1. ABERTURA ACIONADA POR PAINPOINT

Você está gerenciando uma operação de processamento de ouro onde as taxas de transferência e recuperação estão sob pressão constante?? The limitations of traditional crushing and grinding methods directly impact your bottom line. Considere estes desafios operacionais comuns:

Baixo rendimento & Alto tempo de inatividade: Alimentação manual, inconsistent ore sizing, and frequent maintenance stops on primary crushers create bottlenecks, limiting tonsperhour capacity and increasing labor costs.
Liberação Ineficiente de Ouro: Inadequate initial particle size reduction forces your grinding circuit to work harder, consuming excessive energy and still risking poor liberation of gold from host rock.
Altos custos operacionais: Reliance on multiple pieces of equipment for primary crushing, secondary breaking, and feeding results in elevated power consumption, spare parts inventories, and operator overhead.
Limitações de escalabilidade: Fixo, nonmodular systems hinder your ability to efficiently adjust processing capacity in response to changing ore grades or mine plans.

Is there a reliable, heavyduty solution that can serve as the robust first step in your comminution circuit, consistently delivering optimally sized feed to improve overall plant performance?

2. VISÃO GERAL DO PRODUTO: HeavyDuty Stamp Mill for Primary Gold Ore Crushing

Our heavyduty stamp mill is engineered as the foundational primary crushing unit for hard rock gold mining operations. Ele foi projetado para aceitar runofmine (ROM) ore and reduce it to a consistent, manageable size suitable for secondary processing in ball mills or hammer mills.

Fluxo de Trabalho Operacional:
1. Carregando: ROM ore is fed into the integrated feed hopper, designed to manage large, irregular rocks with minimal bridging.
2. Esmagamento: Mechanically driven heavy stamps (camshaft or leveroperated) are lifted and dropped onto the ore bed contained within a durable mortar box.
3. Dimensionamento & Descarga: Crushed material passes through a grated screen at the base of the mortar box. Oversize material remains for further crushing cycles, while correctly sized material discharges for conveyance to the next stage.
4. Integração de Sistemas: The unit functions as the primary node in a circuit, with discharge ideally conveyed to a sorting area or directly into secondary grinding.

Escopo de aplicação & Limitações:
Ideal para: Processing quartz veins, hard rock lode deposits, and sulfide ores where gold is locked within the matrix. Suited for both stationary plant installations and largerscale artisanal operations.
Limitações: Não foi projetado como uma solução de retificação fina. Efficiency decreases with overly clayrich or wet feed material without prior screening. Requires a stable foundation due to dynamic loads.

3. RECURSOS PRINCIPAIS

Design de moldura modular | Base Técnica: Fabricated hightensile steel Ibeam construction with bolted sections | Benefício Operacional: Enables transport to remote sites and allows for future reconfiguration or expansion of the crushing battery | Impacto do ROI: Reduz o tempo de instalação em até 40% versus weldedinplace units and protects longterm asset flexibility.

Sapatos de carimbo de liga endurecida & Mortar Liners | Base Técnica: Airhardened manganese steel or proprietary chromium carbide alloys | Benefício Operacional: Provides exceptional wear resistance against abrasive quartz material, extending component life between replacements | Impacto do ROI: Os dados de campo mostram um 6080% improvement in wear life over standard cast iron parts, directly lowering cost per ton for consumables.

PrecisionCut Camshaft & HeavyDuty Bearings | Base Técnica: Forged steel camshaft with inductionhardened lobes mounted on oversized roller bearings | Benefício Operacional: Ensures consistent stamp lift height and drop force with minimal vibration transfer to the frame | Impacto do ROI: Maximizes energy transfer to the rock crush zone and reduces unscheduled bearing failure downtime by an average of 35%.

Sistema de grelha de descarga ajustável | Base Técnica: Interchangeable grate plates with varying aperture sizes (tipicamente 1/2" para 2") | Benefício Operacional: Allows operators to control final product size based on ore characteristics and downstream mill requirements | Impacto do ROI: Optimizes overall circuit efficiency; achieving correct primary crush size can improve downstream grinding mill throughput by 1525%.

Sistema centralizado de lubrificação com graxa | Base Técnica: Manifold with lines feeding all major bearing points from a single station | Benefício Operacional: Permite segurança, rapid routine maintenance without disassembly, ensuring critical points are never missed | Impacto do ROI: Standardizes preventive maintenance (PM) procedures, reduces lubrication time by 70%, and extends component service life.

Coletor de supressão de poeira integrado | Base Técnica: Preplumbed water line ports around the mortar box for nozzle attachment | Benefício Operacional: Significantly reduces silica dust generation at the point of impact, improving site air quality and operator safety | Impacto do ROI: Mitigates health compliance risks and reduces cleanup labor costs associated with dust accumulation.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Moinho de carimbo básico) | Our HeavyDuty Stamp Mill Solution | Vantagem (% Melhoria) |
| : | : | : | : |
| Disponibilidade de tempo de atividade| ~80%, frequent stops for lubrication/ adjustment| >92%, via centralized lube & robust bearing design| +15% tempo operacional |
| Vida útil da peça (Sapato)| 500 800 horário de funcionamento| 1,200 1,500 horário de funcionamento| +60% mínimo |
| Toneladas por hora (TPH)| Variável; often limited by feed design| Consistent throughput via optimized hopper geometry & cam profile| +2030% throughput stability |
| Eficiência Energética (kWh/tonelada)| Maior devido a perdas por atrito & vibração| Lower via direct drive alignment & efficient kinetic transfer| 18% average power consumption per ton crushed |
| Instalação / Relocation Time| Weeks for foundation setting/assembly| Days due to modular bolttogether design| 65% site commissioning time |

