1. ABERTURA ACIONADA POR PAINPOINT

Are you scaling up your alluvial or eluvial gold operation and facing the critical bottlenecks of highvolume material processing? A standard 500 TPH gold mining washing plant is a significant capital investment, yet many operations struggle with hidden costs that erode profitability. Os desafios comuns incluem:
High Downtime for Maintenance: Frequent clogging in scrubbers or screens halts the entire processing line, custando milhares por hora em perda de produção.
Taxas de recuperação inconsistentes: Variable feed material can overwhelm traditional trommels and sluices, leading to fine gold loss that directly impacts revenue.
Excessive Water & Consumo de energia: Inefficient pump systems and plant design lead to unsustainable operational expenses, especially in remote sites.
Rapid Component Wear: Abrasive clays and gravel degrade standard liners and screens quickly, increasing part replacement frequency and labor costs.
Difficulty in Achieving SteadyState Operation: Balancing feed rate, scrubbing efficiency, and gold concentration across a 500 TPH system is complex, often resulting in suboptimal throughput.

How do you ensure your major equipment investment delivers not just capacity, but reliable, costeffective ounces? The solution lies in an engineered approach focused on durability, recovery optimization, e custo total de propriedade.

2. VISÃO GERAL DO PRODUTO

Esse 500 TPH mobile or modular gold mining washing plant is a complete gravity separation system designed for highvolume placer, alluvial, and eluvial deposits. It integrates robust scrubbing, precise classification, and efficient concentration into a continuous process flow.

Fluxo de Trabalho Operacional:
1. Primary Feed & Scrubbing: Runofmine material is fed via hopper or conveyor into a heavyduty rotating scrubber, thoroughly breaking down clay agglomerates and liberating gold.
2. Material Classification: The discharged slurry is processed by a vibrating screen deck to separate oversize waste rock (+10mm to +75mm depending on deposit) from the valuable fines.
3. Fine Material Concentration: The undersize slurry containing gold reports to a series of enhanced gravity concentrators (such as centrifugal concentrators or pulsating sluices) for primary recovery.
4. Gestão de Rejeitos & Water Handling: Waste streams are directed to a settling system or dewatering unit for water reclamation, critical for environmental compliance and reducing fresh water intake.

Escopo de aplicação & Limitações:
Ideal para: Largescale alluvial operations, riverine deposits, weathered eluvial zones with high clay content, and gravel pit reconcentration projects.
Limitações: Not suitable for hard rock (lode) mining without prior crushing. Optimal performance requires adequate water supply (though recirculation systems minimize this). Feed material size typically limited to less than 250mm.

3. RECURSOS PRINCIPAIS

HeavyDuty Scrubber Module | Base Técnica: Hightorque drum drive with internal lifters | Benefício Operacional: Ensures complete disaggregation of tough claybound feeds without clogging, maintaining consistent 500 TPH throughput | Impacto do ROI: Reduces feedrelated downtime by up to 70%, maximizando a utilização da planta.

Modular Vibrating Screen Deck | Base Técnica: Multistage polyurethane screen panels with highGforce vibration | Benefício Operacional: Provides accurate sizing separation even with high moisture content, protecting downstream concentrators from overload | Impacto do ROI: Extends screen panel life by 40% compared to rubber panels and improves overall recovery stability.

Optimized Pumping System | Base Técnica: Hydraulically sized slurry pumps with wearresistant liners | Benefício Operacional: Maintains designed flow rates with lower required horsepower through reduced system head loss | Impacto do ROI: Cuts power consumption for material movement by an estimated 1525% anualmente.

Primary Gravity Concentration Array | Base Técnica: Parallel configured centrifugal concentrators with automated concentrate bowl discharge | Benefício Operacional: Delivers high recovery rates on both fine and coarse gold across fluctuating feed grades with minimal operator intervention | Impacto do ROI: Increases overall gold recovery by 38% compared to traditional sluicebased plants for typical alluvial feeds.

Integrated Water Recirculation System | Base Técnica: Clarification tank or thickener module with return pumps | Benefício Operacional: Recicla até 85% de água de processo, drastically reducing fresh water requirements and simplifying discharge compliance | Impacto do ROI: Lowers water sourcing costs and mitigates environmental permitting risks.

Controle Centralizado & Monitoring Cabin | Base Técnica: PLCbased control panel with key parameter sensors (pressão, amp draw, taxa de alimentação) | Benefício Operacional: Allows a single operator to monitor and adjust the entire washing plant process from one location | Impacto do ROI: Reduces operational labor requirements and enables rapid response to process upsets.

