1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Are you managing a small to midscale gold operation where consistent, lowcost comminution is critical to profitability? The challenges of processing hard rock gold ore are welldocumented: excessive energy consumption from oversized equipment, high maintenance costs from abrasive materials, and the logistical complexity of operating in remote locations. These factors directly erode your margin. When your primary crushing and grinding circuit is inefficient, you face not only increased power costs but also lost recovery from inadequate liberation. Как добиться надежного, fine grinding for effective cyanidation or gravity recovery without the capital outlay and operational overhead of a full ball mill circuit? The answer lies in a proven, purposebuilt technology: the modern Custom Stamp Mill.

2. ОБЗОР ПРОДУКТА

А Custom Stamp Mill is a mechanized gravitydriven crushing mill designed specifically for the liberation of freemilling gold from quartz or other host rock. It modernizes the historic stamp battery principle with durable materials and precision engineering for continuous, lowtonnage operation.

Операционный рабочий процесс:
1. Кормить: Калиброванная руда (обычно 2" from a primary jaw crusher) is fed into a enclosed mortar box.
2. Дробление & Шлифование: Механически поднятые тяжелые штампы (обувь) are dropped in sequence onto the ore within the mortar box, pulverizing it by repeated impact.
3. Увольнять & Классификация: Pulverized material passes through a screen at the mortar box discharge, with oversize material recycled and fines reporting to subsequent gold recovery processes (например, шлюзы, концентраторы).

Область применения & Ограничения:
Идеально подходит для: Свободная добыча золотых руд, пилотные установки, smallscale commercial operations (150 ТПД), historical mine reprocessing, and locations with limited water or power infrastructure.
Ограничения: Not suitable for refractory ores requiring fine grinding below 100 mesh for liberation, or for hightonnage operations exceeding 75 ТПД. Performance is optimal on brittle, siliceous ores.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Модульная конструкция рамы | Техническая основа: Конструкция из высокоуглеродистой стали, скрепленная болтами | Операционная выгода: Enables transport to remote sites in standard containers and rapid onsite assembly with minimal heavy lifting | Воздействие на рентабельность инвестиций: Сокращает время установки до 60%, lowering total project mobilization costs

Сменные башмаки для штампов & умирает | Техническая основа: Cast manganese steel or alloy chrome iron wear surfaces | Операционная выгода: Operators can reverse or replace highwear components without dismantling the stamp assembly, extending service intervals | Воздействие на рентабельность инвестиций: Cuts planned maintenance downtime by approximately 30% and standardizes spare parts inventory

Регулируемая высота падения & Каденс | Техническая основа: Частотно-регулируемый привод (ЧРП) on camshaft motor | Операционная выгода: Provides precise control over impact energy and grind size to match ore hardness variability; allows softstart capability | Воздействие на рентабельность инвестиций: Optimizes specific energy consumption (кВтч/тонна) and improves overall gold recovery consistency by ensuring target liberation size

Integrated Water Injection System | Техническая основа: Controlled manifold with solenoid valves at each mortar box | Операционная выгода: Suppresses dust at point of impact and creates a slurry for efficient discharge; flow is adjustable per stamp | Воздействие на рентабельность инвестиций: Mitigates health/safety risks and environmental dust emissions while improving material handling

Централизованная смазка консистентной смазкой | Техническая основа: Automated system servicing all major bearings on camshaft and lifters | Операционная выгода: Ensures critical moving parts operate under consistent lubrication pressure in dusty environments | Воздействие на рентабельность инвестиций: Предотвращает преждевременный выход подшипников из строя, a leading cause of unplanned downtime in abrasive applications

Система ситовых картриджей HeavyDuty | Техническая основа: Quickrelease clamp mechanism on mortar box discharge | Операционная выгода: Allows screen mesh changes in under 15 minutes to adjust final product size for downstream process optimization | Воздействие на рентабельность инвестиций: Increases plant operational flexibility and throughput by minimizing process changeover delays

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Отраслевой стандарт (Малая шаровая мельница / Молотковая мельница) | Custom Stamp Mill Solution | Преимущество (% улучшение) |
| : | : | : | : |
| Удельное энергопотребление (кВтч/тонна) | 12 18 кВтч/тонна (for similar grind size) | 8 10 кВтч/тонна (гравитационный удар) | Снижение ~35% |
| Стоимость изнашиваемых деталей на тонну обработки| $1.50 $3.00 (hammers/liners) | $0.75 $1.25 (stamp shoes/dies)| Снижение ~50% |
| Время установки на месте| 46 недели (фундамент, выравнивание) | 12 недели (модульная сборка) | Снижение ~70% |
| Target Grind Size (Р80)| Переменная; can be less efficient at coarser grinds| Optimal range of 20100 mesh for freemilling gold| More efficient within designed range|
| Noise Level at 10m| 95105 дБ(А) (constant noise) | 8590 дБ(А) (intermittent impact)| ~50% Lower Avg. Sound Pressure|

P80 = The sieve size that passes 80% of the product.

