Atacado 500 Planta de lavagem de mineração de ouro TPH: HighCapacity Alluvial Processing Solutions

The Operational Challenge: When Your Feed Rate Outpaces Your Plant Capacity

Every hour your gold recovery circuit operates below 500 toneladas por hora (TPH), you are leaving recoverable gold in the tailings. For a midtier alluvial operation processing 4,000 toneladas por dia, um 10% efficiency loss translates to approximately 14–18 ounces of unrecovered gold per week—at current market rates, that is a recurring cost of $35,000 para $45,000 em receitas perdidas, every single week.

Plant managers in the alluvial gold sector face a specific set of constraints that directly impact profitability:

• Variabilidade alimentar: Claybound material, oversized cobbles, and highmoisture content can reduce effective throughput by 20–30% if the washing circuit lacks sufficient scrubbing energy and screening area.
• Gestão da água: Inefficient water recirculation systems increase makeup water demand by up to 40%, raising operational costs and complicating environmental compliance in waterconstrained regions.
• Downtime accumulation: A washing plant that requires 4–6 hours of weekly maintenance for screen changes, manutenção de bombas, and chute cleaning loses 2–3% of annual operating time—a direct hit to your production budget.
• Mobilization complexity: For contractors moving between sites, a plant that requires 15+ truckloads and 10 days for assembly extends nonrevenue periods significantly.

Does your current washing plant deliver consistent 500 TPH throughput on abrasive, clayladen feed? Can your operation maintain recovery efficiency while processing material with 30%+ teor de argila? Is your plant design optimized for rapid relocation and minimal civil works?

Visão geral do produto: O 500 TPH Alluvial Gold Washing Plant

Este equipamento é um modular, highcapacity rotary trommel washing plant engineered specifically for alluvial gold recovery at a nominal feed rate of 500 TPH. The system integrates feed hopper, hydraulicdriven rotary scrubber, peneira vibratória multideck, and integrated sluice or centrifugal concentrator recovery circuit into a single, transportable processing train.

Fluxo de Trabalho Operacional

1. Carregamento de feed: A heavyduty grizzly feed hopper (with hydraulic tipping grid) accepts direct loading from 50ton haul trucks. O 25 m³ hopper capacity absorbs loader surge, maintaining steady feed to the scrubber.
2. Lavagem Primária & Esfregar: Material enters a 2.4 m diâmetro × 7.5 m long rotary scrubber with 18 mm AR400 steel liners. Highenergy tumbling action (12–14 RPM) breaks down clay agglomerates and liberates gold particles from gangue material.
3. Triagem & Classificação: Discharge from the scrubber passes over a doubledeck vibrating screen (2.4 m × 6.0 eu). Tamanho grande (+50 milímetros) reports to a radial stacker; intermediate fraction (−50 mm + 6 milímetros) is rejected or routed to secondary processing; tamanho menor (−6 mm) feeds the recovery circuit.
4. Recuperação de Ouro: The −6 mm fraction is distributed across a 2stage sluice run (12 m total length) with expanded metal and miners moss, or alternatively directed to a bank of 6 × 20inch Knelsontype centrifugal concentrators for highergrade feed applications.
5. Gestão de Rejeitos: Tailings from the recovery circuit are dewatered via a cyclone cluster and discharged to a lined tailings dam or drystack system, with process water returned to the plant's 1,200 m³/hr recirculation system.

Escopo de aplicação

This plant is suitable for:

• Alluvial gold deposits with clay content up to 35%
• Feed material with particle size up to 600 milímetros
• Operations at altitudes up to 4,000 eu (with derating above 3,000 eu)
• Ambient temperatures from −10°C to +45°C

Limitações



• Não projetado para hardrock (primário) gold ore—requires feed precrushing to −150 mm
• Recovery efficiency for fine gold (−75 µm) is limited to 40–55% in sluice configuration; centrifugal concentrators improve this to 70–80%
• Você precisa do mínimo 450 m³/hr water supply at 60 m head for optimal operation

Recursos principais

HighEnergy Rotary Scrubber | Base Técnica: Countercurrent material flow with 12–14 RPM drum rotation creates interparticle attrition | Benefício Operacional: Breaks down clay balls and coatings in 2–4 minutes retention time, ensuring complete liberation of gold particles before screening | Impacto do ROI: Eliminates the need for separate preconditioning drums, reducing capital cost by 15–20% versus twostage systems

