Targeting: Commercial Gold Mining Operations, Pengurus Loji, Engineering Procurement & Pembinaan (EPC) Firms

1. Operational Challenges in Primary Ore Crushing & Pembebasan

Efficient primary ore processing is the foundation of profitable gold recovery. Inefficiencies at the stamp mill stage create bottlenecks that constrain entire operations. Cabaran utama termasuk:

High Specific Energy Consumption: Traditional singlepass crushing methods often consume excessive power per ton of ore processed, secara langsung menghakis margin keuntungan.
Inconsistent Particle Size Distribution: Poorly controlled discharge from primary crushing leads to uneven feed for downstream concentration (mis., pintu air, tables), reducing overall recovery rates by 515%.
Masa Henti Penyelenggaraan Berlebihan: Frequent wear part replacement and unplanned mechanical failures halt production. Industry data indicates some operations lose over 20% of available runtime to stamp mill maintenance.
LaborIntensive Operation & Pemantauan: Reliance on manual feeding and adjustment leads to process variability and higher operational overhead.
Had Kebolehskalaan: Older designs struggle to maintain efficiency when scaling throughput to match increased feed from expanded mining faces.

Is your operation maximizing recovery from the first critical stage of size reduction? Are your energy and maintenance costs per ton under control?

2. Gambaran Keseluruhan Produk: Modern HeavyDuty Stamp Mill for Gold Ore Processing

A modern stamp mill is a robust, mechanical crushing system designed for the primary liberation of gold from quartz rock and other ores. It functions as a costeffective workhorse for mediumscale operations and specialized highgrade vein processing.

Aliran Kerja Operasi:
1. Pengenalan suapan: Runofmine (ROM) ore is fed into a secure hopper, regulating flow onto a heavyduty anvil block (mortar box).
2. Cyclical Percussive Crushing: Powered camshafts lift and drop a series of weighted stamps (kasut) in a continuous cycle, pulverizing ore through direct impact.
3. Klasifikasi saiz & Pelepasan: Crushed material passes through a perforated screen plate at the base of the mortar box. Oversize material remains for further crushing, while liberated material (<2mm typical) is washed into collection sluices for gravity concentration.

Skop Permohonan & Batasan:
Sesuai Untuk: Processing freemilling gold ores where gravity recovery is effective; operations with intermittent power supply; rugged, remote environments; and processing centers handling ore from multiple smallscale sources.
Pertimbangan: Less efficient for refractory ores requiring fine grinding (<100 mesh) atau pembebasan kimia yang kompleks. Throughput is typically lower than highvolume ball mill or HPGR circuits, making it most suitable for operations processing 50500 tan sehari.

3. Core Features of Our Industrial Stamp Mill Design

Our engineering focus delivers reliability and operational cost savings at the primary crushing stage.

Modular Stamping Assembly | Asas Teknikal: Berdikari, replaceable stamp units with standardized connections | Faedah Operasi: Isolate maintenance to a single stamp without shutting down the entire mill bank. Reduces repair time by up to 70%. | Kesan ROI: Minimizes lost production during wear part changes.
Hardened Alloy Composite Shoes & mati | Asas Teknikal: Chromium carbide inserts cast into highstrength steel bodies | Faedah Operasi: Increases wear life by a factor of 35x compared to standard manganese steel. Maintains consistent weight for uniform crushing force. | Kesan ROI: Lowers consumable parts cost per ton and reduces inventory holding requirements.
Adjustable Screen Grid System | Asas Teknikal: Rapidclamp screen frames with multiple aperture options (1mm 4mm) | Faedah Operasi: Operators can adjust final product size in under 15 minutes to optimize downstream recovery based on ore type. | Kesan ROI: Enables process tuning to maximize gold yield without mechanical modification.
Centralized Grease Lubrication Manifold | Asas Teknikal: Automatik, programmable lubrication points on all major bearings and camshafts | Faedah Operasi: Menghapuskan ralat pelinciran manual, ensures optimal bearing life, and prevents dust ingress. | Kesan ROI: Reduces bearing failure rates by an estimated 40%, mencegah kerosakan sekunder yang mahal.
VibrationDampening Base Frame | Asas Teknikal: Isolated spring mounts or rubber buffer pads between the mill frame and foundation | Faedah Operasi: Significantly reduces transmitted vibration, protecting building structures and allowing installation on more sites without extensive foundational work. | Kesan ROI: Lowers civil engineering costs for new installations by approximately 15%.
Integrated Water Flow Management | Asas Teknikal: Calibrated spray bars within the mortar box with adjustable flow controls | Faedah Operasi: Ensures optimal slurry consistency for efficient discharge through screens and into collection launders. Prevents clogging and sanding up. | Kesan ROI: Improves process stability, reducing operator intervention time.

