1. PAINPOINT DRIVEN OPENING

Are you managing gold recovery operations burdened by inconsistent throughput, excessive downtime for maintenance, and unpredictable operating costs? Key challenges in primary ore crushing and liberation often include:

High Operational Downtime: Frequent liner changes and mechanical failures in crushing circuits halt your entire processing line, costing thousands per hour in lost production.
Inefficient Gold Liberation: Inconsistent particle size from primary crushers leads to poor contact in subsequent leaching or gravity circuits, directly reducing overall recovery rates.
Excessive Energy Consumption: Older crushing technologies consume disproportionate power per ton of ore processed, eroding profit margins.
High Maintenance Labor Costs: Complex, laborintensive maintenance routines for legacy stamp mills or jaw crushers increase your total cost of ownership and safety exposure.
Scalability Limitations: Inflexible equipment that cannot adapt to varying ore hardness or feed grades creates bottlenecks in expanding operations.

Is your operation seeking a robust, highavailability solution for primary gold ore reduction that delivers consistent sizing, reduces lifecycle costs, and protects your recovery circuit’s efficiency?

2. PRODUCT OVERVIEW

The modern heavyduty stamp mill is a mechanized percussion crushing system engineered for the primary liberation of gold from quartz and hard rock ore. It is designed as a reliable, highimpact workhorse for mediumtohigh volume operations where consistent sub10mm output is critical for optimal downstream cyanidation or gravity recovery.

Operational Workflow:
1. Feed Introduction: Runofmine (ROM) ore is fed into a robust steel mortar box.
2. Mechanical Percussion: Powered camshafts lift and release a series of weighted stamps (5002000kg each), delivering controlled, highimpact blows onto the ore bed.
3. Progressive Reduction: Ore is crushed through repeated impact against hardened die plates within the mortar box.
4. Slurry Discharge: Finely crushed material exits through a discharge screen at the mortar box perimeter, mixed with water to form a slurry ready for secondary processing.

Application Scope & Limitations:
Ideal For: Hard rock gold ores (quartz veins), pilot plants, operations prioritizing mechanical simplicity and high uptime over ultrafine grinding.
Limitations: Not suitable for soft, clayrich ores that cause packing; requires consistent feed size (typically <100mm); operates most efficiently within defined moisture content parameters.

3. CORE FEATURES

Modular Mortar Box Assembly | Technical Basis: Segmented, bolttogether highchrome iron casting | Operational Benefit: Enables rapid replacement of individual wear sections during scheduled maintenance without full assembly disassembly. | ROI Impact: Reduces liner change downtime by up to 65%, increasing annual operational availability.

HydroPneumatic Lift Mechanism | Technical Basis: Replaces traditional mechanical cams with controlled fluid power cylinders | Operational Benefit: Provides adjustable stroke length and impact force from a central control panel, allowing realtime optimization for varying ore hardness. | ROI Impact: Optimizes energy use by 1525% compared to fixedstamp systems and minimizes shock load on foundations.

Integrated Water Injection System | Technical Basis: Precision nozzles delivering controlled water volume directly into the crushing chamber | Operational Benefit: Suppresses dust at source and ensures optimal slurry density for discharge, preventing screen blinding. | ROI Impact: Improves downstream pump efficiency and reduces dust collection CAPEX/OPEX while enhancing operator environment.

Centralized Grease Lubrication System | Technical Basis: Automated programmable system delivering grease to all major bearing points | Operational Benefit: Eliminates manual greasing routines, ensures consistent lubrication under highload conditions. | ROI Impact: Extends bearing service life by an estimated 40% and reduces required maintenance labor hours.

HeavyDuty Discharge Grizzly Screen | Technical Basis: Interchangeable screen panels made from abrasionresistant steel | Operational Benefit: Provides precise control over final product size while resisting deformation under continuous impact. | ROI Impact: Ensures consistent feed for downstream processes; panel replacement takes under 2 hours versus full grid replacement.

Foundation StressDispersion Frame | Technical Basis: Reinforced steel base frame engineered to distribute dynamic loads over a wider area | Operational Benefit: Dramatically reduces vibration transmission, protecting plant infrastructure and allowing installation on more sites. | ROI Impact Lowers civil engineering requirements by approximately 20%, reducing initial installation costs.

4. COMPETITIVE ADVANTAGES

| Performance Metric | Industry Standard (Legacy Stamp Mill/Jaw Crusher) | Modern Stamp Mill Solution | Advantage (% Improvement) |
| : | : | : | : |
| Availability (Uptime)| 8085% (due to frequent liner/bearing maintenance) | 9295% (modular design & autolubrication)| +12% operational time |
| Tons per kWh| Lower efficiency; fixed energy draw per cycle| Adjustable stroke optimizes energy per ton crushed| +18% energy efficiency |
| Mean Time Between Failure (Major)| ~1,500 operating hours| ~2,800 operating hours| +87% reliability |
| Liner Change Duration| 1624 hours (full crew)| 68 hours (modular swap)| 67% downtime event |
| Product Size Consistency (% within target range)| +/ 15% variation common|< +/ 8% variation typical| +47% consistency |