SkidMounted / Projeto Modular | Base Técnica: Bolttogether structural modules with integrated walkways and lifting points | Operational Benefit Enables faster onsite assembly (30% less time than fully fieldwelded builds) and future plant reconfiguration or relocation| ROI Impact Lowers installation costs and protects longterm asset flexibility

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da indústria para 500 Plantas TPH | Esse 500 TPH Gold Mining Washing Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade / Tempo de atividade| 8588% (downtime for unclogging/liner change)| >92% (engineered material flow & quickaccess liners)| +5% para +8% horas mais produtivas |
| Gold Recovery Rate| Varies significantly; ~8892% for fine gold (<100 malha)| Consistent recovery range of 9296% for 6mm material| +4% average increase in yield |
| Water Consumption| High fresh water demand; limited recirculation| Integrated closedloop system with >85% recirculation| Até 80% reduction in fresh water use |
| Consumo de energia (kWh/T)| Estimado 1.8 2.2 kWh/Ton processed| Optimized design targets 1.5 1.7 kWh/Ton processed| ~15% improvement in energy efficiency |
| Tempo de montagem no local| Extensive field welding; 812 weeks typical| Preassembled modular skids; target of 68 semanas| ~2530% faster commissioning |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade de projeto: Nominal 500 metric tonnes per hour (550 Toneladas dos EUA por hora), variable based on specific gravity and clay content of feed material.
Requisitos de energia: Carga total conectada aproximadamente 800 950 kW. Configured for HV supply (6kV/11kV) or stepdown transformers for LV distribution.
Principais especificações de materiais:
Scrubber Drum & Chute Liners: Abrasionresistant steel (AR400) or replaceable rubber composite.
Plataformas de tela: Modular polyurethane panels.
Concentrator Bowls/Beds:Ceramic or polyurethane wear surfaces.
Aço Estrutural:ASTM A36 painted or primed for severe service.
Dimensões Físicas (Modular): Approximate footprint of 60m L x18m W x12m H . Configurations vary based on optional modules.
Faixa operacional ambiental: Designed for ambient temperatures from 20°Cto +50°C . Dust suppression spraysand enclosed conveyors are standard.

6. CENÁRIOS DE APLICAÇÃO

LargeScale Alluvial Operation in West Africa

Challenge A concession holder neededto upgrade from multiple smaller plants (~200 TPH total)to a single highcapacity unitto reduce operating complexityand meet production targets.The existing setup sufferedfrom inconsistent fine gold recoveryand high fuel costsfor multiple power gensets
Solution Implementationofa singleline500 TPHgold mining washing plantwitha centralpower gensetand enhanced centrifugalconcentration array.The modular designallowedfor phasedcommissioningwithout haltingall existingproduction
Results The consolidatedoperation achieveda22 increasein tons processedper literof fuel Plant availabilityreached93 due toreduced transferpointsand simplifiedmaterial flow Overall recoveryfor the depositimprovedfroman estimated89to94

Eluvial / Saprolite Gold Project in South America

Challenge Processing highly weatheredclayrichmaterial thatconsistently blindedtrommel screensin previousplants causingfrequentstoppages Water sourcingwas expensiveand tailings dam managementwas acritical costfactor
Solution A500 TPHplant featuringan extralongscrubber sectionfor completeclay breakdownfollowedby linearvibratingscreens The systemincludedahighcapacitywater clarifiertomaximize recirculation
Results Screen blindingwas virtuallyeliminated maintainingdesign throughput Tailings densityincreased allowingfor asmallerfootprintimpoundment Freshwater consumptionwascutby75 deliveringpaybackonthe clarifiermodulein under14 months

7 CONSIDERAÇÕES COMERCIAIS

Equipment pricing fora500 TPHgold mining washingplant is projectspecificbasedon configuration optionsand site conditions

PricingTiers
BasePlant Includescore scrubber screening primaryconcentrationand basiccontrolsystem
EnhancedPackage AddsadvancedPLC automation waterscirculationclarifier additionalconcentratorfor scavenger duty
TurnkeyPremium Includesall modules sparespackage onsite commissioning supervision training extendedwarranty

OptionalFeatures
Onboardpower generation package( diesel)
Oversizematerial secondaryscrubbingcircuit
Tailings dewateringpresses( filteror beltpress)
Comprehensiveinstrumentation package( densityflow meters)
Containerizedworkshop sparesstorage

ServicePackages Availableasannualcontracts includeperiodicinspections wearpart supply prioritytechnical support predictive maintenanceplanning

FinancingOptions Canbe structuredthroughpartner financial institutionsincludingleaseto own arrangementsor equipmentloans typicallyover36to60month terms Projectfinancingmaybe availablefor qualifieddevelopers

8 Perguntas frequentes

Whatis themaximumfeed sizeyour500 TPHwashingplant canaccept?
Thestandardfeed hopperand scrubberinletare designedfor materialupto250mm Optimalperformanceis achievedwithfeed lessthan150mm Largerprimarygrizzliescanbe addedas anoption

Howmanyoperatorsarerequiredtoruntheplant?
Thecentralizedcontrolsystemis designedformonitoringby asingleoperator Additionalgroundpersonnelare typicallyneededfor feedmanagement mechanicalchecksand concentratehandling Totalcrewof34personsper shiftis common

Cantheplant be relocatedafterinitialinstallation?
Yes themodular skiddeddesignfacilitatesdisassembly relocation andrecommissioning Relocationtimelinesdependonsite accesbutare significantlyshorterthanfordismantlingafield weldedstructure

Whatisthetypicalleadtimefromorderto commissioning?
Forastandardconfiguration leadtimeis approximately2632weeks Exworks Criticalpathitems includemajorfabricationsandlong leadtimecomponentslike largegearboxes Customizationsmayextendthistimeline

Doyouprovideperformanceguaranteesfortheplant?
Yes weofferperformanceguaranteeson throughput capacityunderdefinedfeed conditions mechanicalavailability andrecoveryefficiencybasedonrepresentative samplesofclientfeedmaterial Theseare detailedincommercialcontracts