Targeting: Commercial Gold Mining Operations, Plant Managers, Engineering Procurement & Construction (EPC) Firms

1. Operational Challenges in Primary Ore Crushing & Liberation

Efficient primary ore processing is the foundation of profitable gold recovery. Inefficiencies at the stamp mill stage create bottlenecks that constrain entire operations. Key challenges include:

High Specific Energy Consumption: Traditional singlepass crushing methods often consume excessive power per ton of ore processed, directly eroding profit margins.
Inconsistent Particle Size Distribution: Poorly controlled discharge from primary crushing leads to uneven feed for downstream concentration (e.g., sluices, tables), reducing overall recovery rates by 515%.
Excessive Maintenance Downtime: Frequent wear part replacement and unplanned mechanical failures halt production. Industry data indicates some operations lose over 20% of available runtime to stamp mill maintenance.
LaborIntensive Operation & Monitoring: Reliance on manual feeding and adjustment leads to process variability and higher operational overhead.
Scalability Limitations: Older designs struggle to maintain efficiency when scaling throughput to match increased feed from expanded mining faces.

Is your operation maximizing recovery from the first critical stage of size reduction? Are your energy and maintenance costs per ton under control?

2. Product Overview: Modern HeavyDuty Stamp Mill for Gold Ore Processing

A modern stamp mill is a robust, mechanical crushing system designed for the primary liberation of gold from quartz rock and other ores. It functions as a costeffective workhorse for mediumscale operations and specialized highgrade vein processing.

Operational Workflow:
1. Feed Introduction: Runofmine (ROM) ore is fed into a secure hopper, regulating flow onto a heavyduty anvil block (mortar box).
2. Cyclical Percussive Crushing: Powered camshafts lift and drop a series of weighted stamps (shoes) in a continuous cycle, pulverizing ore through direct impact.
3. Size Classification & Discharge: Crushed material passes through a perforated screen plate at the base of the mortar box. Oversize material remains for further crushing, while liberated material (<2mm typical) is washed into collection sluices for gravity concentration.

Application Scope & Limitations:
Ideal For: Processing freemilling gold ores where gravity recovery is effective; operations with intermittent power supply; rugged, remote environments; and processing centers handling ore from multiple smallscale sources.
Considerations: Less efficient for refractory ores requiring fine grinding (<100 mesh) or complex chemical liberation. Throughput is typically lower than highvolume ball mill or HPGR circuits, making it most suitable for operations processing 50500 tons per day.

3. Core Features of Our Industrial Stamp Mill Design

Our engineering focus delivers reliability and operational cost savings at the primary crushing stage.

Modular Stamping Assembly | Technical Basis: Independent, replaceable stamp units with standardized connections | Operational Benefit: Isolate maintenance to a single stamp without shutting down the entire mill bank. Reduces repair time by up to 70%. | ROI Impact: Minimizes lost production during wear part changes.
Hardened Alloy Composite Shoes & Dies | Technical Basis: Chromium carbide inserts cast into highstrength steel bodies | Operational Benefit: Increases wear life by a factor of 35x compared to standard manganese steel. Maintains consistent weight for uniform crushing force. | ROI Impact: Lowers consumable parts cost per ton and reduces inventory holding requirements.
Adjustable Screen Grid System | Technical Basis: Rapidclamp screen frames with multiple aperture options (1mm 4mm) | Operational Benefit: Operators can adjust final product size in under 15 minutes to optimize downstream recovery based on ore type. | ROI Impact: Enables process tuning to maximize gold yield without mechanical modification.
Centralized Grease Lubrication Manifold | Technical Basis: Automated, programmable lubrication points on all major bearings and camshafts | Operational Benefit: Eliminates manual greasing errors, ensures optimal bearing life, and prevents dust ingress. | ROI Impact: Reduces bearing failure rates by an estimated 40%, preventing costly secondary damage.
VibrationDampening Base Frame | Technical Basis: Isolated spring mounts or rubber buffer pads between the mill frame and foundation | Operational Benefit: Significantly reduces transmitted vibration, protecting building structures and allowing installation on more sites without extensive foundational work. | ROI Impact: Lowers civil engineering costs for new installations by approximately 15%.
Integrated Water Flow Management | Technical Basis: Calibrated spray bars within the mortar box with adjustable flow controls | Operational Benefit: Ensures optimal slurry consistency for efficient discharge through screens and into collection launders. Prevents clogging and sanding up. | ROI Impact: Improves process stability, reducing operator intervention time.

