1. PAINPOINT DRIVEN OPENING

Are you facing escalating operational costs and unpredictable recovery rates in your highvolume gold operation? Managing a 500 TPH throughput presents distinct challenges that directly impact your bottom line. Common pain points include:
High Water Consumption & Tailings Management: Inefficient washing and screening can consume millions of liters daily, creating costly water sourcing and tailings pond liabilities.
Frequent Downtime for Maintenance: Robust, continuous operation is critical. Equipment not designed for 24/7 abrasive slurry processing suffers from premature wear, leading to unplanned stoppages and lost production.
Inconsistent Feed Handling & Clay Blindage: Variable or clayrich material can blind screens and disrupt the entire processing circuit, forcing throughput reductions and manual intervention.
SubOptimal Recovery of Fine Gold: Inadequate scrubbing and washing in the initial stages can lead to gold losses downstream, as fines remain trapped in conglomerates or are carried away with waste.
High Operational Labor Costs: Reliance on manual monitoring, cleaning, and adjustment of multiple units increases labor overhead and introduces human error.

Is your primary washing plant a source of reliability, or a bottleneck of constant expense? What would a 15% reduction in water usage or a 20% decrease in unscheduled downtime mean for your annual operating budget?

2. PRODUCT OVERVIEW

The Professional 500 TPH Gold Mining Washing Plant is a heavyduty, modular processing system engineered for the primary scrubbing, screening, and desliming of alluvial, elluvial, or weathered hard rock gold ore. It is designed to prepare feed material for downstream gravity concentration or leaching circuits by liberating gold particles from waste gangue.

Operational Workflow:
1. Feed & PreScreening: Runofmine (ROM) material is uniformly fed via apron feeder onto a coarse scalping screen to remove oversized rocks (+75mm) before entering the scrubber.
2. Intensive Scrubbing & Liberation: The heart of the plant, a largediameter rotary scrubber, aggressively tumbles the material with water. This process breaks down claybound aggregates, dissolves clays, and scrubs mineral surfaces to liberate gold.
3. Primary Screening & Sizing: Discharged scrubber pulp reports to a highcapacity vibrating screen. The undersize (10mm) slurry, containing liberated gold and fine sands/silts, is sent to the recovery circuit. The rinsed oversize (+10mm) gravels are conveyed to waste.
4. Desliming & Classification (Optional): The undersize slurry can be further processed through hydrocyclones or classifying tanks to remove ultrafine slimes (75µm), which can hinder downstream gravity recovery efficiency.

Application Scope & Limitations:
Scope: Ideal for alluvial deposits, placer mining operations, and weathered oxide ores requiring intensive attrition. Effective for materials with high clay content or sticky soils that bind gold.
Limitations: Not suitable for processing unweathered hard rock ores without prior crushing. Performance is contingent on accurate feed characterization (clay content, moisture, rock size distribution).

3. CORE FEATURES

HeavyDuty Rotary Scrubber | Technical Basis: Highimpact lifters combined with optimal rotational speed (critical speed %) | Operational Benefit: Ensures complete disaggregation of claybound material and thorough mineral surface cleaning without excessive particle degradation | ROI Impact: Maximizes downstream gold recovery rates by ensuring full liberation; reduces recirculating load.

Modular BoltTogether Design | Technical Basis: Preengineered structural steel modules with flanged connections | Operational Benefit: Enables rapid onsite assembly with minimal welding; simplifies future plant relocation or expansion | ROI Impact: Reduces installation time by up to 40%, lowering capital deployment delay and mobilisation costs.

LowWater HighPressure Spray Bars | Technical Basis: Laminar flow nozzles with optimized pressure (810 bar) and strategic placement within screens and scrubber discharge | Operational Benefit: Achieves superior rinsing efficiency with lower volumetric water flow per ton processed | ROI Impact: Cuts fresh water consumption by an estimated 1525%, significantly reducing pumping costs and tailings volume.

AbrasionResistant Liner System | Technical Basis: Interchangeable liners made from chromium carbide overlay steel on critical wear areas (scrubber drum, feed chutes) | Operational Benefit: Extends service life in highly abrasive environments; liners can be replaced sectionally during planned maintenance | ROI Impact: Increases mean time between failures (MTBF); lowers lifetime cost of ownership through reduced part replacement frequency.

Centralized Greasing & Monitoring Points | Technical Basis: Manifolded lubrication lines for all major bearings with accessible diagnostic ports | Operational Benefit: Enables safe, routine maintenance without dismantling guards; allows for condition monitoring checks | ROI Impact: Promotes proactive maintenance scheduling, preventing catastrophic bearing failures that cause extended downtime.

