EPC Turnkey Solutions for Gold Ore Processing Plants: Process Design Based on Ore Characteristics and Production Capacity

Small-scale (30–200 metric tons per day)

• Characteristics: Investment-sensitive, relatively simple processes; suitable for dispersed ore deposits, new small-scale plants, and pilot plants;
• Configuration Logic: Prioritize solutions with compact processes (such as CIL with simultaneous leaching and absorption), high equipment standardization, and minimal custom-made components;
• Reference Investment: Complete set of main equipment costs approximately $200,000–$750,000 (based on CIP/CIL processes, for the 30–200 metric tons per day range).

Medium-scale (200–1,000 metric tons per day)

• Characteristics: The mainstream scale for conventional processing plants; offers significant flexibility in process selection; equipment configuration must balance capital and operating costs;
• Configuration Logic: Select CIL or CIP based on ore type; configure crushing and grinding according to the “more crushing, less grinding” principle; determine the number of leaching and adsorption tanks based on leaching time; match desorption and electrolysis capacity with carbon production rate;
• Reference Investment: Complete set of main equipment costs approximately $450,000–$1.9 million (for the 200–1,000 metric tons per day range).

Large-scale (1,000–5,000 metric tons per day)

• Characteristics: Significant economies of scale; high requirements for large-scale equipment and automation; system stability is a top priority;
• Configuration Logic: Floatation prioritizes large-scale XCF/KYF aerated configurations; multi-stage closed-circuit grinding; leaching and adsorption involve multiple tanks in series with segmented control; desorption and electrolysis prioritize high-temperature, high-pressure processes (for hard-to-desorb carbon and large-scale operations); integrated automated control systems;
• Reference Investment: Complete set of main equipment approximately US$1.5–3.8 million (for the 1,000–5,000 metric tons per day range).

Phase 1: Requirements Discussion and Preliminary Assessment

We assess the type of gold deposit, ore grade, expected processing capacity, target product specifications, and site conditions to determine a preliminary process direction. The client provides basic mine data or laboratory test results.

Phase 2: Process Design and Equipment Selection/Quotation

Based on ore data and site conditions, we determine the processing route (gravity separation, flotation, cyanidation, or a combined process) and provide an equipment configuration list, equipment selection plan, and preliminary investment estimate.

Phase 3: Proposal Confirmation and Commercial Contract

Confirm the process flow, equipment list, scope of delivery, project schedule, and responsibilities of both parties item by item. The contract clearly defines the responsibilities of the general contractor and the client, with no hidden costs.

Phase 4: Engineering Drawing Design

Prepare site layout plans, equipment foundation drawings, layout diagrams, piping route diagrams, electrical control schematics, and civil engineering drawings, and provide a comprehensive technical briefing.

Phase 5: Equipment Manufacturing and Supply

Core equipment is manufactured in accordance with drawings and process standards; standard auxiliary equipment not produced in-house is procured through centralized quality inspection. The client simultaneously advances the “three utilities and one leveling” and the construction of the plant foundation.

Phase 6: Logistics and Shipping

Coordinate packaging, shipping, ocean/land transport, customs clearance documentation, and milestone tracking; for overseas projects, plan shipping routes and schedules in advance and allow for a customs clearance buffer.

Phase 7: On-Site Construction Supervision, Installation, and Commissioning

Dispatch engineers to guide equipment positioning, pipeline connections, and electrical installation; lead individual unit commissioning and integrated commissioning tests with water and feed materials; and optimize grinding fineness, chemical dosing regimens, and leaching parameters until the first batch of qualified gold concentrate or blended gold is produced.

Phase 8: Personnel Training and After-Sales Support

Comprehensive theoretical and hands-on training is provided to ensure the client\'s team can independently adjust reagent regimes, grinding fineness, and leaching parameters; upon completion of acceptance and handover, the project transitions to long-term spare parts supply and technical support.

Principle 1: Test First, Then Select Equipment

Without representative ore sample data, any equipment selection is like “the blind men and the elephant.”The grain size distribution, degree of silicification, and associated elements in gold ore vary widely; only by thoroughly understanding these details can the most profitable gold processing flow be designed. Routine validation takes approximately 3–4 weeks, and a complete proposal report takes 30–45 days; complex ores (including those containing arsenic and carbon, or with fine-grained inclusions) require additional validation steps.

Principle 2: Process Design and Equipment Manufacturing by the Same Team

When a design institute produces drawings and an equipment manufacturer produces equipment based on those drawings, it is easy for “drawing parameters to mismatch with equipment performance.” Having the same team handle both process design and equipment manufacturing ensures that mechanical engineers clearly understand the upstream slurry volume and downstream separation requirements, preventing interface conflicts and production capacity mismatches.

Principle 3: Define Scope of Work in the Contract

The EPC contractor is responsible for end-to-end management, while the client\'s local team handles preliminary briefings. If these boundaries are unclear, it is highly likely that disputes will arise later, such as “work stoppages while waiting for workers” or “mutual blame and demands for additional payments.”