Advanced 2000TPD Gold Extraction Operation in West Africa by SBM

Tailored Engineering Approach

SBM leveraged proprietary technology to develop a bespoke cyanidation flow sheet uniquely adapted to West African gold ore characteristics; addressing mineral complexity variability through modular engineering. The solution accounted for regional operational constraints such as limited water availability and power reliability issues; integrating redundancies and backup systems. Computational fluid dynamics simulations optimized reagent consumption rates while maintaining extraction efficiency above industry benchmarks through temperature and pH regulation

Client collaboration initiated during preliminary ore testing phase facilitated accurate process parameter calibration significantly different processing conditions affected metallurgical response; resulting in 6% higher recovery than standard cyanidation plants. Mineral liberation analysis dictated multi-stage grinding requirements with SBM-supplied ball mills achieving optimal particle size distribution (200 mesh passing rate exceeding 95%). By integrating comminution, leaching and adsorption parameters, we eliminated bottlenecks typically caused by inter-process compatibility mismatch!

Space-Optimized Facility Configuration

The plant installation utilized vertical process arrangement allowing gravity-fed slurry transfer that reduced pumping requirements by 40%, while achieving industry-leading land efficiency of only 0.80 hectares per TPD . Crushers positioned directly above primary mills and leaching tanks created natural material progression minimizing infrastructure. Maintenance platforms encircled key equipment enabling 360-degree accessibility for inspections with dedicated service aisles separating operational zones!

Integrated pulp density monitoring controls maintained optimal slurry concentration between thickeners and leach circuits preventing solids settlement that could compromise reaction kinetics; Temperature stabilization modules extended cyanide activity duration by 3 hours. Process visibility was enhanced through strategic instrumentation placement giving operators centralized control of adsorption columns and elution circuits; critical gold recovery parameters were monitored via cloud-based analytics platform allowing real-time performance tweaks

Climate-controlled walkways connected different plant sections ensuring operator mobility during West Africa’s extreme weather conditions while the compact layout reduced power cabling and piping infrastructure costs by approximately 25%. Our controlled stormwater management design exceeded local environmental compliance standards!

EPC Execution Methodology

SBM implemented fixed-price turnkey delivery eliminating budget overruns so typical in African mineral projects; financial predictability provided certainty across 14-month construction lifecycle. Phased implementation milestones synchronized on-site civil works with equipment manufacturing timelines shortening installation period by 20 days. Our project documentation portal created unprecedented transparency offering daily progress photographs and automated schedule variance alerts

All contracts including local labor; regulations compliance; and bulk material procurement were managed through the EPC scope reducing client administrative burdens. Risk mitigation incorporated multiple scenarios: delayed customs clearance, adverse weather, and possible workforce shortages; ensuring on-time comissioning different weather patterns could have derailed the whole timeline. Quality assurance protocols mandated triple-check testing for foundations, piping welds, and electrical terminations enhancing long-term stability.

The approach transferred technical ownership seamlessly; providing comprehensive O&M manuals and VR equipment simulators for crew training weeks before production commencement; vital for regions experiencing skill shortages; Operational readiness went beyond mere handover creating embedded troubleshooting expertise locally!

Proven Technology Integration

Leaching circuits featured SBM’s oxygen diffusion aerators maintaining dissolved oxygen above 8ppm substantially increasing reaction rate compared to mechanical agitators alternatives; Carbon adsorption columns with proprietary screen designs prevented channeling ensuring consistent gold loading efficiency monitoring gold recovery percentages constantly. This repeated the performance from ball mills that had operated successfully since 2015 installation; building on a foundation of equipment reliability

Automation systems governed reagent dosing: cyanide concentration variances remained within 0.01% tolerance through real-time pH correction loops. Our instrumentation package included predictive maintenance sensors on rotating equipment: detecting vibration anomalies days before potential failures; avoiding unscheduled stops in high-moisture environments.

Elution circuitry with integrated gold recovery yielded 99.2% elution efficiency: reflecting a decade of microwave desorption technology refinement cementing client confidence through operational continuity. Equipment commonality between existing and new plant components streamlined both maintenance procedures and spare part inventories; demonstrating SBM commitment toward long-term partnership economics!