Modular Transportable Design | Base Técnica: All components mounted on 3 × 40ft flatrack containers with quickconnect piping and electrical harnesses | Benefício Operacional: Plant can be relocated and recommissioned in 5–7 days with a 25ton crane and 4person crew | Impacto do ROI: Reduces mobilization costs by approximately $180,000–$250,000 per site move compared to stickbuilt plants

AR400 AbrasionResistant Wear Package | Base Técnica: 18 mm AR400 steel in scrubber shell, 12 mm in screen feed box, e 10 mm in all transfer chutes | Benefício Operacional: Service life of 12,000–15,000 operating hours before liner replacement, even on quartzrich feed | Impacto do ROI: Reduces annual wear parts expenditure by 30–40% versus mild steel construction

DualCircuit Recovery Flexibility | Base Técnica: Sluice runs and centrifugal concentrators are installed on independent frames with dedicated feed and discharge points | Benefício Operacional: Operators can switch between sluiceonly (alto rendimento, lower grade feed) and concentratorassisted (lower throughput, higher grade feed) without plant shutdown | Impacto do ROI: Optimizes recovery efficiency across varying feed grades, improving overall gold capture by 5–8% in heterogeneous deposits

ClosedLoop Water Recirculation | Base Técnica: 1,200 m³/hr settling tank array with cyclone dewatering and 4 × 8/6 F rubberlined slurry pumps | Benefício Operacional: Recovers 85–90% of process water, reducing makeup water demand to 120–180 m³/hr | Impacto do ROI: Lowers water procurement and treatment costs by up to $4,500 per month in waterscarce regions

Hydraulic VariableSpeed Drives | Base Técnica: Independent hydraulic motors on scrubber and screen with electronic speed control (±5% accuracy) | Benefício Operacional: Operators adjust drum speed from 8–14 RPM to match feed conditions, optimizing retention time for varying clay content | Impacto do ROI: Improves washing efficiency by 10–15% on highclay feed, reducing gold loss to oversize rejection

Integrated PLC Control with Remote Monitoring | Base Técnica: Siemens S71200 PLC with HMI touchscreen and optional satellite telemetry | Benefício Operacional: Realtime monitoring of feed rate, consumo de energia, temperaturas dos rolamentos, and recovery circuit performance from a central control room or remote location | Impacto do ROI: Reduces operator requirements by 1 person per shift and enables predictive maintenance, cutting unplanned downtime by 20–25%

Vantagens Competitivas

| Métrica de desempenho | Padrão da Indústria (400–500 TPH Class) | 500 Solução para planta de lavagem TPH | Vantagem |
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| Effective throughput on 30% alimentação de argila | 320–380 TPH | 450–500 TPH | 18–32% higher |
| Water consumption per ton processed | 3.5–4.5 m³/ton | 2.4–3.0 m³/ton | 25–33% lower |
| Gold recovery efficiency (−6 mm fraction) | 85–90% (sluice) | 92–96% (sluice + concentrador) | 5–8% higher |
| Screen media changeout time | 8–12 horas | 4–6 horas (quickrelease tensioning) | 40–50% mais rápido |
| Mobilization truckloads | 12–18 loads | 9–11 loads | 25–40% fewer |
| Commissioning time (no local) | 10–14 dias | 5–7 dias | 40–50% mais rápido |
| Wear parts cost per ton processed | $0.08–$0.12/ton | $0.05–$0.07/ton | 30–40% lower |
| Disponibilidade (horário de funcionamento / calendar hours) | 85–90% | 92–95% | 5–8% higher |

