1TPH Rock Gold Process Plant In Kenya

JXSC has provided a complete set of processing plant machinery and all accessories for a Kenyan customer’s rock gold processing Plant. The client is a local mining company focused on small-scale hard-rock gold mining. They have an engineering team to set up this plant, so there is no requirement for our engineer’s site service. We offer the detailed layout design with base construction drawings accordingly, and supply all of the équipement minier for this plant.

1. The client required a processing capacity of 1tph, with the possibility to upgrade to 5 tph in the future.
2. Maximum feeding size: 150 mm
3. Type de minerai : L'or en roche
4. Mineral ore information: The gold particles are mainly fine gold, and need to be ground to 0- 1 mm size, for liberating the gold inside the rocks.

1. The raw ore is manually fed into the concasseur à mâchoires to break rocks down to 20- 30 mm. Below 30 mm, material passes through while larger pieces remain for further crushing. Workers then manually transfer the crushed material to the hammer crusher using shovels or buckets.

2. The broyeur à marteaux output falls by gravity into the ball mill for grinding. With no conveyor system, workers must manually load the ball mill with material from the hammer crusher discharge area.

3. The broyeur à boulets discharge forms a powder slurry, which workers collect manually. They then transport and feed this slurry to the shaking table using basic containers for fine gold concentration.

4. At the table à secousses, workers carefully monitor the gold separation process and manually collect the concentrated gold product, carrying out any necessary retreatment of tailings.

This customer has limit budget, so he didn’t take the connection equipment such as a belt conveyor, slurry pump. He utilizes workers to feed every machine.

Customer Questions & Our Answers

① Why is a hammer crusher needed after a jaw crusher?
A jaw crusher exerts immense force, easily crushing extremely hard raw gold ore. However, the resulting ore fragments remain large (typically several centimeters in size) and cannot be fed directly into a ball mill. The hammer crusher handles the task of further size reduction: positioned after the jaw crusher, it uses high-speed rotating hammers to pulverize the centimeter-sized ore into fine particles just a few millimeters in diameter. This process protects and optimizes the ball mill—adhering to the principle of “more crushing, less grinding.” Ball mills are inefficient at processing coarse material; feeding them directly with the coarse ore from a jaw crusher results in slow grinding speeds, high electricity consumption, and accelerated wear on the steel balls and liners. By using a hammer crusher to reduce the ore to a sand-like consistency before feeding it into the ball mill, you can significantly boost production efficiency and save substantially on electricity costs.

② Why is a ball mill needed after the hammer crusher?
Ball mills can grind materials down to 1mm, and hammer crushers can crush materials to below 2mm. Tests on this customer’s ore showed that crushing it to 1mm allows for the recovery of the maximum amount of gold, so 1mm is more suitable for him. Grinding it too finely would actually negatively affect the recovery rate.

③ Why is a shaking table used directly after the ball mill instead of a centrifugal gold separator?
The main function of the centrifuge is to initially concentrate the gold.
Because a single shaking table has a processing capacity of 1-2 tons per hour, and this customer does not have a big processing volume, using shaking tables after grinding would meet their processing needs.

④ What is the recovery of the processing line?
Depending on the characteristics of the raw ore, the recovery rate is generally around 70%.

⑤Can you provide the equipment drawings?
Once we receive your deposit payment, our engineer will design the detailed plant layout drawing and foundation drawing for you, and also each main machine’s drawing & machine operation manual.
All the technical support will be provided to assist with the installation.

⑥ Why is one belt conveyor system sufficient?
The only section requiring a conveyor belt is the stretch between the jaw crusher and the hammer crusher. This is because the jaw crusher’s discharge outlet is low while the hammer crusher’s feed inlet is high, necessitating a belt to transport the ore upward. The subsequent stages rely entirely on water flow and gravity (natural flow): the fine material discharged from the hammer crusher drops directly into the ball mill, and the slurry exiting the ball mill flows into the shaking tables—which are positioned at a lower elevation—via pipes or chutes, requiring no conveyor belts whatsoever.

⑦ If an engineer is needed, how much will it cost?
If the buyer need JXSC to send engineer to mine site for installation &commissioningguidance, need below extra cost: 1). Engineer salary $150/day/person, installation time is depends on customer minesitepreparation conditions. 2). Round-trip ticket cost 3). Visa application cost 4). Any other potential cost before or after the installation period, such as hotel cost waiting for flight, etc. 5) Arrange food.

JXSC est un fabricant professionnel d'équipements miniers et un expert en solutions minières. Il a à son actif de nombreuses réussites telles que des usines d'extraction d'or, des solutions pour les diamants, etc. nous contacter.