1. ABERTURA ACIONADA POR PAINPOINT

Você está gerenciando operações de recuperação de ouro sobrecarregadas por taxas de transferência inconsistentes?, consumo excessivo de energia por tonelada processada, and high longterm maintenance costs? Manual crushing and grinding methods are laborintensive and limit scale, while outdated or improperly sized stamp mill equipment can lead to premature wear, tempo de inatividade não planejado, e liberação mineral abaixo do ideal. This directly impacts your bottom line through lost production hours and higher operational expenditures.

Os principais desafios incluem:
Alto custo operacional: Inefficient power transmission and excessive consumable part wear drive up the cost per ton of ore processed.
Gargalos de rendimento: Inconsistent feed rates and inadequate crushing force can create backlogs, limiting plantwide recovery efficiency.
Complexidade de manutenção: Poorly designed stamp mills require frequent, lengthy stoppages for die shoe replacement and camshaft servicing, reducing asset availability.
Recovery Inconsistency: Variable impact force and poor feed control can result in uneven particle size distribution, negatively affecting downstream cyanidation or gravity separation stages.

A questão central para os gerentes de fábrica é: como você pode alcançar confiabilidade, costeffective primary crushing of goldbearing quartz ore while maximizing uptime and simplifying maintenance workflows?

2. VISÃO GERAL DO PRODUTO

Our heavyduty stamp mill is engineered for the primary crushing and coarse grinding of gold ores. It functions as a cornerstone piece of gravity concentration or preleach comminution circuits. The operational workflow is a proven mechanical process:

1. Ore Feed: Runofmine or prescreened ore is fed into a mortar box via a regulated feed system.
2. Britagem Mecânica: Powered camshifts lift heavy castiron stamps (sapato) which are then released to drop onto the ore bed within the mortar box.
3. Pulverização & Libertação: O repetido, highimpact blows fracture the quartz matrix, progressively reducing particle size to liberate freemilling gold.
4. Descarga de lama: Crushed material is washed through a perforated screen plate at the mortar box discharge, creating a slurry for subsequent processing.

Escopo de aplicação: Ideal for small to mediumscale mining operations, plantas piloto, or as a rugged backup system where simplicity and reliability are paramount. Effective on hard rock quartz veins and alluvial deposits requiring size reduction.

Limitações: Not suitable for fine grinding to ultrafine sizes; typically integrated with ball mills or concentrator tables in a full recovery circuit. Requires a stable foundation due to dynamic loads.

3. RECURSOS PRINCIPAIS

Design modular de caixa de argamassa | Base Técnica: Bolttogether highchrome iron segments | Benefício Operacional: Enables replacement of individual wear sections without dismantling the entire frame structure. Downtime for liner service is reduced by up to 70%. | Impacto do ROI: Lowers longterm parts inventory costs and minimizes production loss during maintenance cycles.

Forged Eccentric Camshaft | Base Técnica: Singlepiece forging with inductionhardened lobes | Benefício Operacional: Provides consistent liftanddrop motion with minimal deflection under maximum load, ensuring uniform impact energy across all stamps. | Impacto do ROI: Eliminates premature camshaft failure—a major cause of catastrophic downtime—extending service intervals by over 300%.

Sistema automatizado de injeção de graxa | Base Técnica: Programmable central lubrication points on all major bearings | Benefício Operacional: Your operators are removed from hazardous manual lubrication tasks. Bearings receive precise grease volumes on scheduled intervals. | Impacto do ROI: Evita falhas de gripagem nos rolamentos, reduces lubricant consumption by an estimated 25%, and enhances workplace safety compliance.

Adjustable Screen Plate System | Base Técnica: Quickrelease clamp mechanism with multiple aperture options | Benefício Operacional: Allows rapid change of product sizing based on ore characteristics or downstream requirements in under 30 minutos. | Impacto do ROI: Increases circuit flexibility to process varying ore grades without prolonged reconfiguration stoppages.

Dynamic Counterweight Balancing | Base Técnica: Flywheelintegrated adjustable counterweights | Benefício Operacional: Neutralizes vibrational forces transmitted to the foundation during operation, significantly reducing structural stress and ambient noise levels. | Impacto do ROI: Lowers installation foundation costs by approximately 15% and extends the structural life of supporting infrastructure.

Centralized Drive Guarding | Base Técnica: Integrated safety canopy over belts, eixos, and flywheels | Benefício Operacional: Provides complete passive protection for personnel meeting global ISO safety standards for rotating machinery. | ROI Impact Mitigates risk of costly workplace incidents and associated operational delays.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Fábricas de carimbos herdadas) | Nossa solução para fábrica de carimbos | Vantagem (% Melhoria) |
| : | : | : | : |
| Stamp Shoe Lifespan| 400 600 horário de funcionamento| 900 1,200 horário de funcionamento| +100% (based on field data from comparable quartz ore) |
| Tempo médio entre falhas (Árvore de cames)| ~12 meses| 36+ meses| +200% (attributed to forging & hardening spec) |
| Rendimento de tonelagem (for equivalent footprint)| 12 TPH (varies widely)| Consistente 23 TPH rated capacity| +50% eficiência de rendimento |
| Consumo de Energia por Tonelada| ~12 kWh/ton (estimado)| ~9 kWh/ton (documentado)| 25% uso específico de energia |
| Annual Scheduled Downtime (Manutenção)| 1015 days typical| <5 days planned|< 60% reduction in lost time |

