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1Fix the driver behind crashes, sound loss and screen glitches2Clear out junk files and repair common Windows errors3Scan for outdated or missing drivers - takes under a minuteA gold-processing plant is a connected chain of size-reduction, separation and recovery equipment. A typical front end has a primary crusher, screens, stockpiles, feeders, conveyors, grinding mills and hydrocyclones. The back end is selected for the ore: centrifugal concentrators or jigs for free gold, flotation cells for sulfide-associated gold, cyanide leach tanks with activated carbon for suitable free-milling ores, or a combination. Loaded carbon or concentrate then goes through stripping or elution, electrowinning and smelting, while pumps, thickeners, filters, water circuits and tailings facilities keep the plant operating.
That is a menu of equipment, not a universal blueprint. Mineralogy, hardness, target grind, water balance, environmental requirements and metallurgical testwork determine which machines are installed and how they are sized.
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How the equipment fits together
Ore normally moves through the plant in this order:
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- Run-of-mine ore is delivered to a dump pocket, hopper or stockpile.
- Crushing and screening reduce and control particle size.
- Feeders and conveyors meter crushed ore to the grinding circuit.
- SAG, AG, ball or rod mills liberate gold-bearing minerals; classifiers return coarse particles for more grinding.
- A gravity, flotation, leach or combined circuit separates gold from the ground ore.
- Carbon, concentrate or pregnant solution is treated in a recovery and refining area.
- Thickening, filtration, water return and tailings handling manage the remaining solids and process water.
Each stage is designed around the next one. A crusher that produces excessive fines can overload classification; an overly coarse grind can leave gold locked in sulfides; and a recovery circuit without adequate carbon screening, pumping or water treatment will not perform as its laboratory test suggests.
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The operator description for Rosebel Gold Mines lists a representative sequence of gyratory crushing, a coarse-ore stockpile with feeders, grinding, gravity recovery, leaching, carbon-in-leach (CIL), carbon stripping and a refinery. Its description is an example of one operating site, not a standard arrangement for all mines (Rosebel Gold Mines mill description).
Crushing, screening and feeding equipment
Primary crusher
Run-of-mine rock first enters a primary crusher. Large hard rocks are reduced to a size that downstream conveyors and mills can handle. Gyratory crushers are common for high-capacity hard-rock duties; jaw crushers are another possible primary choice where the duty and plant scale suit them. The crusher is fed from a dump pocket or hopper, and a rock breaker may be provided to deal with oversize boulders.
One SEC-filed Arthur Gold Project design specifies a 42-by-65 gyratory primary crusher. That dimension belongs to that project’s design and must not be treated as a default specification for another mine (Arthur Gold Project technical report).
Secondary crushing and screens
If the primary product is too coarse for the mill, a secondary cone crusher reduces it further. Vibrating screens separate particles at a controlled size: undersize goes forward, while oversize returns to the crusher. The same Arthur design identifies an MP1000 cone secondary crusher and vibrating screens, again as project-specific equipment rather than an industry-wide standard.
Stockpiles, feeders and conveyors
A coarse-ore stockpile provides surge capacity between crushing and milling. Apron, belt or vibrating feeders draw a controlled rate from the stockpile. Belt conveyors transfer ore between buildings and allow the crusher and mill circuits to operate at different short-term rates. Chutes, dust-control equipment, magnets or metal detectors, belt scales and sampling points are commonly integrated where the flowsheet requires them.
| Front-end item | What it does | Selection issue |
|---|---|---|
| Primary crusher | Breaks run-of-mine rock to a transportable, mill-feed size | Ore hardness, top-size, capacity and maintenance access |
| Secondary crusher | Provides additional size reduction when primary product is too coarse | Required product size and circulating-load design |
| Vibrating screen | Splits material by size and sends oversize back for crushing | Cut size, moisture, screening area and blinding risk |
| Stockpile and feeder | Buffers production and meters a steady mill feed | Live capacity, reclaim method and ore segregation |
| Conveyor | Moves crushed ore between process areas | Length, elevation, transfer-point dust and spillage control |
Grinding and classification
SAG, AG, ball and rod mills
Crushing does not usually liberate all the gold. Grinding mills reduce the ore until gold particles or gold-bearing minerals can be separated. Autogenous (AG) mills use the ore itself as grinding media; semi-autogenous (SAG) mills use ore with added steel balls. Ball mills provide finer grinding with steel balls, while rod mills use steel rods and are selected for particular feed and product characteristics. Some projects use roller- or trunnion-supported mill arrangements.
Mill selection is a trade-off among throughput, ore competency, required product size, power, liner wear and the downstream recovery process. A mill circuit also needs lubrication, drive, lining, feed and discharge equipment, slurry pumps and instrumentation.
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Hydrocyclones and other classifiers
Classification separates fine particles from coarse particles in the mill discharge. Hydrocyclones send fine overflow to gravity, flotation or leaching and return coarse underflow to the mill for more grinding. Correct cyclone pressure, apex condition and feed density are essential because a coarse overflow can carry unrecovered, locked gold into the wrong part of the circuit.
Rosebel reports grinding its ore to 80% passing 75 microns before leaching. That is a measured, site-specific operating figure, not a universal target; another ore may need a coarser or finer product (Rosebel mill process description).
Gravity concentration for free gold
Gravity recovery is appropriate when a meaningful portion of the gold occurs as liberated, relatively dense particles. It can remove that gold early, reducing the load on a later leach or flotation circuit. The equipment is installed on a suitable cyclone stream or mill discharge, then the concentrate is cleaned or treated separately.
