1. ABERTURA ACIONADA POR PAINPOINT

Are you facing escalating operational costs and unpredictable performance in your highvolume gold recovery operation? Gerenciando um 500 A taxa de transferência de TPH apresenta desafios distintos que impactam diretamente seus resultados financeiros. Consider these critical issues:
Alto consumo de água & Gestão de Rejeitos: Lavagem e triagem ineficientes podem consumir milhões de litros diariamente, criando dispendiosas fontes de água e responsabilidades com bacias de rejeitos.
Tempo de inatividade frequente para manutenção: Poorly constructed trommels and scrubbers suffer from accelerated wear, leading to unplanned stoppages that halt your entire processing line.
Inconsistent Clay & Oversize Handling: Variable feed material with sticky clay or large oversize can blind screens and choke equipment, drastically reducing effective capacity below the 500 TPH design.
Excessive Fines Loss in Alluvial Deposits: Inadequate scrubbing and screening design fails to fully liberate gold from conglomerate, resulting in significant value reporting to tails.
High Operational Manning & Riscos de segurança: Plants requiring constant manual intervention for feed regulation or blockages increase labor costs and exposure to moving machinery.

Is your current setup maximizing recovery per ton while controlling water, poder, and labor expenses? Can you reliably achieve your targeted 500 TPH throughput across variable feed conditions with minimal supervision?

2. VISÃO GERAL DO PRODUTO

This product details a contractmanufactured, certified 500 TPH Gold Mining Washing Plant. It is a complete, modular system engineered for the primary washing, esfregando, triagem, and coarse gold recovery of alluvial or eluvial deposits. The plant is supplied by an established manufacturer holding relevant international quality and fabrication certificates (por exemplo, ISO 9001, ASME), ensuring structural integrity and performance compliance.

Fluxo de Trabalho Operacional:
1. Primary Feed & Escalpelamento: Runofmine (ROM) material is fed via a heavyduty apron feeder to a primary scalping screen, removing large oversize (+150milímetros) before the scrubber unit.
2. Aggressive Scrubbing & Libertação: O coração da planta, a robust rotary scrubber/trommel, aggressively tumbles the ore with water to break down claybound conglomerates and fully liberate gold particles.
3. Precise Particle Size Separation: Discharge from the scrubber reports to a vibrating screen deck for precise separation into multiple product streams (por exemplo, +30mm waste rock, 30mm+2mm gravels for secondary concentration, 2mm slurry).
4. Primary Gold Concentration: The 2mm slurry is immediately routed to primary gravity concentrators (such as centrifugal concentrators or sluices) to capture liberated fine and coarse gold.
5. Efficient Water & Tailings Handling: Screen undersize and concentrator tails are managed via a series of sumps and cyclones for water recovery/recycling before thickened tailings discharge.

Escopo de aplicação & Limitações:
Escopo: Ideal for highvolume alluvial/eluvial gold projects, lateritic deposits, and gemstone recovery where claybreaking and size classification are critical. Effective on feeds with high clay content and moderate oversize.
Limitações: Not suitable for hard rock (lode) ore processing requiring crushing. Feed size is typically limited by scrubber diameter (por exemplo, maximum lump size of 1/3 scrubber diameter). Performance is dependent on accurate feed characterization and consistent water supply.

3. RECURSOS PRINCIPAIS

HeavyDuty Scrubber Module | Base Técnica: Reinforced shell design with internal lifters at optimized angles | Benefício Operacional: Ensures consistent tumbling action and material advance even with high clay content; prevents shortcircuiting | Impacto do ROI: Maintains design throughput of 500 TPH in challenging conditions, protecting overall plant revenue targets.

Certified Modular Fabrication | Base Técnica: ASMEcoded welding procedures & ISO 9001 quality management systems | Benefício Operacional: Guarantees structural integrity under continuous load; enables faster site erection with preassembled modules | Impacto do ROI: Reduz o tempo de construção no local em até 40% versus fieldbuilt plants, accelerating timetoproduction.

Intelligent Water Recycling System | Base Técnica: Multistage settling sumps paired with highcapacity hydrocyclones | Benefício Operacional: Recirculates up to 85% de água de processo; significantly reduces fresh water demand | Impacto do ROI: Cuts water procurement costs by over 70% in arid regions and minimizes environmental licensing complexity.

Centralized PLC Control & Monitoramento | Base Técnica: Industrial programmable logic controller with HMI touchscreen displaying motor loads, taxas de alimentação, and pump statuses | Benefício Operacional: Allows singleoperator oversight of the entire washing circuit; provides early warning of blockages or mechanical stress | Impacto do ROI: Lowers operational manning requirements by approximately 23 shifts per day while preventing catastrophic failures.

QuickAccess Wear Part Design | Base Técnica: Bolton screen panels, modular spray bars, and splittype scrubber lifter bars | Benefício Operacional: Enables replacement of key wear components in hours instead of days without major cutting/welding | Impacto do ROI: Reduces planned maintenance downtime by over 50%, aumentando diretamente as horas de operação anuais.

