1. ABERTURA ACIONADA POR PAINPOINT

Você está enfrentando custos operacionais crescentes e taxas de recuperação imprevisíveis em sua operação de mineração de ouro de alto volume?? Gerenciando um 500 A taxa de transferência de TPH apresenta desafios distintos que impactam diretamente seus resultados financeiros. Os pontos problemáticos comuns incluem:
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: Inferior plant construction and component wear lead to unscheduled stops, halting your entire processing line and costing thousands per hour in lost production.
Inconsistent Recovery of Fine Gold: Standard scrubbers and screens often fail to effectively liberate and capture fine gold particles, deixando valor significativo em seus rejeitos.
Altos custos operacionais de mão de obra: Plants requiring constant manual oversight for feed control, bloqueios, or adjustments increase your workforce expenses and exposure to safety risks.
Escalabilidade & Problemas de integração: Modular plants that don't integrate smoothly with existing crushing or downstream circuits create bottlenecks and limit future expansion.

Is your current solution maximizing recovery while minimizing water, energia, and labor costs? Can your plant sustain 500 TPH throughput with predictable availability? The specification of your washing plant is a critical determinant of longterm project profitability.

2. VISÃO GERAL DO PRODUTO

Este produto é resistente, modular 500 TPH Gold Mining Washing Plant designed for alluvial, à beira da sobrevivência, ou depósitos de rocha dura desgastados. Engineered as a complete preconcentration and scrubbing unit, it prepares material for downstream gold recovery processes such as centrifugal concentrators or sluices.

Fluxo de Trabalho Operacional:
1. Feed principal & Escalpelamento: Runofmine (ROM) material is fed via hopper or conveyor into a robust scalping screen to remove oversize rocks (+75milímetros) before the scrubbing stage.
2. Intensive Attrition Scrubbing: O material sub75mm entra em um diâmetro grande, longlength scrubber where highenergy impellers break down claybound conglomerates and thoroughly clean mineral surfaces.
3. Triagem Primária & Classificação: Discharged scrubber pulp is processed over vibrating screens to separate the target fraction (por exemplo, 10mm to +1mm). Highpressure spray bars ensure effective separation.
4. Secondary Fine Recovery (Opcional): Screen undersize can be routed to a hydrocyclone or spiral classifier pack to deslime and further concentrate fine goldbearing material.
5. Estoque de produtos: Sized and cleaned fractions are conveyed to designated stockpiles for efficient feed to downstream recovery circuits.

Escopo de aplicação & Limitações:
Ideal para: Operações aluviais em grande escala, depósitos eluviais com teor de argila, saprolítico (resistido) hard rock material requiring aggressive preparation.
Limitações: Não é uma solução de recuperação independente; requires downstream gold extraction units. O tamanho da alimentação é normalmente limitado a 200 mm. Performance is dependent on specific feed characteristics such as clay content and moisture.

3. RECURSOS PRINCIPAIS

Módulo de purificação para serviços pesados | Base Técnica: Oversized shaft with proprietary Nihard lifters in a long drum design | Benefício Operacional: Ensures complete disintegration of claybound ore and maximum particleonparticle scrubbing within a single pass | Impacto do ROI: Increases overall gold liberation yield by an estimated 515%, reducing paymetal loss to tailings.

Design modular BoltTogether | Base Técnica: Fabricated from hightensile steel with precision jigbored connection points | Benefício Operacional: Permite montagem rápida no local com soldagem mínima, reduzindo o tempo de instalação em até 40% em comparação com plantas fabricadas em campo | Impacto do ROI: O comissionamento mais rápido se traduz em receita de produção antecipada.

Configuração avançada de deck de tela | Base Técnica: Vários decks, highGforce linear motion screens with polyurethane or rubber modular panels | Benefício Operacional: Provides highly efficient sizing with reduced blinding, even with sticky clays; panels can be changed individually in under 15 minutos | Impacto do ROI: Lowers screen media replacement costs by ~30% and increases screening availability.

Sistema Integrado de Reciclagem de Água | Base Técnica: Designed for closedcircuit operation with thickener or settling pond integration | Benefício Operacional: Dramatically reduces fresh water makeup requirements—field data shows reductions of up to 70% are achievable | Impacto do ROI: Cuts water procurement costs and minimizes environmental licensing complexity.

Graxa Centralizada & Sistema de Lubrificação | Base Técnica: Automated manifold supplying all major bearing points from a single station | Benefício Operacional: Permite segurança, routine maintenance in under 30 minutes without exposing personnel to moving parts | Impacto do ROI: Garante a longevidade do rolamento, evita falhas dispendiosas, and enhances site safety compliance.

Robust Structural Support Frame | Base Técnica: Lattice beam design engineered for dynamic loads exceeding standard static calculations by a factor of 4x | Benefício Operacional: Eliminates structural fatigue cracking and vibration issues common in hightonnage applications | Impacto do ROI: Provides a 20+ year structural service life under continuous operation.

