As gold mining projects increasingly focus on medium and small-scale deposits, efficient mineral processing solutions have become essential. The Indonesia 100t/d Gold Leaching Plant delivered by Xinhai Mining is a prime example of how engineering expertise and practical design can transform low-grade gold ore into a profitable operation.
Understanding the Ore Characteristics
The ore processed in this project contains gold as the sole valuable metal, with an average grade of 2.6g/t. While the absence of complex associated minerals simplifies beneficiation, the relatively low grade requires a highly efficient recovery process to ensure economic viability.
Recognizing these characteristics, Xinhai Mining proposed a leaching-based flowsheet that emphasizes stability, ease of operation, and cost control. This proposal gained the client’s confidence and laid the foundation for successful cooperation.
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Ore Preparation: Crushing and Washing
Ore preparation directly affects the performance of leaching and adsorption. In this project, a cylindrical screen is used to wash the ore, effectively removing fine clay and impurities. This step improves solution permeability and reduces reagent consumption during leaching.
Oversized ore particles retained on the screen are crushed using a hammer crusher, which provides sufficient size reduction while maintaining low operating costs. The combined washing and crushing system ensures consistent feed quality for downstream processes.
Immersion–Adsorption System Design
The heart of the plant lies in its pool immersion–adsorption system. After leaching, gold-bearing solution with a flow rate of approximately 40m³/h is pumped into three adsorption columns. Activated carbon within the columns selectively adsorbs dissolved gold, ensuring high recovery efficiency.
This modular adsorption design allows flexible operation and easy expansion, making it well-suited for 100t/d capacity plants.
Solution Management and Environmental Control
After adsorption, the solution is divided into middle liquid and lean liquid streams. The middle liquid is recirculated through the system, maintaining effective adsorption conditions. The lean liquid, having completed gold adsorption, is treated to remove cyanide ions before discharge.
This approach reflects modern gold processing standards, emphasizing not only recovery efficiency but also environmental protection and operational safety.
Carbon Desorption and Regeneration
Gold-loaded carbon is processed through a desorption electrolysis system, where gold is stripped and recovered efficiently. After desorption, the activated carbon undergoes acid pickling and thermal regeneration, restoring its activity and reducing operating costs associated with carbon replacement.
The regeneration capacity is precisely matched to the desorption and electrolysis system, ensuring continuous and stable plant operation.
Final Smelting and Product Output
The final stage of the process is smelting, where recovered gold is refined into gold doré. This final product can be directly sold or further refined, completing the gold recovery cycle.
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Project Value and Industry Significance
This Indonesian gold leaching project highlights the importance of tailored process design, especially for gold-only ores with moderate grades. By integrating crushing, washing, leaching, adsorption, desorption, regeneration, and smelting into a coherent system, Xinhai Mining delivered a plant that balances efficiency, cost, and sustainability.
For mine owners and investors seeking reliable gold processing solutions, this project offers a proven reference model that can be adapted to similar deposits worldwide.
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