4. Kelebihan Kompetitif & Performance Metrics

Field data from sidebyside comparisons demonstrates clear improvements over legacy stamp mill designs.

| Metrik Prestasi | Piawaian Industri (Legacy Design) | Penyelesaian Kilang Setem Kami | Kelebihan |
| : | : | : | : |
| Pakai Part Life (Kasut) | 2,000 3,000 waktu operasi | 8,000 12,000 waktu operasi | +300% penambahbaikan |
| Masa Min Antara Kegagalan (MTBF) | ~450 jam (komponen utama)| >1,200 jam (komponen utama)| +167% penambahbaikan |
| Penggunaan Tenaga setiap Tan Hancur| ~3.5 kWh/ton (for 2mm product) | ~2.8 kWh/ton (for 2mm product)| 20% pengurangan in specific energy |
| Target Size Consistency (± varians)| High variance due to wear/feed fluctuation| Consistent PSD through adjustable screens & makanan terkawal| Enables more efficient downstream recovery |
| Scheduled Maintenance Downtime| 1015 jam setiap bulan| 46 jam setiap bulan| ~60% reduction in planned downtime |

5. Spesifikasi Teknikal

Julat Model & Kapasiti: Available in configurations from 1stamp (5 TPD pilot) to 20stamp batteries (500 TPD). Standard commercial unit is a 10stamp mill rated for 200250 tons per day of quartz ore.
Keperluan kuasa: Driven by a hightorque electric motor or diesel drive option. Standard 10stamp unit requires a 75 kw (100 Hp) motor at 1500 Rpm.
Spesifikasi Bahan: Mortar box constructed from ASTM A36 steel plate with replaceable liner plates.Stamp stems from hightensile steel; shoes from proprietary hardened alloy composite.Camshafts are forged steel, induction hardened.
Dimensi Fizikal (10Stamp Mill): Lebih kurang. Panjang: 4m x Width 2m x Height 3m . Weight approx 18 tan metrik .
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 10°C hingga +45°C . Dust seals rated for IP54 protection . Suitable for altitudes up to 3000m above sea level .

6. Senario Aplikasi

Vein Mining Operation in West Africa

Cabaran:A remote site with unreliable grid power needed a simple robust solution to process high grade quartz vein ore at 150 TPD . Downtime was catastrophic for cash flow .
Solution Installation of two parallel 5stamp mills powered by dedicated diesel generators . The modular design allowed transport via difficult access roads .
Results The operation achieved 92% gold liberation at 2mm crush size . Mill availability exceeded 94% due to reduced maintenance . The consistent feed improved overall plant recovery by 11% .

Central Processing Facility for Artisanal Aggregators

Challenge A buying center receiving variable ore types from multiple small scale miners required flexible rapid adjustment to process different materials without cross contamination .
Solution A bank of four independent 3stamp mills each with its own feed hopper water control and adjustable screen grid .
Results Operators can switch between ore types in minutes optimizing crush size for each batch This flexibility increased throughput by 30% and allowed premium pricing for superior liberation services .

7. Pertimbangan Komersial

Peringkat Harga
Base Equipment Package Includes mill frame stamps drive motor starter panel and base lubrication system .
Premium Package Adds automated grease system spare parts kit wear monitoring sensors and onboard control PLC .
Turnkey Installation Package Includes civil engineering drawings supervised installation commissioning support operator training .

Ciri Pilihan
Diesel drive package
Dust suppression canopy
Advanced vibration monitoring system
Remote performance telemetry package

Pakej Perkhidmatan
Standard Warranty months parts months labor
Extended Service Plan years including scheduled maintenance inspections priority support
OnSite Parts Consignment Stocking Program ensures critical spares are available locally minimizing downtime risk

Financing Options Available through partner institutions include equipment leasing capital loan structures and lease topurchase agreements tailored to mining project cash flows .

8. Soalan Lazim Soalan Lazim

What upstream crusher is best paired with a stamp mill?
A jaw crusher is ideal for primary reduction feeding ROM ore down to mm fragments which optimizes feed size for the stamp mortar box This combination maximizes throughput efficiency

Can your stamp mill be retrofitted into an existing plant layout?
Yes Our modular design allows adaptation to most existing foundations Feed hoppers discharge launders can be custom fabricated onsite Integration with existing water supply slurry collection systems is standard practice

How do you ensure consistent performance as wear parts degrade?
The adjustable screen grid compensates for slight reductions in crushing efficiency Furthermore our composite shoes exhibit linear wear profiles not catastrophic failure allowing predictable scheduling of replacements

What are the lead times for major replacement parts?
Standard wear parts shoes dies screen grids are stocked regionally with guaranteed delivery within days Critical structural components have a typical manufacturing lead time of weeks

Adakah anda menawarkan jaminan prestasi?
Yes We provide guaranteed throughput capacity within % based on defined ore hardness indices specific energy consumption within % tolerance availability based on adherence prescribed maintenance schedules