Oversize Waste Conveyor System | Technical Basis: Integrated heavyduty belt conveyor with impact idlers at loading point to handle +10mm waste rock | Operational Benefit: Efficiently removes coarse waste from the circuit without requiring auxiliary equipment or doublehandling | ROI Impact: Streamlines material flow; reduces plant footprint and ancillary equipment investment.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard for 500 TPH Plants | Our Professional 500 TPH Washing Plant Solution | Advantage (% Improvement) |
| : | : | : | : |
| Water Consumption per Ton Processed| ~2.5 m³/tonne | ~1.9 m³/tonne| 24% Reduction |
| Scrubber Liner Lifespan (Abrasive Ore) | ~46 Months| ~810 Months| ~80% Increase |
| OnSite Assembly Time (Modular) | 68 Weeks| 34 Weeks| ~50% Reduction |
| Screening Efficiency (Clayey Feed)| Frequent blinding; requires manual cleaning
every shift| Minimal blinding due to dualmotion vibration
and spray bar design; cleaning weekly.| >300% increase in
operational uptime |
| Overall Plant Availability (Scheduled) |>92% |>96%| >4 Percentage Point Increase |

5. TECHNICAL SPECIFICATIONS

Design Capacity: 500 tonnes per hour (dry feed basis).
Power Requirements: Total installed power approximately 850 kW. Primary consumers include scrubber drive (~250 kW), screen motors (~60 kW), conveyor drives (~150 kW), pumps (~200 kW).
Material Specifications:
Structural Steel: ASTM A36 / S355JR.
Scrubbing Drum & Wear Liners: AR400 Steel with Chromium Carbide Overlay on highimpact zones.
Screen Decks: Polyurethane modular panels on first deck; woven wire mesh on secondary decks.
Chute Work & Launders: 10mm Mild Steel plate with replaceable AR400 liner kits.
Physical Dimensions (Approximate):
Scrubber Unit (L x Dia.): 9m x 3.2m
Primary Screen Deck Size: 3m x 7m
Plant Footprint (L x W): ~35m x 18m
Environmental Operating Range: Designed for ambient temperatures from 20°C to +50°C. Dust suppression systems included as standard.

6. APPLICATION SCENARIOS

West African Alluvial Gold Operation

Challenge: A largescale placer mine was experiencing severe screen blinding due to high lateritic clay content at a target throughput of 450 TPH. This caused hourly stoppages for cleaning and reduced effective capacity by over 30%.
Solution: Implementation of our Professional 500 TPH Washing Plant featuring the dualmotion screen system paired with intensified lowpressure spray bars within the scrubber discharge chute.
Results: Screen blinding incidents reduced from multiple times per shift to once per week. Sustained throughput achieved consistently at design capacity of >480 TPH.

Southeast Asian Eluvial Deposit

Challenge: An operation processing weathered saprolitic ore faced significant losses of fine gold (<100 mesh) during initial washing due to inefficient desliming before their gravity circuit.
Solution: Integration of a hydrocyclone cluster package into our standard washing plant design after the primary screening stage.
Results: Field data shows removal of over 75µm slimes increased from an estimated ~60% efficiency to >92%. This led directly to a measured increase in overall gravity recoverable gold yield by approximately ~18%.

7 COMMERCIAL CONSIDERATIONS

Our Professional series plants are offered under three main tiers:

1.Base Configuration Tier: Includes core modules—apron feeder / hopper unit , heavyduty rotary scrubber , primary sizing screen , oversize waste conveyor , walkways , ladders , basic electrical control panel . Priced as a turnkey capital package .

2.Enhanced Recovery Tier: Base configuration plus integrated desliming cyclones , process water sump tank recycle pumps automated control system SCADA interface . Optimized plants where feed characterization indicates significant fine gold presence .

3.Full Modular / Remote Site Tier: Enhanced tier plus containerized motor control centers MCCs diesel generator power modules packaged water treatment clarifier units . Designed remote locations lacking infrastructure .

Optional features include trommel screens instead vibratory types specific ore characteristics automated polymer dosing systems clay dispersion custom paint specifications corrosion protection coastal environments .

Service packages range from annual inspection plans comprehensive multiyear partsandlabor maintenance agreements covering all wear components . Financing options available through partner institutions including leasetoown structures project financing support major expansions .

FAQ

Q1 Is this washing plant compatible with our existing crushing circuit or downstream concentrators?
Yes it is designed modular integration Standard discharge chute heights conveyor positions adjustable match typical layouts Detailed interface drawings required ensure seamless connection your specific equipment

Q2 What kind operational crew required run this tph plant effectively?
Plant designed semiautomated operation requiring one control room operator one field technician general oversight per shift Field data similar installations indicates reduction direct labor compared older multiunit setups

Q3 How does handle extreme fluctuations feed grade particle size distribution?
Robust design includes variable speed drives apron feeder scrubber allowing operators adjust retention time based observed conditions Grizzly section front end rejects boulders exceeding maximum design size preventing blockages

Q4 What are lead times delivery installation support?
Standard lead time manufacturing shipping major components months exworks Site assembly commissioning typically requires weeks supervised our engineers following arrival all components port

Q5 Are spare parts readily available globally?
We maintain strategic inventory critical wear parts hubs North America West Africa Southeast Asia Guaranteed availability key components like liner kits screen panels bearing assemblies support uninterrupted operation

Q6 Can plant be relocated another site once current deposit exhausted?
Yes bolttogether modular construction specifically facilitates disassembly relocation Core modules designed withstand multiple assembly cycles minimizing redeployment costs extending asset life across multiple projects

Q7 What performance guarantees provided?
We offer guaranteed minimum throughput capacity based your provided feed sample analysis along warranty materials workmanship key structural mechanical components Specific terms outlined commercial proposal