Acionamento Inteligente & Pacote de controle | Base Técnica: Unidades de frequência variável (Inversores de frequência) on scrubber and conveyor motors with integrated PLC monitoring | Benefício Operacional: Allows softstart capabilities and precise speed adjustment to optimize process for varying feed conditions; provides amp/tonnage data for operators | Impacto do ROI: Reduz a demanda de pico de energia (redução das tarifas de serviços públicos) and optimizes specific energy consumption per ton processed.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da indústria para 500 Planta TPH | Our OEM Factory Washing Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade Anual| 8588% (aprox.. 4555 days downtime) | 92%+ (aprox.. 29 days downtime)| +5% para +8% Disponibilidade |
| Consumo de Água por Tonelada| ~1,5 2 m³/ton processado (circuito aberto)| <0.8 m³/ton processado (closedcircuit ready)| Até 60% Redução |
| Vida útil do revestimento purificador| Chrome White Iron – 46 meses| Proprietary Alloy – 1012 meses| ~100% Increase |
| Instalação & Tempo de comissionamento| 1620 semanas no local| 1012 semanas no local| ~40% mais rápido |
| Fine Gold Recovery Efficiency (100 malha)| Altamente variável; muitas vezes 70% reporting to concentration stage.| Significant reduction in initial losses. |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade de projeto: Nominal 500 toneladas métricas por hora (TPH) of 200mm feed material at a bulk density of ~1.6 t/m³.
Requisitos de energia: Carga total conectada aproximadamente 650750 kW (depende da configuração). Primary supply recommended at 1000V /50Hz or as specified.
Especificações de materiais:
Aço Estrutural: S355JR
Concha do tambor purificador & Levantadores: Aço resistente à abrasão (>400 BNH) / Optional Nihard castings
Screen Decks/Chutes/Launders:: Wear plates ≥AR400; replaceable liners in AR500
Correia transportadora:: Mínimo EP630/4
Dimensões Físicas (Modular):
Módulo de purificação (CxLxA): ~16m x 5m x .5m
Módulo de triagem:: ~12m x 0,5m x 0,5m
Feed/Discharge Conveyors:: Variable lengths; standard width = mm
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C. Dust suppression spray system included as standard.

6. CENÁRIOS DE APLICAÇÃO

Operação aluvial em grande escala na África Ocidental |

Desafio:: A mine processing deeply weathered gravels faced severe clay blinding in their existing trommel screens, causing hourly cleanout stops and an estimated fine gold loss exceeding % through inefficient classification.
Solução:: Implementation of this OEM factorybuilt washing plant featuring the intensive attrition scrubber followed by linear motion screening decks with highpressure spray bars.
Resultados:: Clay blinding was eliminated, allowing continuous operation at design capacity of TPH without manual intervention. Combined with optimized hydrocyclones for desliming overall project recovery increased by percentage points within the first quarter

Weathered Hard Rock (Saprolita) Processing in South America |

Desafio:: Transitioning from hard rock milling oxide ore required effective scrubbing liberation without over grinding the fragile saprolite which contained valuable coarse gold particles prone sluicing
Solução:: The modular washing plant was configured lower rotational speed scrubber longer retention time gentle but thorough cleaning followed precise screening separate plus fraction direct gravity circuit minus fraction cycloning
Resultados:: achieved near complete liberation while preserving natural particle size coarse gold enabling simple efficient downstream gravity recovery circuit overall processing cost per ton reduced compared traditional crushing milling route

Mine Development Contractor Specializing FastTrack Projects |

Desafio:: Needed reliable high capacity pre concentration plant that could be deployed within weeks new site minimal civil works quickly demobilized project end reduce client capital exposure
Solução:: Selected this bolt together modular washing plant due its proven rapid installation timeline standardized containerized electrical packages precommissioned factory
Resultados:: Successfully commissioned three separate projects under month contract each from delivery site first production demonstrating model repeatable scalable deployment significantly enhancing contractor competitive bidding position

CONSIDERAÇÕES COMERCIAIS

Pricing tiers are structured around core configuration scope:

Base Plant Tier Includes primary feed hopper scalping screen heavy duty scrubber primary sizing screen product conveyors walkways ladders basic PLC control panel Priced competitively as turnkey module

Enhanced Recovery Tier Adds secondary fine screening deck hydrocyclone cluster sump pump package advanced instrumentation monitoring Priced additional representing significant uplift recovery efficiency

Full Closed Loop Tier Incorporates slurry distribution system thickener clarified water return pumps comprehensive automation package Requires detailed site assessment priced project specific basis

Optional Features High frequency screen deck final rinsing sand product ceramic lined slurry pumps remote telemetry access real time performance data

Service Packages Extended warranty years parts labor Annual inspection maintenance contracts Onsite operator training programs Inventory consignment kits critical wear parts

Financing Options Available through partnered financial institutions include equipment leasing structures trade existing assets flexible payment terms aligned with project cash flow timelines

Perguntas frequentes

What upstream crushing requirements are needed for this TPH washing plant The plant designed handle nominal feed size maximum mm ideally requires consistent feed from primary secondary crushing circuit ensure optimal performance scrubber screening decks

Can the plant be modified handle different mineral sands like chromite iron ore Yes core scrubbing sizing modules can be adapted specific gravity particle size distribution other minerals Consult engineering team application review required modifications spray patterns screen apertures etcetera

What typical operational workforce required run this plant Designed highly automated requiring personnel per shift oversee feed monitor systems perform routine checks significantly reducing labor intensity compared older technology plants

How does OEM factory build ensure quality over site assembled construction Manufacturing controlled environment allows precision jig boring superior welding quality comprehensive pre shipment testing individual modules This results better alignment faster installation higher long term structural integrity verifiable through dimensional reports test certificates supplied delivery

What lead time expected from order placement commissioning Lead times vary based configuration current production schedule Typically range between months ex works Expedited options may available additional cost includes sea freight delivery basic civil drawings foundation plans support timely implementation