H1: Engineered for HighValue Recovery: Custom Gold Ore Crushing Solutions

1. ABERTURA ACIONADA POR PAINPOINT

Processing goldbearing ore presents distinct and costly challenges that standard crushing circuits often exacerbate. Are you facing these operational realities?

Recoverable Gold Loss in Fines: Conventional crushers can overgrind softer gold ore, creating ultrafine particles that are unrecoverable by gravity separation or leach circuits, directly reducing your overall yield.
Unscheduled Downtime from Abrasive Quartz: The high quartz content in many gold ores accelerates wear on crusher liners and components, levando a frequentes, disruptive maintenance stops and high parts replacement costs.
Inefficient Throughput for Variable Feed: Rock pesado, alluvial, and sulfide ores behave differently. A rigid plant struggles with feed variability, causing bottlenecks that limit tonsperhour capacity and increase energy cost per tonne.
Alta Complexidade Operacional: Does your process require multiple stages of jaw, cone, and impact crushing to achieve optimal liberation? This complexity increases footprint, manpower needs, and points of potential failure.

A questão central é: how can you configure a crushing circuit that maximizes particle liberation for optimal recovery while minimizing wear costs and operational complexity? The answer lies in purposeengineered custom gold ore crushing equipment.

2. VISÃO GERAL DO PRODUTO

Our custom gold ore crushing equipment refers to engineeredtoorder primary and secondary crushing systems configured specifically for the mineralogy, tamanho da alimentação, and target product of your gold processing plant. The workflow is designed for efficient liberation:

1. Redução Primária: Large runofmine ore is reduced to a manageable size using a robust jaw or gyratory crusher selected for its capacity and ability to handle abrasive material.
2. Secondary Liberation: The crushed material is fed into a cone crusher or specialized impactor tuned to produce a particle size that optimally exposes the gold for downstream cyanidation or gravity recovery.
3. Dimensionamento & Recirculação: A vibrating screen classifies the output; onspec material proceeds to milling or leaching circuits, while oversize is recirculated for further reduction.

Escopo de aplicação: Ideal for greenfield projects, plant expansions, or retrofits targeting hard rock lode deposits (quartz veins), complex sulfide ores, and highvolume operations. Limitações: These are fixed or semimobile solutions requiring foundational support; not intended for smallscale artisanal mining or purely alluvial (placer) operations without associated hard rock feed.

3. RECURSOS PRINCIPAIS

Geometria de revestimento patenteada | Base Técnica: Análise de Elementos Finitos (FEA) optimized wear profile | Benefício Operacional: Redirects abrasive wear to replaceable cartridge sections, extending service life by up to 40% | Impacto do ROI: Reduces liner inventory costs and increases crusher availability for production

Acionamento de velocidade variável (DSV) Controlar | Base Técnica: Precise adjustment of crusher eccentric speed | Benefício Operacional: Allows operators to finetune the product gradation in realtime based on ore hardness changes | Impacto do ROI: Maintains optimal throughput and target P80 size consistently, improving downstream recovery efficiency

Tramp Metal Relief & Limpeza | Base Técnica: Hydraulic adjustment and clearing systems with automated reversal cycles | Benefício Operacional: Minimizes stall events from uncrushable material; clears chamber in minutes versus hours | Impacto do ROI: Prevents catastrophic damage and significantly reduces unplanned downtime events

Modular Wear Assembly Design | Base Técnica: As bolas, segmented wear components | Benefício Operacional: Enables partial liner replacement during scheduled maintenance; reduces changeout time by over 30% | Impacto do ROI: Lowers labor costs per maintenance event and shortens production windows

Coletor de supressão de poeira integrado | Base Técnica: Sealed housing with directed spray nozzles at key transfer points | Benefício Operacional: Controla eficazmente o pó de sílica na fonte, improving site safety and regulatory compliance | Impacto do ROI: Reduces health risks and avoids potential fines related to airborne particulate

HighRatio Reduction Capability | Base Técnica: Engineered chamber profiles allowing larger feed opening relative to setting | Benefício Operacional: A single unit can often replace two stages of conventional crushing in certain flowsheets | Impacto do ROI: Lowers capital expenditure footprint and simplifies the overall crushing circuit