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Диапазон мощности: Настраивается из 1 к 75 Тонн в день (ТПД), based on number of stamps (310 units common).
Требования к питанию: Primary drive motor(с): 1575 kW total (20100 HP), dependent on stamp weight and count. Standard supply: 400/480В, 3фаза, 50/60 Гц.
Характеристики материала: Рамка: ASTM A36 Carbon Steel; Марки & Обувь: Высокохромистый чугун или марганцевая сталь; Вкладыши для минометных коробок: AbrasionResistant Steel Plate (>400 БХН).
Физические размеры: Single stamp unit footprint: ~1m x 1m; A typical 5stamp mill with feed conveyor occupies approx. L6m x W3m x H4m.
Экологический рабочий диапазон: Температура окружающей среды: 20°С до +45°С; Humidity Tolerance: До 95% неконденсирующийся; Designed for operation at altitudes up to 3,000m.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

Малый рудник с твердыми породами, Западная Африка

Испытание:A remote site with limited grid power required a simpletooperate grinding circuit for vein quartz ore to replace manual crushing. Diesel generation costs made highenergy milling prohibitive.
Решение:A customdesigned fivestamp mill powered by a single diesel generator was installed alongside shaking tables.
Результаты:The operation achieved a stable throughput of 8 TPD at a grind of 30 сетка. Gold recovery improved to >92%, while fuel consumption dropped by over half compared to the previously considered small ball mill option.

Historic Tailings Reprocessing Project

Испытание:A contractor needed to reprocess old mill tailings containing coarse liberated gold locked in silicate fragments using a mobile plant with quick setup.
Решение:A skidmounted threestamp mill was integrated into a containerized gravity recovery plant.
Результаты:The plant was operational within five days of arrival on site.The stamp mill effectively broke apart the silicate conglomerates without overgrinding malleable gold particles.Gravity recovery rates exceeded initial estimates by over fifteen percent due to improved liberation characteristics.

7.КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Ценовые уровни:
Базовый блок(3Stamp):Includes frame,камеры,мотор,ЧРП,and one set of wear parts.
PlantReady Package(5Stamp):Includes base unit plus integrated feed conveyor,отстойник,and slurry pump,motor control center(МСС).
SkidMounted/Turnkey Module:Fully assembled unit tested prior to shipment including all ancillary equipment.

Дополнительные функции:Dust enclosure kit,screen cartridge sets(assorted meshes),advanced vibration monitoring sensors,wash water recycling system.

Пакеты услуг:Standard warranty covers structural integrity.Available extended service agreements include annual inspections,скидки на изнашиваемые детали,and priority technical support.Financing options include equipment leasing through partner institutions tailored towards mining projects.

8.Часто задаваемые вопросы

вопрос:What primary crusher feed size is required for an efficient stamp mill operation?
A.For optimal performance,the feed should be reducedto minus two inches(50мм).This is typically achievedwitha small jaw crusher.A correctly sized feed prevents jammingand ensures consistentstamp drop energyis appliedto particle breakage rather than oversized rocks.

вопрос:Cana stamp mill handle wet or clayrich ore?
A.Stamp mills perform beston dryor moderately moist,friable ore.High clay contentcan leadto packingin themortar box reducing efficiency.In such cases,a scrubbingor classification step priorto crushingis recommended.Field data showsaddinga simple trommel screen aheadof themill can resolve this issue.

вопрос:Whatisthe expectedlifespanof keywear components?
A Under normal operation processing quartz ore manganese steel shoes require rotation after approximately500 hoursand replacementafter1500to2000 hoursof operation.Mortarbox dies last significantly longer.This will varybasedon specificore abrasiveness which we can evaluatefrom asample.

Q How does thenoise compareto other milling options?
A Whilethe impactcreates sound itis intermittentand often perceivedas less disruptive than constant highfrequency noisefrom hammer mills Proper installationwith basic acoustic enclosuresreadily achievescompliancewith mostsite regulations

Q Доступны ли запасные части??
A Yes All wearing parts are standardizedand stockedfor immediate dispatch Critical structural componentsare fabricatedfrom common industrial steel profiles minimizing supplychain risk evenfor remote locations