1. ABERTURA ACIONADA POR PAINPOINT

Suas operações de recuperação de ouro estão limitadas por um rendimento inconsistente?, consumo excessivo de energia por tonelada, or unplanned maintenance halting your entire milling circuit? Legacy stamp mill configurations often lead to three critical challenges:

Libertação abaixo do ideal & Recuperação: Inefficient crushing and grinding can fail to fully liberate gold from complex ores, leaving measurable value in your tailings and directly impacting your bottomline recovery rate.
Altos gastos operacionais: Aging stamp mills with manual controls consume disproportionate power for their output. Unoptimized wear part cycles lead to frequent, costly replacements and associated labor downtime.
Inflexible Plant Design: Fixedconfiguration equipment struggles to adapt to varying ore hardness and feed grades, forcing operations to run at a constant, often inefficient, pace regardless of feedstock variability.

How do you increase tonnage throughput while improving recovery consistency? Can you reduce energy and maintenance costs without a complete plant overhaul? The answer lies in a purposeengineered, customized stamp mill assembly plant.

2. VISÃO GERAL DO PRODUTO

Um moderno Customized Stamp Mill Gold Mining Assembly Plant is not a single machine but an integrated processing system engineered for the specific comminution (esmagamento) of goldbearing ore. It replaces antiquated, standalone stamp batteries with a synchronized circuit designed for reliability and efficiency.

Fluxo de Trabalho Operacional:
1. Feed principal & Regulation: Runofmine (ROM) ore is fed via a regulated conveyor system to a primary scalping or jaw crusher for initial size reduction.
2. Controlled Stamp Milling: Precrushed ore is fed uniformly to a battery of modernized stamp mills. Each camdriven stamp (or pestle) is precisely weighted and dropped in a controlled cycle onto the ore within a hardened mortar box.
3. Formação de Polpa & Descarga: Crushed material mixes with water in the mortar box to form a slurry, which passes through a discharge screen with precise aperture sizing, ensuring only sufficiently liberated material exits the circuit.
4. Gravity Concentration Ready: A lama descarregada, containing nowliberated gold particles, is directed to downstream processes like sluices, agitando mesas, or centrifugal concentrators for separation.

Escopo de aplicação & Limitações:
Escopo: Ideal for smalltomedium scale hard rock gold mining operations, particularly where ore is amenable to gravity recovery methods. Effective for both freemilling ores and as a primary crusher for refractory ores ahead of leaching.
Limitações: Not suitable for hightonnage operations exceeding several hundred TPD where ball mill/cyanide circuits are more economical. Performance is highly dependent on correct customization for local ore characteristics.

3. RECURSOS PRINCIPAIS

Design de moldura modular | Base Técnica: Aparafusados, highcarbon steel structural sections | Benefício Operacional: Enables staged deployment and easier future plant expansion or reconfiguration with minimal foundation work | Impacto do ROI: Reduces initial capital outlay and cuts expansion downtime by up to 40% compared to welded monolithic frames.

Variable Weight & Lift Control | Base Técnica: Adjustable camshaft profiles and interchangeable stamp head weights | Benefício Operacional: Operators can finetune impact energy and cycle frequency in response to realtime ore hardness readings | Impacto do ROI: Os dados de campo mostram um 1525% improvement in energy efficiency (kWh/tonelada) when optimized for feed stock variability.

Forro & Wear Part Standardization | Base Técnica: Commonality in mortar box liners, discharge screens, and stamp shoe designs across the battery | Benefício Operacional: Simplifies inventory management and allows for faster changeouts during scheduled maintenance windows | Impacto do ROI: Reduces spare parts inventory costs by ~30% and decreases mean time to repair (MTTR).

Integrated Water Management Manifold | Base Técnica: Centralized piping with individual flow controls to each mortar box | Benefício Operacional: Ensures consistent slurry density across all stamps, critical for optimal screen discharge and downstream recovery | Impacto do ROI: Improves overall recovery consistency by maintaining ideal process conditions, minimizing gold loss to coarse tailings.

Sistema centralizado de lubrificação com graxa | Base Técnica: Automated network delivering measured grease to all major bearing points on camshafts and guides | Benefício Operacional: Elimina pontos de lubrificação manual, reducing contamination risk and ensuring bearing longevity under highload conditions | Impacto do ROI: Extends major bearing service life by an average of 50%, preventing costly unscheduled stoppages.

