Comprehensive Solution: 250TPH Alluvial Gold Processing Plant in Ghana

Gold mining in Ghana is a thriving industry, but alluvial deposits with sticky clay pose unique challenges for efficient extraction. As a trusted mining machinery manufacturer, we recently designed and supplied a 250TPH alluvial gold processing plant for a client in Ghana. The project required a tailored approach to handle the clay-rich ore, ensure maximum gold recovery, and maintain smooth operation. In this article, we’ll break down the process design, equipment selection, and key solutions that made this project successful—providing insights for mining professionals facing similar conditions.

 

Understanding the Ghana Alluvial Gold Project

Project Overview

Location: Ghana (a gold-rich region with significant alluvial deposits)

Processing Capacity: 250 tons per hour (TPH)

Ore Characteristics: High clay content, sticky texture, and mixed particle sizes (0-300mm)

Target Gold Concentrate Sizes: 0-6mm & 6-20mm

Caption: Due to clay interference, Ghana’s alluvial gold deposits often require specialized processing.

 

Key Challenges & Solutions

Challenge	Solution
Sticky clay hindering the material flow	High-pressure water spray guns installed on the vibrating feeder for pre-washing
Efficient scrubbing of clay-bound ore	Trommel scrubber (5000mm length, 2000mm screen) with 4 motors
Further cleaning & sizing optimization	High-frequency vibrating screen for better classification
Gold recovery from different particle sizes	Centrifugal concentrators + sluice boxes + shaking tables
Final gold purification	Smelting furnace & amalgamation for high-purity gold bars

 

Our initial assessment of the ore samples revealed the significant impact of the sticky clay. Traditional methods would have resulted in low efficiency and significant downtime due to clogging and material build-up. To combat this, our engineering team implemented a multi-stage process designed to effectively dewater and disaggregate the ore before introducing it to the core processing stages. This included a specifically designed high-efficiency washing and scrubbing system, followed by a robust vibrating sluice box to size the ore for optimal processing. The inclusion of a trommel scrubber proved crucial in managing the high clay content and maintaining the desired throughput. The careful selection of equipment was critical to ensuring optimal performance under these demanding circumstances.

 

Customized Process Design for Sticky Clay Alluvial Gold

 

 

1st stage: Feeding System

The raw materials will be sent to one hopper first, then dropped to the vibrating feeder, evenly feeding raw materials to the next machine. The vibrating feeder design with a grizzly bar, and the gap bar is 100 mm, so above 100 mm big waste stones can be easily removed here and will be sent to the waste stockpile by one belt conveyor. Less than 100 mm of materials will go to the Trommel scrubber.

 

2nd stage: Washing Screening System

0-100 mm raw materials will be evenly sent to the trommel scrubber by a vibrating feeder. The function of a trommel scrubber is to effectively remove mud/clay from raw materials, so as to separate free gold from mud/ clay. The raw materials are washed more cleanly, the gold recovery effect will be better.

After the raw materials are washed by the trommel scrubber. The Trommel scrubber is designed with a 1-layer screen equipped with a 20mm aperture. The gravel stone +20mm -100mm will be transported to the stocky pile by belt conveyor. The 0-20mm part will go to a vibrating screen for further washing and sieving out different particle sizes: 0-6 mm and 6-20mm.

6-20mm parts will go to a vibrating sluice box separately.  0-6mm parts will go to a mixing tank for well-mixed. Then use a slurry pump to pump the slurry to the next gold separators.

 

3rd stage: Gold Separator System

0-6 mm materials go to two sets of gold centrifugal concentrators for first concentrates enrichment.

The tailings of the centrifugal concentrator will go to sluice boxes to recover gold again.

All the 0-6 mm gold concentrate from the 4 sets sluice boxes after concentrator and the centrifugal concentrator will go through one handmade sieve to sieve out 0-2 mm gold concentrate,  0-2mm concentrates will be sent to a shaking table for further separation of gold and to improve gold content.

6-20mm from the vibrating screen will go to the vibrating sluice box to catch the big gold particles/ nuggets separately.

 

4th stage: Gold Purification System

All gold concentrate from sluice boxes and shaking tables is sent to a gold smelting furnace, distiller, and gold amalgamation machine for the refinery so that you can get a high-purity gold bar.

 

 

FAQ During Communication

1. Question: The raw ore with much sticky clay, we need water spray on the feeding.
   Answer: Yes, no problem, we can add two high-pressure water spray guns to the vibrating feeder silo. This allows the material to be rinsed.

   

2. Question: Based on the quoted model JXSC2500 Drum Trommel scrubber with 5000mm scrubber length and 2000mm screen part, how many motors?
   Answer: It will be 4 motors combined with 4 reducers.
3. Question: Shall we just use the Trommel scrubber screen part for screening, which means a layered screen?
   Answer: Based on your ore condition with much sticky clay your capacity is not small. Here we suggest you use one high-frequency vibration screen for further washing and screening. Then the material will be much cleaner before goes to the separation system.
4. Question: The shaking table shall be placed inside the Gold Room, and the bucket collecting underflow of the shaking table will be locked with a clear glass window panel?
   Answer: Yes, most clients place the shaking table inside the door and you can have a reliable person to operate it.
   Regarding the clear glass window panel, It’s better if you can design it when you are installing this plant. But please consider that you also need to collect the concentrate manually.
5. Question: All the oversized materials are transported to one side to facilitate subsequent truck operations
   Answer: Yes. That’s ok. We can design like that based on your requirements.

 

 

Why Ghana’s Alluvial Gold Needs Specialized Equipment?

Alluvial gold processing in Ghana requires durable, high-capacity machinery due to:

• High Clay Content: Equipment must resist clogging.
• Corrosive Environment: Coastal or humid conditions demand stainless steel or coated components.
• Local Regulations: Sustainable water and tailings management are mandatory.
  Our client’s 250TPH plant now achieves:
• Gold Recovery Rate: Over 90% (depending on ore grade).
• Minimal Downtime: Easy-maintenance design reduces operational interruptions.

 

Designing a 250TPH alluvial gold processing plant for Ghana’s sticky clay deposits required innovative solutions—from trommel scrubbers with high-pressure wash systems to gravity concentrators for maximum gold recovery. As a mining equipment manufacturer, we pride ourselves on delivering customized, efficient, and sustainable ore processing plants tailored to challenging conditions.

Need a solution for your alluvial gold project? Contact us today for expert process design and reliable mining equipment.