In 2024, Xinhai Mining successfully undertook and implemented the 1000t/d gold processing plant project in Zimbabwe. This project not only demonstrated our professional capabilities in the mineral processing field but also provided the client with an efficient and economical solution through optimized design and technological innovation.
The process flowsheet for this project was scientifically sound and reasonable, covering the stages of crushing, grinding, classification, leaching, and tailings handling. Here is a detailed description of each system:
A new crushing system was established, adopting a two-stage one closed-circuit process. ROM ore is fed by the vibrating feeder F5X1045 into the jaw crusher PE600x900 for primary crushing. The crushed product is conveyed by belt conveyor to the vibrating screen S5X2760 for screening. The undersize (qualified product) enters the fine ore bin, while the oversize is returned to the cone crusher HST250H1 for secondary crushing. The crushed product from the cone crusher is then conveyed back to the vibrating screen S5X2760, forming a closed circuit. This design ensures high crushing efficiency and a high yield of qualified product, laying a solid foundation for subsequent processes.
A new grinding and classification system was set up, utilizing a two-stage grinding and two-stage classification circuit. Primary grinding employs an MQGg2760 grate discharge ball mill, with primary classification handled by a cluster of XCII-350x4 cyclones. Secondary grinding uses an MQYg2760 overflow ball mill, and classification is performed by a cluster of XCII-250x10 cyclones. The cyclone underflow returns to the overflow ball mill, while the overflow (fine slurry) flows by gravity to the trash remover screen DZS1530 and then to the NZY-24 thickener. This process ultimately produces a slurry with 90% passing 200 mesh, providing ideal conditions for the leaching circuit.
The leaching system utilizes 10 x SJ8.5x9.0 leaching agitation tanks, designed for an eight-stage Leach while Adsorb (LAA) process. Through a primary pre-leach thickening stage and multiple adsorption stages, the leaching rate stabilized around 90%. This system, integrated with our reagent storage tanks and compressor house design, ensured the continuity and high efficiency of the leaching process.
Tailings are pumped to the client's existing tailings storage facility (TSF), achieving efficient resource utilization and environmentally sound management. The fresh water supply system utilizes a head tank, while reclaim water is stored in an excavated pond, optimizing water circulation and reducing operating costs.
In this project, we fully leveraged our technical expertise and service advantages to provide a customized solution tailored to the client's needs. Here are the core highlights:
Facing the challenge of diverse opinions from the client's team and frequent design changes, we demonstrated exceptional flexibility and professionalism. By rapidly iterating and optimizing the design, we ensured the project's efficient advancement. Simultaneously, we deeply integrated the geotechnical survey data, enabling precise design and utilization of the site elevation and topography. This significantly reduced earthworks and civil engineering costs, laying a solid foundation for shortening the project timeline and reducing overall costs.
Regarding the process flow and core equipment, we implemented key innovations: the pre-leach thickening stage ensured optimal slurry density, and the innovative configuration of a dedicated screw air compressor for the airlift device resolved the common pain point of unstable air supply inherent in traditional Roots blower systems.
This significantly enhanced system stability and the leaching rate. Furthermore, the modular, independent layout of the classification system effectively reduced the structural complexity and construction difficulty of the main processing plant. This series of technical measures collectively formed the core advantage enabling the project's efficient, stable operation and the achievement of a 90% high leaching rate.
Through the successful implementation of this project, we not only enabled the client to achieve highly efficient gold recovery but also significantly enhanced the project's economic viability and sustainability through optimized design and technological innovation. Achieving a 90% leaching rate, coupled with reduced civil investment and a shortened construction period, fully demonstrates our comprehensive service capabilities in the mineral processing field.
In the future, Xinhai will continue to uphold the service philosophy of "What you need is exactly what we can deliver!" to provide more high-quality solutions for global mining projects.
If you have a similar project requirement, please feel free to contact us. We will tailor a solution to your specific needs.
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