HeavyDuty Discharge Screen System | Base Técnica: Replaceable screen decks with reinforced clamping mechanisms made from abrasionresistant steel | Benefício Operacional: Provides uniform particle sizing control; screens can be replaced on individual stamps without shutting down the entire battery | Impacto do ROI: Maintains steadystate throughput; industry testing demonstrates <5% throughput variance over a screen’s service life.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Legacy Stamp Battery) | Customized Stamp Mill Assembly Plant Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Consistência de rendimento +/ 20% variance due to manual feed/water control +/ 5% variance via integrated feed & slurry management >15% melhoria |
| Eficiência Energética ~2.5 3.5 kWh/ton ~1.9 2.4 kWh/ton with VFD controls Up to 30% melhoria |
| Tempo médio entre falhas (MTBF) 450600 horas (major bearings) 8001000 horas (major bearings) ~65% improvement |
| Recovery Grade (% Au in +100 mesh fraction) Higher fine gold loss in tailings Optimized crush size & slurry control reduces coarse +100 mesh loss Measurable reduction; sitedependent |

5. ESPECIFICAÇÕES TÉCNICAS

Classificação de capacidade: Configurável de 5 TPD (singlestamp pilot plants) até 300 TPD multibattery industrial installations.
Requisitos de energia: Primary drive via electric motor(é). Typical range from 15 kW per stamp for smaller units up to integrated plant systems requiring 150400 kW carga total conectada.
Especificações de materiais: Mortar boxes lined with ASTM A532 Class III Type NiHard alloy or equivalent; Stamps constructed from forged highcarbon steel with replaceable alloy shoes; Structural frame from ASTM A36 steel.
Dimensões Físicas: A singlestamp unit footprint starts at approx. 2m x 2m. Full assembly plants are customdesigned but typically require a prepared area of 15m x 25m minimum for a midrange circuit including feed systems.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +50°C. Enclosed gear drives protect against dust ingress; special seals available for highhumidity environments.

6. CENÁRIOS DE APLICAÇÃO

MidScale Hard Rock Mine Expansion

Desafio:
An existing operation using two legacy stamp batteries faced bottlenecks after opening a new vein with harder quartzite ore. Throughput dropped by 35%, energy costs soared, and maintenance frequency increased unacceptably.
Solução:
Implementation of a customized fourstamp assembly plant module designed specifically for the harder ore characteristics, featuring our Variable Weight & Lift Control system.
Resultados:
Plant restored target throughput of 85 TPD within six weeks of commissioning at the new site while operating at an improved specific energy consumption of <2 kWh/tonne—a net gain despite harder feedstock—and scheduled liner changes extended from every two weeks back out monthly intervals.

Artesanal & Mineração em pequena escala (ASM) Cooperative Upgrade

Desafio:
A cooperative using disparate manual stamps had inconsistent recovery rates between operators leading internal disputes over revenue sharing along with significant environmental concerns regarding uncontrolled water use
Solução:
Deployment standardized threestamp assembly plant complete Integrated Water Management Manifold centralized collection settling ponds
Resultados:
Achieved uniform recovery rate across all operators increasing overall yield Measurable water recycling reduced fresh water consumption Tailings management improved meeting basic regulatory requirements

7 CONSIDERAÇÕES COMERCIAIS

Pricing tiers are projectspecific based on required capacity level customization However typical brackets include:

Basic Tier ($80k$150k):
Includes core stamped battery modular frame essential drives motors Suitable brownfield replacement projects where existing infrastructure reused

Nível de desempenho ($150k$400k):
Comprehensive turnkey package including primary scalping crusher automated feed conveyor belt water recycling system PLCbased monitoring controls

Atualizações de recursos opcionais:
Ore presorting grizzly feeder Advanced vibration monitoring sensors Remote operational diagnostics package Alternative wear part materials specific highly abrasive ores

Pacotes de serviços:
Standard warranty covers defects materials workmanship Extended service agreements available covering scheduled preventive maintenance parts discounts priority technical support Financing Options Equipment leasing structures available through partners as well progressbased milestone payment plans large projects

8 Perguntas frequentes

Q1 How compatible is this customized plant our existing downstream gravity concentration equipment?
A1 Our engineering team conducts full process review ensure seamless interface Your current sluices tables concentrators Typically we design discharge launder systems match your existing setup minimizing integration costs

Q2 What typical implementation timeline look like from order commissioning?
A2 For standard Performance Tier system lead time manufacturing ranges Delivery installation commissioning typically completed within weeks following arrival site depending local infrastructure readiness

Q3 Can this system handle both alluvial placer concentrates hard rock ores?
A3 While primarily engineered hard rock applications systems can be configured process highgrade placer concentrates However feed size distribution must controlled achieve optimal performance

Q4 What operator training provided?
A4 We provide comprehensive onsite training covering normal operation routine maintenance troubleshooting procedures Documentation includes detailed manuals schematics Training ensures your team achieves rated performance quickly safely

Q5 Are spare parts readily available internationally?
A5 Yes We maintain global distributor network ensure critical wear parts like shoes screen decks standardized bearings stocked key regions minimizing potential logistics delays

Q6 How does pricing structure work optional features added later?
A6 We employ modular design philosophy allows many upgrades retrofitted field However some features like centralized lubrication more economical include initial build Discussing longterm plans during design phase recommended maximize value

Q7 Do you offer performance guarantees?
A7 Yes We provide guaranteed throughput capacity based your provided ore samples bond work index specifications Recovery rates are function entire process circuit but we guarantee mechanical performance crushing efficiency our equipment