Inflexible Plant Design: Fixedconfiguration equipment struggles to adapt to varying ore hardness and feed grades, forcing operations to run at a constant, often inefficient, pace regardless of feedstock variability.

How do you increase tonnage throughput while improving recovery consistency? Can you reduce energy and maintenance costs without a complete plant overhaul? Jawapannya terletak pada purposeengineered, customized stamp mill assembly plant.

2. GAMBARAN KESELURUHAN PRODUK

Yang moden Customized Stamp Mill Gold Mining Assembly Plant is not a single machine but an integrated processing system engineered for the specific comminution (menghancurkan) of goldbearing ore. It replaces antiquated, standalone stamp batteries with a synchronized circuit designed for reliability and efficiency.

Aliran Kerja Operasi:
1. Suapan Utama & Peraturan: Runofmine (ROM) ore is fed via a regulated conveyor system to a primary scalping or jaw crusher for initial size reduction.
2. Controlled Stamp Milling: Precrushed ore is fed uniformly to a battery of modernized stamp mills. Each camdriven stamp (or pestle) is precisely weighted and dropped in a controlled cycle onto the ore within a hardened mortar box.
3. Pembentukan Slurry & Pelepasan: Crushed material mixes with water in the mortar box to form a slurry, which passes through a discharge screen with precise aperture sizing, ensuring only sufficiently liberated material exits the circuit.
4. Gravity Concentration Ready: Buburan yang dilepaskan, containing nowliberated gold particles, is directed to downstream processes like sluices, menggoncang meja, or centrifugal concentrators for separation.

Skop Permohonan & Batasan:
Skop: Ideal for smalltomedium scale hard rock gold mining operations, particularly where ore is amenable to gravity recovery methods. Effective for both freemilling ores and as a primary crusher for refractory ores ahead of leaching.
Batasan: Not suitable for hightonnage operations exceeding several hundred TPD where ball mill/cyanide circuits are more economical. Performance is highly dependent on correct customization for local ore characteristics.

3. CIRI TERAS

Reka Bentuk Bingkai Modular | Asas Teknikal: Bolttogether, highcarbon steel structural sections | Faedah Operasi: Enables staged deployment and easier future plant expansion or reconfiguration with minimal foundation work | Kesan ROI: Reduces initial capital outlay and cuts expansion downtime by up to 40% compared to welded monolithic frames.

Variable Weight & Lift Control | Asas Teknikal: Adjustable camshaft profiles and interchangeable stamp head weights | Faedah Operasi: Operators can finetune impact energy and cycle frequency in response to realtime ore hardness readings | Kesan ROI: Data lapangan menunjukkan a 1525% improvement in energy efficiency (kWj/tan) when optimized for feed stock variability.

Liner & Wear Part Standardization | Asas Teknikal: Commonality in mortar box liners, discharge screens, and stamp shoe designs across the battery | Faedah Operasi: Simplifies inventory management and allows for faster changeouts during scheduled maintenance windows | Kesan ROI: Reduces spare parts inventory costs by ~30% and decreases mean time to repair (MTTR).

Integrated Water Management Manifold | Asas Teknikal: Centralized piping with individual flow controls to each mortar box | Faedah Operasi: Ensures consistent slurry density across all stamps, critical for optimal screen discharge and downstream recovery | Kesan ROI: Improves overall recovery consistency by maintaining ideal process conditions, minimizing gold loss to coarse tailings.

Centralized Grease Lubrication System | Asas Teknikal: Automated network delivering measured grease to all major bearing points on camshafts and guides | Faedah Operasi: Menghapuskan titik pelinciran manual, reducing contamination risk and ensuring bearing longevity under highload conditions | Kesan ROI: Extends major bearing service life by an average of 50%, preventing costly unscheduled stoppages.

HeavyDuty Discharge Screen System | Asas Teknikal: Replaceable screen decks with reinforced clamping mechanisms made from abrasionresistant steel | Faedah Operasi: Provides uniform particle sizing control; screens can be replaced on individual stamps without shutting down the entire battery | Kesan ROI: Maintains steadystate throughput; industry testing demonstrates <5% throughput variance over a screen’s service life.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Legacy Stamp Battery) | Customized Stamp Mill Assembly Plant Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Ketekalan Throughput +/ 20% variance due to manual feed/water control +/ 5% variance via integrated feed & slurry management >15% penambahbaikan |
| Kecekapan tenaga ~2.5 3.5 kWh/ton ~1.9 2.4 kWh/ton with VFD controls Up to 30% penambahbaikan |
| Masa Min Antara Kegagalan (MTBF) 450600 jam (major bearings) 8001000 jam (major bearings) ~65% improvement |
| Recovery Grade (% Au in +100 mesh fraction) Higher fine gold loss in tailings Optimized crush size & slurry control reduces coarse +100 mesh loss Measurable reduction; bergantung kepada tapak |