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade da gama de modelos: 110 Toneladas por hora (TPH), depending on ore hardness and target discharge size.
Requisitos de energia: Configured for electric motor or diesel drive options.
Acionamento por motor elétrico: 3075 HP (2256 kW), 3fase.
Diesel Drive Option: Direct coupling to industrial diesel engines.
Especificações de materiais:
Construção de moldura: Aço estrutural ASTM A36.
Componentes de desgaste (Shoes/Liners): Aço Manganês (1114% Mn) or Chromium Carbide Overlay Plate.
Árvore de cames & Levantadores: AISI forjado 4140 Aço, heattreated.
Dimensões Físicas (Típico 5 Unidade TPH):
Pegada (C x L): Approximately 4m x 2.5m.
Altura: ~3m including hopper.
Peso aproximado: 8,500 kg.
Faixa operacional ambiental: Projetado para operação em temperaturas ambientes de 20°C a +50°C. All bearings feature sealed housings rated IP65 for dust and moisture protection.

6. CENÁRIOS DE APLICAÇÃO

MediumScale Lode Mine Expansion

Desafio:
A West African gold operation expanding its plant capacity was constrained by its manual jaw crusher setup,
which caused erratic feed to the new ball mill circuit,
leading to constant operator intervention
and suboptimal grinding performance.

Solução:
Implementation of two parallel heavyduty stamp mills as dedicated primary crushers,
configured with a specific discharge grate size
to produce ideal ball mill feed.

Resultados:
Primary crushing throughput stabilized at
5 TPH per unit,
providing consistent,
optimally sized feed
to the new grinding circuit,
which achieved its target recovery rate within two weeks of commissioning,
and overall plant throughput increased by
40%.

Cooperative Artisanal Mining Sector Upgrade

Desafio:
A South American mining cooperative using individual,
smallscale hammer mills faced high equipment failure rates
and poor recovery due
to inefficient initial particle size reduction from large ROM ore.

Solução:
Centralized processing center installation featuring
a heavyduty stamp mill as
the shared primary crushing hub,
feeding multiple secondary grinding lines.

Resultados:
A cooperativa relatou um
60%
reduction in hammer mill wear part costs due
to betterprepared feed,
a collective increase in gold yield estimated at
20%
due
to improved liberation,
and enhanced working conditions from reduced dust
and noise at individual worksites.

7. CONSIDERAÇÕES COMERCIAIS

Our stamp mills are offered in three primary tiers based on capacity scale:

1.
Standard Duty Units
(13 TPH):
Ideal for pilot plants or lowervolume operations;
includes core features like alloy liners
and modular frame;
base pricing structure available

2
HeavyDuty Production Units
(38 TPH):
Full feature set as described above;
includes centralized lube
and dust suppression manifold;
most common configuration

3
Custom HighCapacity Battery Systems
(8+ TPH):
Multiplestamp configurations on single frame;
custom engineered drives
and discharge systems;
priced per project specification

Recursos opcionais:
VFD motor controls for speed adjustment,
onboard belt conveyor systems for discharge handling,
advanced vibration monitoring sensors,
kits iniciais de peças de reposição

Pacotes de serviços:
Escolha entre Garantia Básica (
12 months parts),
Extended Service Plans (
up t o36 months),
or Onsite Training &
Commissioning Support packages

Opções de financiamento:
Commercial leasing structures are available through partners,
enabling Capex preservation;
also eligible f ortradein programs f orexisting comminution equipment

8.Perguntas frequentes

P:What is t hemaximum input rock size your stamp mill can accept?
UM:The feed hopper is designed t oaccommodate ROM ore with amaximum dimension of approximately350mm (
14 polegadas).
Consistent feeding of oversize material beyond this will reduce efficiency

P:C anyour stamp mill beintegrated wit hexisting jaw crusher orb allmill circuits?
A Yes effectively It often serves as adirect replacement f oraprimary jaw crusher ordirect feeder t oasecondary ballmill Our engineering team canreview your flow sheet t oensure compatibility an dspecify t hecorrect discharge grate sizeforyour downstream process

P:What are t hecritical daily maintenance requirements?
A Daily checks involve visual inspection offasteners wear components an dthe centralized greasing system which requires operation once pershift Weekly inspections should focus oncamshaft lifter wear an dgrate integrity Adetailed PM checklist is provided

Q How does operating astamp mill impact overall site power consumption comparedt oalternative primary crushers?
A While apowerful unit our design focuses onefficient kinetic transfer Industry testing demonstrates thatforhard rock goldore it offers acomparable ort ot allylower kWh/ton rating than many jaw crusher configurations when considering t hefull circuit benefitofoptimized feedsizeforgrinding mills

Q What is t hetypical lead time f oraheavy duty production unit?
A F orstandard models inthe3–8TPH range lead times aretypically12–16weeks fromorder confirmation todelivery port Custom configurations may require additional engineering time