4. Competitive Advantages & Performance Metrics

Field data from sidebyside comparisons demonstrates clear improvements over legacy stamp mill designs.

| Performance Metric | Industry Standard (Legacy Design) | Our Stamp Mill Solution | Advantage |
| : | : | : | : |
| Wear Part Life (Shoes) | 2,000 3,000 operating hours | 8,000 12,000 operating hours | +300% improvement |
| Mean Time Between Failure (MTBF) | ~450 hours (major components)| >1,200 hours (major components)| +167% improvement |
| Energy Consumption per Ton Crushed| ~3.5 kWh/ton (for 2mm product) | ~2.8 kWh/ton (for 2mm product)| 20% reduction in specific energy |
| Target Size Consistency (± variance)| High variance due to wear/feed fluctuation| Consistent PSD through adjustable screens & regulated feed| Enables more efficient downstream recovery |
| Scheduled Maintenance Downtime| 1015 hours per month| 46 hours per month| ~60% reduction in planned downtime |

5. Technical Specifications

Model Range & Capacity: Available in configurations from 1stamp (5 TPD pilot) to 20stamp batteries (500 TPD). Standard commercial unit is a 10stamp mill rated for 200250 tons per day of quartz ore.
Power Requirements: Driven by a hightorque electric motor or diesel drive option. Standard 10stamp unit requires a 75 kW (100 HP) motor at 1500 RPM.
Material Specifications: Mortar box constructed from ASTM A36 steel plate with replaceable liner plates.Stamp stems from hightensile steel; shoes from proprietary hardened alloy composite.Camshafts are forged steel, induction hardened.
Physical Dimensions (10Stamp Mill): Approx. Length: 4m x Width 2m x Height 3m . Weight approx 18 metric tons .
Environmental Operating Range: Designed for ambient temperatures from 10°C to +45°C . Dust seals rated for IP54 protection . Suitable for altitudes up to 3000m above sea level .

6. Application Scenarios

Vein Mining Operation in West Africa

Challenge:A remote site with unreliable grid power needed a simple robust solution to process high grade quartz vein ore at 150 TPD . Downtime was catastrophic for cash flow .
Solution Installation of two parallel 5stamp mills powered by dedicated diesel generators . The modular design allowed transport via difficult access roads .
Results The operation achieved 92% gold liberation at 2mm crush size . Mill availability exceeded 94% due to reduced maintenance . The consistent feed improved overall plant recovery by 11% .

Central Processing Facility for Artisanal Aggregators

Challenge A buying center receiving variable ore types from multiple small scale miners required flexible rapid adjustment to process different materials without cross contamination .
Solution A bank of four independent 3stamp mills each with its own feed hopper water control and adjustable screen grid .
Results Operators can switch between ore types in minutes optimizing crush size for each batch This flexibility increased throughput by 30% and allowed premium pricing for superior liberation services .

7. Commercial Considerations

Pricing Tiers
Base Equipment Package Includes mill frame stamps drive motor starter panel and base lubrication system .
Premium Package Adds automated grease system spare parts kit wear monitoring sensors and onboard control PLC .
Turnkey Installation Package Includes civil engineering drawings supervised installation commissioning support operator training .

Optional Features
Diesel drive package
Dust suppression canopy
Advanced vibration monitoring system
Remote performance telemetry package

Service Packages
Standard Warranty months parts months labor
Extended Service Plan years including scheduled maintenance inspections priority support
OnSite Parts Consignment Stocking Program ensures critical spares are available locally minimizing downtime risk

Financing Options Available through partner institutions include equipment leasing capital loan structures and lease topurchase agreements tailored to mining project cash flows .

8. Frequently Asked Questions FAQ

What upstream crusher is best paired with a stamp mill?
A jaw crusher is ideal for primary reduction feeding ROM ore down to mm fragments which optimizes feed size for the stamp mortar box This combination maximizes throughput efficiency

Can your stamp mill be retrofitted into an existing plant layout?
Yes Our modular design allows adaptation to most existing foundations Feed hoppers discharge launders can be custom fabricated onsite Integration with existing water supply slurry collection systems is standard practice

How do you ensure consistent performance as wear parts degrade?
The adjustable screen grid compensates for slight reductions in crushing efficiency Furthermore our composite shoes exhibit linear wear profiles not catastrophic failure allowing predictable scheduling of replacements

What are the lead times for major replacement parts?
Standard wear parts shoes dies screen grids are stocked regionally with guaranteed delivery within days Critical structural components have a typical manufacturing lead time of weeks

Do you offer performance guarantees?
Yes We provide guaranteed throughput capacity within % based on defined ore hardness indices specific energy consumption within % tolerance availability based on adherence prescribed maintenance schedules