5. ESPECIFICAÇÕES TÉCNICAS

Gama de modelos & Capacidade: Disponível em 3stamp (1 TPH), 5carimbo (~2 TPH), e 10 carimbos (~34 TPH) configurations under continuous feed conditions with standard ore hardness.
Requisitos de energia: Driven by a hightorque electric motor ranging from 15 HP (3carimbo) para 50 HP (10carimbo). Voltage adaptable to site specifications (380V480V / 5060hertz).
Especificações de materiais: Mortar box liners manufactured from NiHard or highchrome cast iron (500+ BNH). Stamps constructed from forged steel with interchangeable cast iron shoes.
Dimensões Físicas (5Stamp Exemplar): Operating footprint of approximately 3m L x 2m W x 2.5m H excluding feed hopper discharge chutes.
Faixa operacional ambiental: Designed for operation in ambient temperatures from 20°C to +45°C with appropriate lubricants. Enclosed bearings provide protection against dust ingress in nonhazardous area classifications.

6. CENÁRIOS DE APLICAÇÃO

Hard Rock Quartz Vein Processing – West Africa

Desafio: A midtier operation experienced frequent breakdowns of aging stamp mill equipment processing hard quartz ore (>7 Mohs), causing unpredictable downtime exceeding two weeks monthly.
Solution Implementation of a new heavyduty stamp mill featuring the forged camshaft modular mortar box design was integrated into their existing gravity circuit.
Results Field data collected over six months showed a reduction in unplanned crusherrelated downtime by over %. Throughput stabilized at metric tons per day enabling more consistent feed to their shaking tables

Planta Piloto & Bulk Sampling – Canada

Challenge An exploration company required reliable semicontinuous crushing for bulk sampling but needed equipment that could be transported between sites without complex reassembly
Solution A modularized stamp mill skidmounted design was deployed allowing for disconnection into three major subassemblies for transport
Results The unit achieved targeted particle size distribution PSD across varying sample batches providing consistent material for metallurgical testing Setup time between sites was reduced by compared to previous contractorbased crushing solutions

Artesanal & SmallScale Mining Formalization – South America

Challenge A cooperative sought to upgrade from manual crushing methods improve gold recovery rates reduce environmental impact from mercury use
Solution A complete turnkey circuit centered on our stamp mill paired with dewatering cyclones shaking tables was installed including operator training
Results Gold recovery rates increased from an estimated % using manual methods % through measured concentrate production The mechanical system provided safer predictable output supporting better operational planning

CONSIDERAÇÕES COMERCIAIS

O preço do equipamento é escalonado com base na configuração da capacidade:
Nível I (Stamp Pilot/Skidded Unit): Entrylevel pricing suitable for bulk sampling or very smallscale production
Nível II (Stamp Standard Production Unit): Our most common configuration offering optimal balance of throughput capital cost includes standard guarding lubrication system
Nível III (Stamp HighCapacity Unit): Designed for continuous duty in established plants includes premium features like automated grease systems enhanced monitoring sensors

Recursos opcionais:
Variable frequency drive VFD motor control finetuning impact frequency power management
Integrated water spray bars dust suppression within mortar box
Remote vibration monitoring sensors predictive maintenance data collection
Spare parts kits tailored expected first years operation

Pacotes de serviços:
Basic Warranty months parts months labor covering manufacturing defects
Extended Service Agreement Includes annual inspections priority parts dispatch discounted labor rates
Onsite Commissioning Training Recommended ensures optimal startup operator proficiency safety protocols

Financing Options Available through partner institutions include equipment leasing structures tradein programs legacy machinery facilitating capital expenditure management

Perguntas frequentes

What upstream preparation does my ore require before feeding into your stamp mill?
Runofmine ore should ideally be reduced below mm via primary jaw crusher ensure efficient operation prevent blockages maximize throughput consistency

Can this equipment be integrated into my existing gravity concentration circuit?
Yes our stamp mills are designed compatibility standard slurry handling systems Particle size discharge controlled via interchangeable screen plates match requirements downstream concentrators like shaking tables jigs

Quais são os prazos de entrega típicos para instalação?
For standard models lead time ranges weeks exworks Custom configurations may require additional time Site installation commissioning typically requires days supervised our technician depending foundation readiness

Are spare parts readily available what expected inventory should we hold?
We maintain global distributor network critical wear parts shoes screen plates Based operational data we recommend holding minimum one set shoes one set screen plates liner segments minimize potential production delays due logistics

Você oferece garantias de desempenho?
We provide guaranteed mechanical performance specifications including rated throughput under defined conditions specific energy consumption within stated range Equipment must installed operated according our provided guidelines achieve these guarantees