Turn-Key Ore Processor

The jaw crusher, hammer mill and fine gold shaker table form the heart of the basic ore processor system. They are integrated into a turnkey unit by installing them into structural frameworks, linking them with hoppers, feeders and conveyors, and wiring them, ready for connection to a power source and water source. For long term operations, we recommend using a ball mill instead of the hammer mill to grind finer and reduce maintenance costs.

For questions and/or an expert opinion on what size and accessories you’ll need to complete your job, we’re here to help answer anything you have.


Contact us

 

Overview

Product Description

Our turnkey systems are gravity concentration plants that are easy to run and easy to maintain: simple, proven mechanics with no computers or electronics. Environmental and personnel safety issues are minimized with no use of leach chemicals or mercury.

For the small scale miner, these are the most cost effective, industrial grade processors available for continuous operation. The jaw crusher, hammer mill and fine gold shaker table form the heart of the processor. They are integrated into a turnkey unit by installing them into structural frameworks, linking them with hoppers, feeders and conveyors, and wiring them, ready for connection to a power source and water source.

Our basic turnkey ore processors utilize a cost-effective, heavy-duty hammer mill for the final pulverization just prior to the gravity shaker table.   They are intended for proof-of-concept and bulk sampling programs, as well as commercial production of up to several thousand tons of ore.

However, the maintenance cost and downtime is significant with a hammer mill, so a longer term milling operation will usually choose to utilize a ball mill.  The operator must consider the cost/benefit equation, as the initial cost of a ball mill is multiple times more costly than a hammer mill.  However, our turnkey ore processors are designed so that the hammer mill can be directly replaced by a ball mill at a future time, with all other machinery remaining in service.

Standard Milling Process

Step 1

Ore enters the jaw crusher and is reduced to ~½” minus to be fed into the hammer mill. Primary crushing to -½” material substantially reduces wear on the hammer mill.


Step 2

The material then enters the hammer mill with a small amount of water to keep dust down and to mix the material into a wet slurry. Dry powder does not “wet out” thoroughly for sluicing and tabling. Retention time in the mill is minimized in order to avoid over-grinding the free milling gold and sulfides. When limited to a gravity recovery system, over-grinding is the enemy of recovery, since abraded “micron” gold is lost in the tailings unless chemical leaching is used.

The discharge from the mill has a bell curve distribution of sizes: a few larger pieces, some extremely fine material, and a high percentage somewhere in the middle (~20-100 mesh). The oversized gangue material needs to be recirculated back to the inlet of the mill for finer grinding, but the larger gold needs to be removed from the ore stream to avoid over grinding. The discharge of the mill enters a “nugget trap” sluice where the larger free gold (~50 mesh and larger) is removed. The discharge of the sluice is then screened to a nominal +20 mesh, and now barren of the oversized gold, is sent back to the mill. The -20 mesh slurry from the sluice, containing fine gold, sulfides and gangue, goes to the shaker table.

Many people ask about ball mills for fine grinding. Ball mills are the industry standard for fine grinding, but they are expensive, permanent, and take a lot of power. They are best suited for long term installations where all the slurry is ground to a fine texture and recovery is via flotation and/or cyanide leaching. A serious challenge with ball mills for gravity circuits is to avoid over-grinding the values. Hammer mills have a high rate of wear, but are cost effective, easy to maintain, and have a high through-put for their small footprint.


Step 3

Once the material exits the sluice and screen, it feeds directly onto the shaker table as a -20 mesh wet slurry. The MBMM shaker table has been designed and tuned to capture very fine free gold (smaller than 325 mesh) and has the unique feature of a ramp and plateau to specifically separate the concentrates, middlings and gangue into three separate streams. The sulfide middling product will have very little free gold (less than 5%), but there may be fine gold contained within in the sulfides that can later be processed to release gold (The sulfide middling’s processed from our hard rock property assay 3-5 oz/ton with no free gold).


 

Step 4

With ore that fractures along crystalline boundaries, grinding to a -20 mesh slurry often provides a satisfactory recovery of values on the table, with a minimum of treatment. This provides immediate cash flow for the operator. If significant values are still present in the table tailings, the operator can stockpile the tailings for later re-processing, or classify the tailings with a simple gravity spiral classifier. When a spiral classifier is used, the oversized material (based on the operator’s specific ore) is sent back to the mill for further grinding and re-run again on the shaker table. Testing for the practical liberation size will determine the cut-off for the maximum size of ore particles sent to the tailings.

Uses

Uses

The turn-key ore processors:

  • Operate with mechanical crushing and grinding of the ore
  • Gravity recovery of the values on a concentrating shaker table
  • No mercury, leaching or flotation is used
  • No computers or electronic controls
  • Ninety five percent of the free milling gold down to 325 mesh is captured when operated properly. Recovery of gold as fine as 400 mesh is documented
  • The shaker table is designed to produce 3 distinct fractions:
    1. high grade (precious metals, minimal contamination)
    2. high specific gravity concentrates (middlings and value­bearing sulfides, minimal contamination) and
    3. tailings (waste)

 

The processor is designed for use as a pilot plant or for processing a limited tonnage of ore (1,000s of tons rather than 10,000s of tons), consisting of a jaw crusher, hammer mill and fine gold shaker table. The hammer mill is the limiting factor for long­term, permanent installations, as it is a high­-wear, high-maintenance machine. A ball mill is a logical and more permanent upgrade that can replace the hammer mill later, if needed.

 

More complex processing plants use flotation and/or cyanide leaching, which can be added later to this MBMMLLC system for even greater recovery, but those systems are beyond the scope of supply for MBMMLLC at this time.