1. ABERTURA ACIONADA POR PAINPOINT

Are you scaling up your alluvial or hard rock gold operation and finding that your washing and recovery processes are the bottleneck? At a planned 500 Tph throughput, common pain points quickly escalate into significant financial losses:
Manuseio inconsistente de feeds: Variable clay content or particle size distribution can blind screens and clog scrubbers, leading to frequent stoppages and reducing effective capacity well below 500 Tph.
Inefficient Fines Recovery: Traditional sluices or jigs often struggle with gold fines below 150 mícrons, resulting in unrecovered value reporting to tailings. Even a 0.1% loss at this scale represents substantial annual revenue erosion.
High Water & Consumo de energia: Inefficient plant design leads to excessive water recirculation and oversized pump requirements, inflating both operational costs and environmental footprint.
Excessive Maintenance Downtime: Poorly constructed or configured washing modules suffer from abrasive wear, requiring frequent liner changes and component replacement, cutting into productive operating hours.

Is your current setup reliably achieving target availability and recovery rates at a true 500 Tph? Are your operating costs per ton under control, or are they being undermined by inefficiency?

2. VISÃO GERAL DO PRODUTO

UM 500 Tph Gold Mining Washing Plant is a modular, highcapacity processing system designed for the primary scrubbing, classification, and gravity concentration of goldbearing ores. Ele transforma cru, excavated material into concentrated heavy mineral product for further upgrading.

Fluxo de Trabalho Operacional:
1. Esfrega primária & Disaggregation: Feed material is aggressively scrubbed in a robust trommel or rotary scrubber to break down clays and cemented aggregates.
2. Particle Size Classification: The discharged material is screened to separate oversize waste rock (+10mm to +75mm, depending on ore) from valuable undersize.
3. Primary Gravity Concentration: The undersize slurry reports to primary concentrators (por exemplo, concentradores centrífugos) to recover free gold and heavy minerals.
4. Gestão de Rejeitos & Water Clarification: Processed tailings are dewatered via cyclones or linear screens, with clarified water recirculated to minimize fresh water demand.

Escopo de aplicação & Limitações:
Escopo: Ideal for alluvial/eluvial deposits, placer operations, and freemilling hard rock ores where liberation occurs via scrubbing. Effective on a range of materials from weathered conglomerates to lateritic clays.
Limitações: Not suitable for refractory ores requiring chemical leaching or complex sulphide ores needing flotation. Performance is highly dependent on accurate feed characterization (teor de argila, umidade, particle size).

3. RECURSOS PRINCIPAIS

Design modular de deslizamento | Base Técnica: Pré-projetado, bolttogether structural skids | Benefício Operacional: Reduces site installation time by up to 60% versus fieldfabricated builds. Allows for future plant reconfiguration or relocation. | Impacto do ROI: O comissionamento mais rápido acelera a geração de receita; lower capital installation costs.

HighG Force Centrifugal Concentrator Array | Base Técnica: Interconnected battery of enhanced gravity separators creating sustained high Gforces | Benefício Operacional: Achieves superior recovery rates of fine gold down to 30 microns that escape static sluices. Continuous concentrate discharge allows for unattended operation. | Impacto do ROI: Direct increase in overall gold yield; reduces manpower needed for cleanup operations.

Intelligent Water Management System | Base Técnica: Closedloop circuit with automated thickener/clarifier controls and cyclone staging | Benefício Operacional: Cuts fresh water consumption by over 70%. Maintains optimal slurry density for recovery equipment without manual adjustment. | Impacto do ROI: Lowers water licensing and pumping costs; enables operation in waterscarce regions.

AbrasionResistant Liner Package | Base Técnica: Customwelded AR400/500 steel plate liners in highwear zones (tambor de lavagem, rampas de alimentação) | Benefício Operacional: Extends service life of critical components by 35x compared to standard mild steel liners under abrasive conditions.| Impacto do ROI: Reduces spare parts inventory cost and frequency of downtime for liner replacement.

Centralized Process Control Station | Base Técnica: PLCbased control panel with HMI displaying motor loads, taxas de alimentação, and pump pressures | Benefício Operacional: Enables singleoperator monitoring of the entire washing plant circuit from one location. Provides alarm logging for predictive maintenance.| Impacto do ROI: Optimizes labor allocation; early fault detection prevents secondary equipment damage.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Typical Plant) | Nosso 500 Tph Gold Washing Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Effective Availability | 8085% (downtime for blockages/liner wear) | 9295% (optimized flow design & wear package) | +10% (+400+ operational hrs/yr) |
| Fine Gold Recovery (<75µ)| ~65% recovery via traditional sluices | >92% recovery via tuned centrifugal array| +27% more fine gold captured |
| Water Consumption| ~4m³ per ton of ore processed| <1.2m³ per ton processed (closedloop system)| 70% reduction in fresh water use |
| Instalação & Tempo de comissionamento| 1216 weeks onsite fabrication/assembly| 57 semanas (preassembled modular skids)| ~60% faster timetoproduction |