Especificações Técnicas

| Parâmetro | Especificação |
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| Nominal Feed Rate | 500 TPH (máx. 550 TPH on freedigging material) |
| Tamanho superior da alimentação | 600 milímetros (with grizzly) |
| Dimensões do purificador | 2.4 m diâmetro × 7.5 m comprimento |
| Scrubber Speed | 8–14 RPM (hydraulic variable) |
| Scrubber Drive Power | 2 × 75 kW hydraulic power packs |
| Tipo de tela | Doubledeck horizontal vibrating screen, 2.4 m × 6.0 eu |
| Screen Deck Openings | Top deck: 50 milímetros; Bottom deck: 6 milímetros (painéis de poliuretano) |
| Screen Drive | 2 × 22 motores vibratórios kW, 750–900RPM |
| Recovery Circuit | 12 m sluice run (2 × 6 m modules) OU 6 × 20inch centrifugal concentrators |
| Sluice Width | 1.5 m per module |
| Necessidade de água | 450–550 m³/hr at 60 m head |
| Water Recirculation Rate | 1,200 m³/h (settling tank capacity) |
| Potência Instalada | 320 kW (excluding feed conveyor and stackers) |
| Generator Requirement | 500 kVA mínimo |
| Dimensões da planta (L × W × H) | 38 m × 12 m × 8 eu (operando) |
| Dimensões de Transporte | 3 × 40ft flatrack containers + 2 × 20ft containers |
| Total Transport Weight | 185,000 kg (aprox.) |
| Faixa de temperatura operacional | −10°C to +45°C |
| Max Operating Altitude | 4,000 eu (desclassificar 3% por 500 m above 3,000 eu) |
| Nível de ruído (no 10 eu) | ≤ 85 dB(UM) |
| Material Estrutural | Aço estrutural S355JR, galvanizado a quente |
| Wear Liner Material | AR400 (18 mm scrubber, 12 mm screen feed, 10 mm chutes) |

Cenários de aplicação

LargeScale Alluvial Mining Operation – West Africa

| Desafio | Solução | Resultados |
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| Deposit contained 25–35% plastic clay that plugged conventional screens every 2–3 hours, reduzindo o rendimento efetivo para 280 TPH. Manual cleaning required 6 trabalhadores por turno. | Deployed the 500 TPH washing plant with highenergy scrubber and polyurethane screen panels. Adjusted drum speed to 13 RPM and increased water flow to 500 m³/h. | Throughput stabilized at 480–510 TPH. Screen plugging reduced to once per 12hour shift. A recuperação do ouro aumentou de 82% para 93% (confirmed by monthly reconciliations). Período de retorno: 7 meses. |

Contract Mining Operation – Central Asia (Alta Altitude)

| Desafio | Solução | Resultados |
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| Site at 3,200 m altitude with short 5month operating season. Previous plant required 18 days for relocation between two pits 40 km apart, consumindo 25% of the season. | Utilized the modular containerized design. Preassembled all piping and electrical connections at the workshop. Mobilized with 11 truckloads and a 25ton crane. | Mudança concluída em 6 days including recommissioning. Temporada operacional estendida por 12 dias. Adicional 6,000 tons processed per season, generating incremental revenue of $240,000. |

River Terrace Deposit – South America

| Desafio | Solução | Resultados |
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| Feed material contained 15% +50 mm oversize with high abrasivity (85% quartzo). Standard screen media lasted only 300 horas. Water supply limited to 400 m³/hr from river. | Specified the AR400 wear package and polyurethane screen panels (expected life 2,000+ horas). Activated the closedloop water recirculation system with cyclone dewatering. | Screen media life extended to 1,800 horas. Water makeup demand reduced to 100 m³/h. Disponibilidade da planta alcançada 94% over a 6month operating campaign. Operating cost per ton reduced by 22% versus previous equipment. |

Considerações Comerciais

Níveis de preços de equipamentos

| Configuração | Descrição | Indicative Price Range (FOB) |
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| Pacote Básico | Purificador, tela, sluice recovery, transportadores, sistema de controle | $1,850,000 – $2,200,000 |
| Pacote Aprimorado | Base + concentradores centrífugos (6 unidades), cyclone dewatering, enhanced PLC | $2,400,000 – $2,800,000 |
| Pacote chave na mão | Aprimorado + feed hopper with hydraulic grizzly, all stackers, settling tanks, 500 kVA genset, 12month wear parts kit | $3,100,000 – $3,600,000 |

Recursos opcionais

• Pacote de telemetria remota: Satellitebased monitoring with monthly performance reports – $45,000
• Additional sluice modules: Increase recovery area by 50% – $85,000 por módulo
• Heavyduty feed hopper: 40 m³ capacity with twin hydraulic rams – $120,000
• Dieseldriven hydraulic power packs: For operations without grid power – $95,000
• Coldclimate package: Enclosed operator cabin, heated lubrication systems, lowtemperature hydraulic oil – $65,000