5. TECHNICAL SPECIFICATIONS

Model Range & Capacity: Available in 5stamp to 20stamp configurations; throughput from 1 to 12 tons per hour per stamp depending on ore hardness and target grind.
Power Requirements: Electric motor driven; power range from 30 kW (5stamp) to 250 kW (20stamp). Configured for 400V/50Hz or other industrial standards.
Material Specifications: Mortar box liners and dies manufactured from NiHard or HighChrome Cast Iron (600+ BHN). Stamps constructed from forged alloy steel with replaceable heads.
Physical Dimensions (20Stamp Unit): Approx. Length: 8m x Width:3m x Height:4m . Weight:~45 metric tons.
Environmental Operating Range: Designed for ambient temperatures from 20°C to +45°C . Dust suppression system maintains compliance in enclosed buildings.

6. APPLICATION SCENARIOS

MidTier Gold Mine Expansion Challenge:| Challenge:A West African operation needed to double primary crushing capacity but faced space constraints and unreliable power quality that caused frequent jamrelated stoppages in their jaw crusher circuit.| Solution:| Implementation of two parallel modular stamp mill lines with hydropneumatic drives capable of handling variable power input without stalling.| Results:| Achieved target throughput with a 30% smaller footprint than a jaw/cone circuit; unscheduled stoppages reduced by 90%. Payback period was calculated at 22 months based on recovered production time.

Artisanal & SmallScale Mining Formalization Challenge:| Challenge:A South American cooperative processing hard rock vein material required a scalable solution to move from manual pounding methods to mechanized processing while maintaining simplicity of operation.| Solution:| A containerized fivestamp mill plant with preinstalled foundations was deployed as part of an integrated gravity recovery circuit.| Results:| Throughput increased from <0.5 TPH to consistent 3 TPH . Gold recovery rates improved by an estimated 35% due to consistent liberation size . The system was operational within one week of site delivery .

Pilot Plant & Bulk Sampling Challenge:| Challenge:A mineral exploration company required reliable primary crushing for variably mineralized bulk samples without crosscontamination between batches.| Solution:| A skidmounted tenstamp mill with easily cleaned surfaces , stainless steel slurry launders ,and quickdisconnect washdown ports was installed.| Results:| Enabled rapid processing of over ,000 tons of sample material with thorough cleanout between zones , providing accurate grade data for feasibility studies . The unit was later relocated twice with minimal cost .

7 COMMERCIAL CONSIDERATIONS

Equipment pricing tiers are structured based on capacity , automation level ,and material specifications:

• Base Configuration Tier Includes core stamp mill assembly , standard motors ,and manual controls . Suitable for operations with existing plant infrastructure .
• Advanced Automation Tier Adds PLC control systems , variable frequency drives VFDs , remote monitoring sensors ,and automated lubrication . Recommended for new greenfield installations .
• Premium Wear Package Tier Upgrades all wear components NiHard liners / forged alloy stamps / AR discharge screens )and includes an initial spare parts inventory .

Optional Features:
• Integrated feed hopper with vibrating grizzly
• Dedicated slurry sump & pump package
• Acoustic enclosures / dust containment systems
• Predictive maintenance sensor suite vibration / temperature monitoring

Service Packages:
• Commissioning & Operator Training Onsite
• Annual Preventative Maintenance Inspections
• Guaranteed Wear Parts Supply Program

Financing Options:
Capital expenditure can be structured through established partnerships with equipment financing specialists offering leasetoown agreements or extended payment terms aligned with project cash flow typically over , ,or month periods .

8 FAQ

Q What upstream crusher is required before feeding ore into the stamp mill?
A A modern stamp mill typically requires ROM ore precrushed to approximately mm via a small jaw crusher or gyratory breaker This ensures efficient operation within the mortar box .

Q How does the stamp mill solution compare financially vs installing new cone crushers?
A While cone crushers offer higher throughputs they carry significantly higher capital cost greater operational complexity require specialized maintenance skills The modern stamp mill presents lower CAPEX simpler OPEX profile making it highly competitive up TPH range particularly where robustness easeofmaintenance are prioritized

Q Can this equipment process tailings or previously leached material?
A It is not recommended The abrasive nature combined lack valuable mineral content leads accelerated wear without economic return The system is engineered specifically virgin hard rock gold ore

Q What are typical lead times delivery installation?
A For standard models lead time ranges weeks exworks Delivery installation timelines depend site readiness but typical commissioning period supervised team days

Q Are training operator manuals provided?
A Yes comprehensive digital paperbased manuals provided along mandatory onsite commissioning training covering safe operation routine maintenance troubleshooting procedures

Q What warranty offered?
A Standard warranty covers manufacturing defects major structural components months operating hours whichever comes first Extended warranties available purchase cover wear parts drive components

Q Can existing foundation be used retrofit?
A Engineering team can assess existing foundation plans provide retrofit specifications Dynamic load characteristics modern mills differ legacy units so professional review essential