5. SPESIFIKASI TEKNIKAL

Penilaian Kapasiti: Boleh dikonfigurasikan daripada 5 TPD (singlestamp pilot plants) hingga 300 TPD multibattery industrial installations.
Keperluan kuasa: Primary drive via electric motor(s). Typical range from 15 kW per stamp for smaller units up to integrated plant systems requiring 150400 kW jumlah beban bersambung.
Spesifikasi Bahan: Mortar boxes lined with ASTM A532 Class III Type NiHard alloy or equivalent; Stamps constructed from forged highcarbon steel with replaceable alloy shoes; Structural frame from ASTM A36 steel.
Dimensi Fizikal: A singlestamp unit footprint starts at approx. 2m x 2m. Full assembly plants are customdesigned but typically require a prepared area of 15m x 25m minimum for a midrange circuit including feed systems.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +50°C. Enclosed gear drives protect against dust ingress; special seals available for highhumidity environments.

6. SENARIO APLIKASI

MidScale Hard Rock Mine Expansion

Cabaran:
An existing operation using two legacy stamp batteries faced bottlenecks after opening a new vein with harder quartzite ore. Throughput dropped by 35%, energy costs soared, and maintenance frequency increased unacceptably.
Penyelesaian:
Implementation of a customized fourstamp assembly plant module designed specifically for the harder ore characteristics, featuring our Variable Weight & Lift Control system.
Keputusan:
Plant restored target throughput of 85 TPD within six weeks of commissioning at the new site while operating at an improved specific energy consumption of <2 kWh/tonne—a net gain despite harder feedstock—and scheduled liner changes extended from every two weeks back out monthly intervals.

Artisanal & Perlombongan Berskala Kecil (ASM) Cooperative Upgrade

Cabaran:
A cooperative using disparate manual stamps had inconsistent recovery rates between operators leading internal disputes over revenue sharing along with significant environmental concerns regarding uncontrolled water use
Penyelesaian:
Deployment standardized threestamp assembly plant complete Integrated Water Management Manifold centralized collection settling ponds
Keputusan:
Achieved uniform recovery rate across all operators increasing overall yield Measurable water recycling reduced fresh water consumption Tailings management improved meeting basic regulatory requirements

7 PERTIMBANGAN KOMERSIL

Pricing tiers are projectspecific based on required capacity level customization However typical brackets include:

Basic Tier ($80k$150k):
Includes core stamped battery modular frame essential drives motors Suitable brownfield replacement projects where existing infrastructure reused

Peringkat Prestasi ($150k$400k):
Comprehensive turnkey package including primary scalping crusher automated feed conveyor belt water recycling system PLCbased monitoring controls

Peningkatan Ciri Pilihan:
Ore presorting grizzly feeder Advanced vibration monitoring sensors Remote operational diagnostics package Alternative wear part materials specific highly abrasive ores

Pakej Perkhidmatan:
Standard warranty covers defects materials workmanship Extended service agreements available covering scheduled preventive maintenance parts discounts priority technical support Financing Options Equipment leasing structures available through partners as well progressbased milestone payment plans large projects

8 Soalan Lazim

Q1 How compatible is this customized plant our existing downstream gravity concentration equipment?
A1 Our engineering team conducts full process review ensure seamless interface Your current sluices tables concentrators Typically we design discharge launder systems match your existing setup minimizing integration costs

Q2 What typical implementation timeline look like from order commissioning?
A2 For standard Performance Tier system lead time manufacturing ranges Delivery installation commissioning typically completed within weeks following arrival site depending local infrastructure readiness

Q3 Can this system handle both alluvial placer concentrates hard rock ores?
A3 While primarily engineered hard rock applications systems can be configured process highgrade placer concentrates However feed size distribution must controlled achieve optimal performance

Q4 What operator training provided?
A4 We provide comprehensive onsite training covering normal operation routine maintenance troubleshooting procedures Documentation includes detailed manuals schematics Training ensures your team achieves rated performance quickly safely

Q5 Are spare parts readily available internationally?
A5 Yes We maintain global distributor network ensure critical wear parts like shoes screen decks standardized bearings stocked key regions minimizing potential logistics delays

Q6 How does pricing structure work optional features added later?
A6 We employ modular design philosophy allows many upgrades retrofitted field However some features like centralized lubrication more economical include initial build Discussing longterm plans during design phase recommended maximize value

S7 Adakah anda menawarkan jaminan prestasi?
A7 Yes We provide guaranteed throughput capacity based your provided ore samples bond work index specifications Recovery rates are function entire process circuit but we guarantee mechanical performance crushing efficiency our equipment