5. ESPECIFICAÇÕES TÉCNICAS

Nominal Capacity: 500 toneladas métricas por hora (base de ração seca).
Tamanho da alimentação: Up to 250mm (subject to scrubber model).
Requisitos de energia: Aprox.. 8501100 kVA total connected load; configured for 415V/50Hz or 480V/60Hz.
Especificações de materiais:
Primary Structure: Heavyduty Hbeam steel frame.
Tambor de esfrega: 20mm mild steel shell with bolton AR400 liner segments.
Slurry Launders & Tanks: 6mm mild steel with abrasionresistant coating.
Dimensões Físicas (Modular): Typical layout footprint of ~40m L x 20m W x 12m H; modules designed for standard shipping container widths.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C; dust suppression system included; electrical components rated IP65.

6. CENÁRIOS DE APLICAÇÃO

Alluvial Placer Operation in West Africa

Challenge A midtier miner needed to upgrade from multiple smaller plants (~200 Tph total) to a single highcapacity unit due to new lease holdings with higher clay content causing severe blinding in existing equipment.
Solution Implementation of a singlestream modular 500 Tph Gold Mining Washing Plant featuring an aggressive clay scrubber trommel frontend and a twostage vibrating screen deck for classification.
Results Achieved consistent throughput of 520 Tph at >93% availability within two weeks of commissioning.Fine gold recovery improved by an estimated 31%, contributing directly to a payback period calculated at under 14 months based on increased yield alone.

Hard Rock Tailings Reprocessing Project

Challenge An engineering contractor was tasked with recovering residual free gold from historical tailings dams where material was partially oxidized but contained problematic fine silt that hampered earlier processing attempts.
Solution A tailored 500 Tph Gold Mining Washing Plant was deployed using highpressure attrition scrubbers followed by desliming cyclones before the gravity circuit.This removed interfering slimes prior to concentration effectively increasing the grade fedto concentrators
Results The plant consistently processed difficult tailings material achieving target throughput while reducing final tails grade by over 40 comparedto previous test work Project met its target internal rateof return IRR within the first year

Considerações Comerciais

Pricing is projectspecific based on final configuration but typically falls within three tiers:

1\. Base Plant Package Includes core modules scrubber screening primary gravity concentration basic control systemand walkways Pricing starts withina defined competitive range

2\. Enhanced Recovery Package Adds secondary gravity scavenger circuit advanced instrumentationfor densitycontroland upgradedpump specifications This tier offers optimal balanceof capital cost versus maximum metallurgical performance

3\. Turnkey MineReady Package Includes fullwater clarificationcircuit sludge management dewatering presses extendedwearliners premium PLC automationwith remote monitoring capabilitiesand commissioning spares package

Optional Features HighG magnetic separatorsfor tramp iron removal standby powergenerator integration bulk reagent dosing systemsfor pH adjustment

Service Packages Annual inspectionand optimization contractsare recommended Critical spare parts kitsare availableto support maintenance schedules Financing options including equipment leasingand project financingcan be structured through our partners

Perguntas frequentes

Q What preliminary data is requiredto ensurea TphGold MiningWashingPlantis correctly specified
A A comprehensivefeed samplefor pilotscale testingis critical We requireminimum kgfor analysisof particle size distribution claycontent moistureand head grade Pilottest resultsdetermine key parameterslike scrubber selectionand retentiontime

Q How does thisplant manage variationsin feed gradeor claycontent duringoperation
A The PLCcontrolsystem allows operators adjustcritical variableslike scrubber rotation speedfeed rateand waterspray bar pressurein realtime Field data shows these adjustmentscan compensate formoderate feed variability maintainingconsistent product quality

Q Are these plants compatiblewith existing crushing circuitsor heap leachoperations
A Yes They are commonly installedafter primarycrushingto processrunofmine ROMmaterialor asa standaloneunitfor alluvialdeposits Concentratecan be feddirectlyto intensive cyanidationCILor MerrillCrowe circuitsor upgradedonsitevia smelting

Q Whatisthe typical deliverylead timefrom orderto commissioning
A Fora standardconfiguration leadtimeis approximately monthsThis includesengineering fabrication shop testing dismantlingfor shipment Deliveryof longlead itemslike motorsis confirmedupon order Final sitecommissioningrequires weekswith oursupervision

Q What operator trainingand technical supportis provided
A We provide comprehensiveclassroomand handson trainingfor operational maintenancecrewsat commissioning Detailedoperations manuals PIDs Piping Instrumentation Diagramsand maintenancevideosare supplied Ongoing technicalsupportis availablevia direct phoneand emailwith guaranteed response times