Pacotes de serviços

| Pacote | Escopo | Annual Cost |
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| Manutenção preventiva | 2 scheduled site visits/year, diagnóstico remoto, inspeção de peças de desgaste | $48,000 |
| Manutenção completa | 4 visitas ao local/ano, all wear parts supplied, 48resposta de emergência por hora | $185,000 |
| Garantia de Desempenho | Plant availability ≥92%, throughput ≥480 TPH on specified feed, recovery ≥90% | $220,000 (includes penalties/credits) |

Opções de financiamento

• Locação Operacional: 36–Termos de 60 meses, monthly payments from $52,000 (based on $2.4M equipment value)
• Empréstimo de equipamento: 20–30% down payment, 5termo do ano, fixed or floating rates
• ProductionLinked Payment: Monthly payment calculated as percentage of gold recovered (minimum guaranteed payment applies)
• SaleandLeaseback: For operations with existing equipment looking to upgrade

Perguntas frequentes

1. What is the minimum feed grade required for economic operation of this 500 Planta de TPH?

Based on current operating cost benchmarks ($3.50–$4.50 per ton processed including depreciation, combustível, trabalho, e peças de desgaste), a feed grade of 0.15–0.20 g/m³ is the practical economic threshold at current gold prices. No 0.15 g/m³, daily production is approximately 60–75 grams (2–2.4 oz) per 12hour shift. Operations with feed grades below 0.10 g/m³ should consider highercapacity equipment to achieve economies of scale.

2. How does the plant perform on feed with high clay content (acima 35%)?

The rotary scrubber is designed for clay content up to 35% at full rated throughput. Acima deste nível, we recommend reducing feed rate to 400–450 TPH and increasing drum speed to 14 RPM. For deposits with clay content exceeding 45%, a preconditioning drum or highpressure water cannons at the feed hopper may be required. Field data from West African operations shows 92% availability maintained on 30–35% clay feed over 6month campaigns.

3. What is the expected gold recovery rate, and how is it verified?

Recovery efficiency depends on feed particle size distribution and gold liberation:

• Sluiceonly configuration: 85–92% for gold coarser than 150 µm
• Sluice + concentradores centrífugos: 92–96% for gold coarser than 75 µm
• Fine gold (−75 µm): 40–55% in sluices, 70–80% with concentrators

Recovery is verified through monthly reconciliation comparing feed grade (from drilling and sampling) against gold production, with adjustments for incircuit inventory. We provide a sampling protocol and calculation methodology with the plant documentation.

4. What are the site preparation requirements before plant delivery?

The plant requires a level area of approximately 60 m × 40 eu (including settling ponds). Civil works include:

• Compacted hardstand (300 mm compacted fill or existing competent ground)
• Concrete pads for settling tanks and genset (opcional, depending on soil conditions)
• Water supply line (mínimo 200 mm de diâmetro) to the plant feed point
• Tailings containment area with sufficient capacity for 4,000–5,000 m³/day of tailings

Site preparation typically takes 5–7 days with a dozer and compactor. The plant itself requires a 25ton crane for assembly.

5. What is the lead time for manufacturing and delivery?

Standard manufacturing lead time is 16–20 weeks from order confirmation, depending on current production schedule. Isso inclui:

• Engineering and documentation: 2 semanas
• Fabrication and assembly: 10–12 weeks
• Factory acceptance testing (GORDO): 1 semana
• Disassembly and containerization: 1–2 weeks
• Envio (Porta FOB): 1–2 weeks to major ports

Entrega rápida (12–14 weeks) is possible with a 10% sobretaxa, subject to production slot availability.

6. How does the plant handle oversize material (+50 milímetros)?

Oversize material is rejected by the top screen deck and discharged via a radial stacker to a separate stockpile. This material typically represents 10–20% of feed volume and is either rehandled for further processing (if it contains goldbearing material) or used for road construction and backfill. For deposits where oversize carries significant gold values, an optional secondary scrubber and screen module can be added to process this fraction.

7. What training and ongoing support do you provide for operator teams?

The standard package includes:

• 2week onsite commissioning with 2 senior technicians
• Treinamento de operadores: 5 days covering plant operation, procedimentos de segurança, e manutenção de rotina
• Maintenance training: 3 days covering wear parts