1. PAINPOINT DRIVEN OPENING

Is your gold recovery operation constrained by persistent bottlenecks and escalating costs? For plant managers and engineering contractors, the crushing and grinding circuit is often the source of critical inefficiencies that directly impact the bottom line. Common challenges with traditional comminution equipment include:

Excessive Downtime for Maintenance: Frequent liner changes and unplanned repairs on critical components halt production, costing thousands per hour in lost throughput.
Inconsistent Particle Size Distribution: Poorly calibrated or worn equipment yields uneven ore feed to concentration processes, reducing overall gold recovery rates.
High Energy Consumption per Ton: Older stamp mill designs and inefficient drives lead to unsustainable power costs, a primary operational expense.
LaborIntensive Operation & Monitoring: Reliance on manual adjustments and sampling increases labor costs and introduces human error, affecting process stability.
Scalability Limitations: Difficulty in efficiently scaling operations to process highergrade zones or increased ore volumes without major capital redesign.

Are you seeking a robust solution that enhances throughput predictability, reduces total operating cost per ton, and delivers consistent grind for optimal cyanidation or gravity recovery? The evolution of the modern stamp mill addresses these exact operational challenges.

2. PRODUCT OVERVIEW: HeavyDuty Gravity Discharge Stamp Mill

This product is a modern, industrialgrade stamp mill engineered for the continuous crushing and fine grinding of goldbearing ore. It is designed as a core component within a hard rock gold processing plant, typically following primary jaw crushing.

Operational Workflow:
1. Feed Introduction: Sized ore (typically 2") is fed uniformly into the mortar box via a regulated feed system.
2. GravityPowered Percussion: A series of mechanically lifted heavy stamps (shoes) are released to drop onto the ore bed within the mortar box, applying repeated impact force.
3. Particle Size Reduction: Ore is fractured by direct impact and ground via attrition between particles beneath the stamp shoe.
4. Slurry Discharge: Finely ground material is washed through a perforated screen plate at the mortar box end by a continuous water flow, creating a slurry for subsequent concentration stages.

Application Scope & Limitations:
Scope: Ideal for freemilling gold ores where liberation occurs at relatively coarse grinds. Highly effective in remote operations due to mechanical simplicity and reliability. Suited for both smallscale commercial mining and larger modular plant configurations.
Limitations: Not optimal for ultrafine grinding requirements (<100 mesh) or highly abrasive, lowgrade deposits where wear costs may be prohibitive. Requires a consistent feed size and controlled water volume for optimal operation.

3. CORE FEATURES

Modular Mortar Box Design | Technical Basis: Segmented, highchrome alloy castings with independent screen sections | Operational Benefit: Allows for replacement of individual wear sections without dismantling the entire mill frame. Reduces liner change downtime by up to 65%. | ROI Impact: Direct labor savings and increased plant availability translate to higher annual throughput.

Precision Camshaft & Lifter System | Technical Basis: Computermodeled cam profile with sealed roller bearings | Operational Benefit: Ensures synchronized, consistent lift and drop of all stamps for uniform particle size distribution. Minimizes vibrationinduced stress on the frame structure. | ROI Impact: Consistent grind improves downstream recovery efficiency by 25%, protecting revenue from gold losses.

Engineered Stamp Shoe Geometry | Technical Basis: CADoptimized weight distribution and wear profile manufactured from forged alloy steel | Operational Benefit: Maximizes kinetic energy transfer to the ore bed while promoting selfsharpening characteristics to extend service life. | ROI Impact: Reduces consumable part replacement frequency by an average of 40%, lowering direct operating costs.

Integrated Water Management Manifold | Technical Basis: Calibrated spray bars with independent zone control | Operational Benefit: Delivers precise wash water across the entire mortar box width, ensuring efficient slurry transport without dilution flooding. Your operators maintain optimal pulp density effortlessly. | ROI Impact: Conserves process water—a critical resource—and reduces pumping energy costs.

Centralized Grease Lubrication System | Technical Basis: Automated manifold delivering grease to all major bearing points from a single station | Operational Benefit: Eliminates manual greasing requirements during operation, enhancing safety and ensuring bearing longevity under highload conditions. | ROI Impact: Prevents costly bearing failures and extends major overhaul intervals, protecting capital investment.

Robust Structural Frame | Technical Basis: Laminated steel beam construction with dynamic load damping analysis | Operational Benefit: Provides exceptional stability under cyclical loading, eliminating foundation cracks and misalignment issues common in older designs.| ROI Impact: Ensures decades of service life with minimal structural maintenance, delivering longterm asset value.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Legacy Mills) | Our Stamp Mill Solution | Advantage (% Improvement) |
| : | : | : | : |
| Liner Change Downtime | 1624 hours per full changeout| 68 hours with modular design| ~67% reduction |
| Energy Efficiency (kWh/ton) | Highly variable; often >25% motor oversizing| Optimized cam design reduces parasitic load| 1520% improvement |
| Wear Part Service Life (Shoes) | 500700 operating hours typical| 9001100 hours with forged alloy design| Up to 60% longer life |
| Particle Size Consistency (P80 Variance) +/ 15% from target grind| +/ 7% from target grind under controlled feed| Over 50% more consistent output|
| Major Bearing Service Interval| 2,000 3,000 hours| 5,000+ hours with automated lubrication| Over 65% longer interval |

