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“Ten months—Phase II reached full design capacity ahead of schedule, with actual throughput exceeding the design by 25%!” These figures represent the efficiency report we delivered for the Phase II expansion of the oxidized gold ore processing plant in Iran. Yet what speaks louder than numbers is the client’s decision to choose us again—after the Phase I plant had run successfully and steadily for years. This renewed trust is rooted in our consistent, reliable delivery, continuous innovation, and our core capability to create superior value for clients.
This is a project story about “trust.”
In 2020, Xinhai completed the EPC turnkey construction of the client’s first 500 t/d gold processing plant. From design to commissioning, the project took less than one year and achieved rapid startup. The final processing capacity steadily reached 600 t/d, with all key indicators outperforming contractual requirements. The long-term, stable, and efficient performance of Phase I established a solid foundation of trust between the parties.
Three years later (2023), when the client decided to expand production, this time-tested trust naturally evolved into another collaboration. The client clearly requested a standardized replication of the proven process and equipment system. By adding a new 600 t/d production line, we expanded the total design capacity to 1200 t/d. From project kickoff to meeting and surpassing the target capacity took only ten months, and the actual processing capacity reached an impressive 1500 t/d. With stable operation and outstanding performance, the project once again fulfilled—and exceeded—its promise.
For this project, we provided full-process EPC services from the fine ore bin to the desorption and electrowinning workshop. We deeply understand that the essence of EPC lies not in simply supplying equipment, but in taking full responsibility and optimizing the entire system. The highlights of this expansion include:
(1) Maximizing use of existing equipment: We thoroughly assessed the original crushing system and integrated it seamlessly with the new line through precise engineering design, effectively reducing both capital investment and construction time.
(2) “Surgical-level” upgrades to ensure uninterrupted production: Through targeted modifications to the Phase I leaching system—such as enlarging pipelines and upgrading screening units—we significantly increased overall processing capacity while keeping the original line running continuously, ensuring zero interruption to the client’s cash flow.
(1) Tailings dry stacking with enhanced economic benefits: The selected filter press, equipped with pressure filtration and cake-washing functions, not only ensures environmental compliance but also increases pregnant solution recovery and produces high-solids filter cakes. This directly reduces tailings transportation costs and long-term storage risks for the client.
(2) Eliminating long-standing operational bottlenecks: In the grinding and classification stage, we replaced the traditional sand-return belt conveyor with a high-efficiency classifier, fundamentally solving issues of slurry leakage and spillage, creating a clean plant environment, and significantly lowering long-term maintenance costs and safety risks.
Forward-looking design to remove bottlenecks: We proactively expanded the fresh-water storage tank to eliminate potential water-supply constraints that could limit future full-capacity operation, ensuring long-term stable performance across the entire system.
The expansion strictly followed and optimized the mature flowsheet verified in Phase I: Crushing → Grinding & Classification → Cyanide Leaching → Carbon Adsorption → Desorption & Electrowinning → Tailings Dewatering.
Crushing: Reuse of the original system with added conveying links; final product size ≤15 mm.
Grinding & Classification: Two-stage closed-circuit grinding achieves a final fineness of 80–85% passing through a 200-mesh screen, ensuring optimal leaching efficiency.
Cyanide Leaching: Upgraded to 10-stage leaching with a guaranteed 26-hour retention time and a high-efficiency aeration system to maximize gold recovery.
Carbon Adsorption & Refining: Loaded carbon undergoes desorption and electrowinning to produce gold sludge, which is then smelted into high-purity bullion, ensuring a closed, highly efficient recovery circuit.
Tailings Dewatering: Advanced filter presses produce dry-stackable filter cakes, ensuring safety and environmental compliance.
The successful continuation of the Iran project fully demonstrates the EPC+M+O full-lifecycle cooperation model advocated by Xinhai. What we deliver is not only a high-performance plant, but also predictable success, a replicable experience model, and the potential for continuous future optimization.
For investors seeking to build or expand gold processing plants—especially those focused on capital efficiency, long-term operating costs, and project certainty—choosing a partner with deep process expertise, holistic system integration capability, and long-term operational service competence is the most critical factor for project success.
Every successful project delivered is our promise to clients; every renewed collaboration is the most valuable recognition from our clients. We look forward to becoming your trusted long-term partner, leveraging our global experience and comprehensive solutions, especially in oxidized gold ore processing.
— About Us —
Xinhai Mineral Processing EPC specializes in providing EPC+M+O (Engineering, Procurement, Construction + Mine Management + Operation) full-lifecycle services to the global mining industry. In gold processing—particularly oxidized gold ore treatment—we possess deep technical expertise, mature process solutions, and extensive successful case studies. We are committed to safeguarding the value, growth, and sustainable development of our clients’ mining assets through comprehensive professional services.
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