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Gold mine development in Zimbabwe is often seen as a modern “gold rush frontier.” But behind the glamour, cost overruns, construction delays, and unstable production indicators after commissioning are the real pain points many investors have personally experienced.
In reality, as long as you choose the right partner, none of these have to be problems. In the 1,000 t/d gold mine EPC turnkey project in Zimbabwe, Xinhai Mining delivered real, measurable value by solving industry-wide challenges in cost control and construction delays through three smart and innovative design strategies.
Today, let’s take a closer look at this project story.
Design is the first step of every EPC project. As the “turnkey steward,” Xinhai Mining was responsible for the full-process design, covering the crushing system, grinding workshop, leaching workshop, thickening tanks, and both high- and low-voltage substations.
During the review of the geological survey, Xinhai’s Mine Design Institute accurately determined a reasonable site elevation and skillfully utilized the natural terrain, significantly reducing the total earthwork volume required for multiple workshops and large water ponds.
This alone saved the client tens of thousands to well over a hundred thousand dollars in civil construction costs and shortened the basic construction schedule by several weeks.
A well-designed gold processing flow sheet is the cornerstone of stable and efficient production. For this project, we adopted the mature and reliable process of:
Two-stage closed-circuit crushing + two-stage grinding and classification + thickening–leaching–adsorption
Crushing: A PE600×900 jaw crusher combined with an HST250H cone crusher ensured efficient reduction of 0–500 mm ore to the required size.
Grinding: A two-stage configuration using an MQGg2760 grate ball mill and an MQYg2760 overflow ball mill, paired with XCII-series high-efficiency hydrocyclone unit, ensured the final slurry fineness reached 90% passing 200 mesh, providing an optimal foundation for high-efficiency leaching.
This mature, proven process flow, together with precise equipment selection, is the guarantee of our commitment to long-term, stable operation.
The leaching recovery rate is directly tied to the client’s final revenue.
In this project, we installed 10 large leaching agitation tanks (SJ8.5×9.0) to form an 8-stage leaching–adsorption system targeting a 90% leaching rate.
To reliably achieve this core metric, we abandoned the traditional interconnected air supply method—which commonly causes flow interference—and designed an independent screw air compressor exclusively for the air-lifters.
This innovation:
Significantly improved carbon transfer speed
Eliminated “air competition” between components
Ensured a stable ~90% leaching rate, directly protecting the client’s economic return
In traditional plant design, the hydrocyclone clusters for both classification stages (XCII series) are typically installed within the main grinding building. This arrangement increases the building height, structural complexity, and overall construction cost.
We made a bold optimization by moving the second-stage classification system outside of the main workshop and installing it on a dedicated steel platform.
This change:
Significantly reduced the height and load requirements of the main building.
Lowered structural investment
Allowed the cyclone platform and grinding building to be constructed in parallel, effectively shortening the critical construction schedule for the grinding workshop and related civil works.
Conclusion
A successful mineral processing EPC project is not only about “building it well,” but about building it smart, cost-effective, and fast through professional engineering design.
This is precisely the core value of Xinhai Mining’s EPC+M+O service model—delivering a modern processing plant with lower investment, faster commissioning, and more stable long-term operation through forward-thinking design and holistic cost control.
If you are seeking a reliable global mining EPC provider—or facing challenges such as unstable leaching recovery or budget overruns—contact us today to learn how Xinhai can tailor a cost-reduction and efficiency-enhancement solution specifically for your project!
+86 13811510145