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria | Custom Gold Ore Crushing Solution | Vantagem (% melhoria) |
| : | : | : | : |
| Liner Life in Abrasive Quartz Ore | 450 550 horário de funcionamento | 700 800 horário de funcionamento (with patented liners)| +40% |
| Crusher Availability (Tempo de atividade) | ~8590% (including unscheduled stops)| >94% (with advanced relief systems)| +59% aumento absoluto |
| Consumo Específico de Energia (kWh/tonelada)| Varia muito; less efficient multistage circuits average higher consumption.| Optimized singlestage or hybrid circuits reduce energy use.| Os dados de campo mostram 1525% reduction possible |
| Optimal Product Yield (+/ target P80)| Often requires screening & recrush loops.| VSD control yields consistent product; reduces recycle load.| Até 20% increase in firstpass yield |

5. ESPECIFICAÇÕES TÉCNICAS

Faixa de capacidade: Configurável de 50 TPH pilot/test plant modules up to 1,200+ TPH productionscale installations.
Requisitos de energia: Dependent on configuration; primary units typically range from 75 kW para 400 kW. All drives are compatible with softstart technology for grid stability.
Especificações de materiais: Highchrome martensitic steel or manganese alloy wear liners standard; tungsten carbide options available for extreme abrasion zones. Fabricated main frames from ASTM A36 steel.
Dimensões Físicas: Designs are sitespecific. Semimodular designs facilitate transport; typical primary unit footprint ranges from 25m² to 60m² including walkways.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 25°C a +50°C. Sealed bearings and heated gear options available for extreme environments.

6. CENÁRIOS DE APLICAÇÃO

Hard Rock Lode Mine Expansion

Desafio: A mine expanding into a new quartz vein zone experienced rapid cone crusher liner wear (sub400 hours) and excessive sub100micron fines generation, hampering gravity recovery.
Solução: Implementation of a customconfigured secondary cone crusher with our patented liner geometry and a slightly modified chamber profile to produce a coarser product ideal for their Knelson concentrators.
Resultados: Vida útil do revestimento estendida para 650 horas. Fines generation reduced by 18%. Gravity recovery circuit efficiency improved by an estimated 12%, significantly increasing revenue per tonne.

Sulfide Ore Processing Plant Retrofit

Desafio: An existing plant processing refractory sulfide gold ore had a bottleneck in their tertiary crushing stage, limiting feed to the grinding mill and causing throughput delays.
Solução: Replacement of two older tertiary crushers with one highcapacity custom gold ore crushing unit featuring VSD control. The system was integrated into the existing PLC network.
Resultados: Tertiary stage throughput increased by 35%. The VSD allowed optimization for varying sulfide/oxide blend ratios, stabilizing mill feed density. Overall plant throughput rose by an average of 22%.

7. CONSIDERAÇÕES COMERCIAIS

Níveis de preços:
Standard Module Retrofit: For upgrading an existing crusher station with new technology liners/controls.
SemiMobile Skid Package: A preassembled crushing circuit on multiple skids for faster deployment.
Turnkey Station Design/Build: Full engineering, fabricação, instalação, and commissioning of a custom circuit.

Recursos opcionais & Atualizações: Sensores avançados de monitoramento de condição (vibração/temperatura), automated setting adjustment systems remote PLC integration packages premium ceramic composite wear components.

Pacotes de serviços: Tiered plans include scheduled inspection parts kits guaranteed response times for critical breakdowns remote diagnostics access.

Financing Options Available through partners include capital lease operating lease project financing terms tailored to mine development schedules.

8.Perguntas frequentes

1.Q How do I determine if my operation needs "custom" equipment versus standard models?
A Customization becomes critical when your ore's abrasiveness work index or target product size falls outside the midrange performance envelope of catalog models An initial ore testing review can determine this need

2.Q What site data is required for an effective custom gold ore crushing equipment proposal?
A Provide details on your feed size distribution Bond Work Index abrasion index annual tonnage targets desired product P80 size any existing spatial constraints

3.Q Can these systems integrate with my existing PLC/DCS control room?
A Yes industrialstandard communication protocols Modbus TCP/IP Ethernet/IP allow full integration into most modern plant control systems providing operators with realtime data

4.Q What is the typical delivery lead time for a major custom unit?
A Lead times vary based on complexity For major primary units expect detailed engineering fabrication testing within a range of months following finalized design approval

5.Q How does the warranty structure work given the variable nature of ores?
A We provide base warranties on materials workmanship Performance warranties related specifically tonnage throughput under agreedupon feed conditions are structured as separate contractual guarantees

6.Q Are performance trials or pilotscale testing available before full commitment?
A Yes we offer rental pilot plants scaled testing at our facility using customerprovided bulk samples This provides definitive performance data before investment