5. TECHNICAL SPECIFICATIONS

Capacity & Rating: Configurable from 1ton per hour (single stamp pilot units) to modules exceeding 20 TPH per mill frame.
Power Requirements: Dependent on configuration; typical range from 30 kW (5stamp unit) to 150 kW (20stamp unit). Motors are standard IE3 efficiency class.
Material Specifications:
Mortar Box Liners / Screen Plates: HighChrome Alloy Cast Iron (550+ BHN)
Stamp Shoes & Heads: Forged Alloy Steel, heattreated
Camshaft & Lifters: Inductionhardened steel with sealed roller bearings
Structural Frame: ASTM A36 Steel
Physical Dimensions (Example 10 Stamp Mill): ~6m L x 3m W x 4m H (foundation footprint required).
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C. Enclosed bearing systems are rated for highdust environments common in milling plants.

6. APPLICATION SCENARIOS

MidScale Hard Rock Mine Expansion

Challenge:A West African operation needed to double its processing capacity but faced space constraints and unreliable power.The existing legacy mills caused excessive vibration and required constant maintenance attention.
Solution:The installation of two modular heavyduty stamp mills configured for coarse grinding (20 mesh), paired with efficient gyratory crushers.The mills' stability allowed placement on an elevated platform,saving footprint.
Results:Downtime related to grinding circuit maintenance fell by over70%.The predictable power draw enabled effective generator management.Plant throughput reliably achieved22 TPH,supportingthe planned expansion without requiringa new building structure.

Historical Tailings Retreatment Project

Challenge:A contractor reprocessing historical tailings in North America requireda rugged,easily relocatable solutionto process variable material on different sites.The abrasive nature ofthe old slag material caused rapid wearin conventional hammer mills.
Solution:A skidmounted fivestamp mill unitwith easily adjustable discharge screens.The forged alloy shoes proved highly resistantto abrasion,andthe simple mechanical design allowedfor quick setupand teardownby asmall crew.
Results:The unit achieveda consistent grind suitablefor subsequent gravity concentration acrossthree different sites.Wear part costs were45% lower than previous methods,andthe project met its recovery targets aheadof schedule due toreduced mechanical delays.

7.COMMERCIAL CONSIDERATIONS

Our stamp mills are offeredin clear pricing tiers basedon capacityand construction:

1.Standard Duty Series(Up to5 TPH): Costeffective designfor steadystate operationswith lower tonnage requirements.Includes core featureswith manual lubrication options.Idealfor expanding existing small minesor specialized reprocessing plants.
2.HeavyDuty Modular Series(5–20+TPH): The flagship range featuring full modularity,the automated lubrication system,and premium wear materials.Recommendedfor new greenfield projectsor complete circuit upgrades where uptimeis critical.Pricingis structuredper modulewith volume discounts available formultiunit purchases.Optional featuresinclude advanced vibration monitoring sensors,wash water flow meters,and custom discharge screen configurations.Service packages range from basic commissioningand operator trainingto comprehensive annual inspectionand partskit programs.Financing options including equipment leasingand milestonebased project financing can be structuredto alignwith your project's cash flow timeline.We provide detailed CAPEX/OPEX models toprecisely forecast your cost per ton overthe equipment lifecycle

8.FAQ

Q:What feed size doesyour stamp mill require?
A.For optimal performance,a maximum feed sizeof 2 inches(50mm)is recommended.This typically requires primary jaw crushing beforehand.We can provide specificationsfor compatible crushers

Q:Canyour mills be integrated intoan existing carboninpulp(CIP)or gravity circuit?
A Yes.They are engineeredtodelivera consistent slurry product suitablefor direct feedingintoshaking tables centrifugal concentrators or cyanidation leaching tanks We will reviewyour target P80 grind sizeto ensure compatibility

Q:Whatisthe expected operational noise level?
A While percussive action inherently generates sound our heavyduty frames incorporate damping measures Field data shows sound levelsat10 meters typically range between85–90 dB(A) whichis comparableto other industrial grinding equipment Proper hearing protectionfor personnelis always advised

Q:Whatarethe lead timesfor deliveryand installation?
A Lead times varyby model complexity Standard Duty unitscan ship within12 weeks while fully customized HeavyDuty modules may require16–20 weeks We provide supervised installationby our technical team as part ofthe commissioning package

Q:Doyou offerwear part guarantees?
A Yes We provide performance warrantieson our forged alloy shoesand highchrome liners basedon processed tonnage under normal abrasive conditions Guarantee detailsare specifiedinthe commercial agreement

Q:What trainingis providedfor ouroperators?
A Comprehensive training covers safe startup/shutdown procedures daily inspection checkpoints routine maintenance tasks like screen changesand troubleshooting guides foreommon issues This occurs during onsite commissioning

Q:Arethere options fora fully enclosed dust control system?
A Yes We can engineer bolton enclosureswith integrated dust extraction ports Thisis often specifiedfor plants locatedin environmentally sensitive areasorto improve overall site working conditions