Integrated Primary Recovery Circuit | Base Técnica: HighG force centrifugal concentrators plumbed directly into the screen undersize launder system | Benefício Operacional: Captures free gold immediately after liberation without unnecessary pumping or intermediate steps | Impacto do ROI: Improves overall gravity recovery efficiency by an estimated 510%, capturing value that would otherwise report to tails.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da indústria para 500 Plantas TPH | This ContractManufactured Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Consumo de Água por Tonelada Processada| ~2,5 m³/tonelada (oncethrough systems) | 70% Redução |
| Scrubber Trommel Panel Life (Abrasive Feed)| ~1.200 horas de operação| ~2.000 horas de operação| ~67% Increase |
| Tempo médio entre falhas (MTBF) Caminho Crítico| ~450 horas| >720 horas| >60% Melhoria|
| OnSite Commissioning & Erection Time| ~1216 weeks| ~810 weeks| ~33% Faster|
| Overall Gravity Recovery Efficiency (Free Gold)| ~8588% range| Consistentemente >92% fieldtested >4% Aumento Absoluto |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade de projeto: Nominal 500 toneladas por hora (TPH) of 150mm feed material at specified bulk density.
Requisitos de energia: Potência total instalada aproximadamente 800900 kW. Primary motors include scrubber drive (~250kW), peneira vibratória (~45kW), alimentador (~30kW), centrifugal pumps (~150kW total).
Especificações de materiais:
Scrubber/Trommel Shell: Highabrasion resistant steel (HARDOX® or equivalent), minimum thickness 16mm.
Structural Supports & Passarelas: ASTM A36 steel with nonslip grating.
Screen Panels: Polyurethane modular panels on primary screens; wire mesh on secondary where applicable.
Dimensões Físicas (Modular):
Scrubber Module (L x W x H): ~18m x 6m x 5m
Tela & Concentrator Module: ~15m x 8m x 6m
Feed Hopper/Feeder Module: ~8m x .5m x .5m
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C. Electrical components rated IP65 for dust/moisture protection.

6. CENÁRIOS DE APLICAÇÃO

West African Alluvial Gold Project |

Challenge A project required processing highly variable lateritic material with pockets of extremely sticky clay at a sustained rate of over .00 TPH Frequent blinding of competitor equipment reduced effective throughput by over .0%, creating a production bottleneck
Solution Implementation of this certified .00 TPH washing plant featuring the heavyduty scrubber module with aggressive lifters an intelligent spray bar system Results Within one month rampup plant achieved consistent .0+ TPH throughput regardless of clay variability Clayinduced downtime was eliminated increasing monthly processed tonnage by %

Depósito Eluvial do Sudeste Asiático |

Challenge Coarse gold was locked within heavily weathered conglomerate Existing scrubbing was insufficient leading to high fines loss estimated at g/tonne reporting to tailings due to poor liberation
Solution Installation focused on optimizing retention time within the scrubber integrating highG centrifugal concentrators directly onto the undersize launder Results Postinstallation metallurgical accounting showed overall gravity recovery increased from % Plant payback period was achieved in under months based on recovered value alone

7 CONSIDERAÇÕES COMERCIAIS

Equipment pricing tiers are structured around scope definition:
Tier Basic Package Includes core modules feeder scrubbing unit primary screening deck primary concentrators basic PLC controls Tier Enhanced Package Adds comprehensive water recycling circuit advanced instrumentation spare wear parts package extended walkways Tier Turnkey Lite Includes Basic Package plus detailed installation supervision commissioning services operator training

Optional Features Highfrequency fine screening deck secondary stage gravity concentration security fencing lighting packages remote monitoring telemetry

Service Packages Annual inspection maintenance contracts full wear parts supply agreements priority technical support hotline

Financing Options Available through manufacturer partnered financial institutions include equipment leasing capital loan facilitation renttoown structures tailored to project cash flow

8 Perguntas frequentes

What certifications does the manufacturer hold
The contract manufacturer holds ISO certification for quality management systems along with ASME welding certifications providing documented assurance of fabrication quality structural safety

How does this plant handle variations in feed size distribution
The combination of an adjustable stroke apron feeder heavyduty scalping screen protects the downstream scrubbing circuit Oversize rejection is handled prior to scrubbing maintaining optimal conditions inside the trommel

What are the ongoing operational costs per ton
Field data indicates operational costs excluding feed mining primarily power consumables wear parts range between $X$Y per ton processed depending on local utility rates material abrasiveness

Can this plant be integrated into an existing processing circuit
Yes The modular nature allows it function as standalone washing facility or as frontend unit feeding existing grinding cyanidation circuits Integration engineering support available

What is typical delivery lead time from contract signing
For standard .00 TPH configuration lead time typically ranges from months subject current manufacturing capacity order confirmation Final site commissioning requires weeks depending site readiness