Centrifugal concentrators
A centrifugal concentrator uses an enhanced gravity field to retain dense gold while lighter gangue leaves with the slurry. It is often used for fine free gold and produces a small concentrate that can be upgraded or sent to intensive leaching.
Jigs and shaking tables
Jigs use pulsating water to separate dense particles and are useful where coarser free gold is present. Shaking tables provide a visual, controllable cleaning step for a gravity concentrate. The choice depends on particle-size distribution, mass yield, water availability and the value of recovering gold early.
Intensive-leach treatment
A gravity concentrate may be treated in an intensive-leach reactor rather than returned directly to the main circuit. This keeps a high-grade, small mass stream separate and can improve control of reagent contact. Gravity recovery is optional: if testwork shows little liberated gold, the capital and operating cost of a gravity circuit may not be justified.
Flotation when gold is tied to sulfides
When gold is associated with sulfide minerals, flotation can make a sulfide-rich concentrate for further treatment. A flotation circuit conditions the ground slurry with reagents, then uses air in flotation cells to attach hydrophobic mineral particles to bubbles. The froth is collected, while non-floating material continues to tails or another recovery stage.
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Rougher, scavenger and cleaner cells
Rougher cells recover most of the valuable mineral into a bulk concentrate. Scavenger cells recover valuable particles left in rougher tails. Cleaner cells upgrade the rougher concentrate by rejecting entrained gangue. Flash flotation may recover fast-floating particles directly from the grinding circuit; conventional flotation treats a larger conditioned stream. SGS identifies conventional and flash flotation as options, not requirements, for gold flowsheets (SGS Gold Processing brochure).
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Concentrate equipment
Flotation concentrate normally passes through concentrate pumps, a thickener and a filter before transport or downstream treatment. Filter cloths, air or vacuum systems and wash-water circuits determine the moisture of the final concentrate. The concentrate route may lead to a separate pressure-oxidation, roasting, smelting or off-site treatment facility; the correct choice depends on sulfide mineralogy and permitting.
Leaching and activated-carbon recovery
Cyanide leach tanks
For a suitable free-milling ore, cyanide dissolves gold into a pregnant solution. Agitated leach tanks provide residence time, oxygen transfer and mixing. The circuit requires cyanide and lime or other pH-control systems, oxygen or air, slurry pumps, sampling and online controls. Cyanide circuits must be designed and operated under applicable safety and environmental requirements; the chemical choice is not a justification for skipping containment, detoxification or monitoring.
Carbon-in-leach (CIL)
In CIL, leaching and adsorption occur in the same series of agitated tanks. Activated carbon moves counter-currently through the tanks, adsorbing dissolved gold as it is leached. Interstage screens retain carbon while allowing slurry to flow onward. Carbon transfer pumps, screen sprays and carbon safety screens prevent valuable carbon from escaping with tails.
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CIP separates the operations: ore is leached first, then the gold-bearing slurry enters adsorption tanks containing activated carbon. The equipment is similar—agitated tanks, interstage screens and carbon-transfer systems—but the tank duties and residence-time arrangement differ from CIL.
| Feature | CIL | CIP |
|---|---|---|
| Where adsorption occurs | In the leach tank sequence while dissolution is taking place | In separate adsorption tanks after leaching |
| Core equipment | Agitated leach/adsorption tanks, activated carbon, interstage screens and carbon pumps | Leach tanks followed by adsorption tanks, carbon screens and carbon pumps |
| Why a designer may choose it | Combines two duties in one train and can suit ores with appropriate leach kinetics | Separates leach and adsorption control and can fit a different residence-time strategy |
Rosebel describes leach tanks feeding a CIL process and states that 70% of feed gold is leached in the described tanks. That percentage applies to Rosebel’s operation and should not be presented as a general CIL recovery rate (Rosebel mill description).
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Carbon stripping, electrowinning and doré production
Carbon handling and elution
Loaded carbon is screened from slurry, washed and transferred to a stripping or elution circuit. Acid washing removes scale and contaminants; carbon regeneration uses heat to restore adsorption capacity. The Arthur Gold Project technical report describes pressure elution using the Zadra process, carbon acid washing and regeneration. These are design details for that project, not mandatory equipment at every plant.
Electrowinning
Elution produces a gold-bearing solution. Electrowinning cells pass current through the solution so gold deposits as a sludge or precipitate on cathodes. Rectifiers, cells, pumps, screens and solution tanks form the electrowinning circuit. Poor solution clarity, inadequate conductivity or dirty cathodes can reduce current efficiency and complicate sludge handling.
Smelting and doré
Electrowinning sludge is dried and smelted in a furnace with suitable fluxes. The molten product is poured into molds as doré, an impure gold-silver alloy that is sent for further refining. A refinery, bullion scales, fume extraction, furnace controls and secure bullion handling complete this part of the plant. Rosebel’s operator page includes carbon stripping and a refinery in its mill sequence, while the Arthur report includes electrowinning and smelting.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.Thickening, filtration, water and tailings equipment
Recovery machines cannot operate without the solids-handling infrastructure around them.
- Slurry and process pumps: Move abrasive ore, concentrate, carbon and tailings between tanks, cyclones, thickeners and filters. Pump metallurgy, standby capacity and access for seal or liner changes are design decisions.
- Thickeners: Use settling and flocculants to produce a dense underflow and recover clarified water. Concentrate and tailings thickeners reduce water demand and stabilize downstream filtration or storage.
- Filters and dewatering: Pressure, vacuum or other filters remove additional water from concentrate or tailings. Filtered tailings can require conveyors, stacking equipment and a carefully engineered storage area.
- Reagent systems: Mixing tanks, day tanks, dosing pumps, storage, containment and instrumentation prepare and deliver lime, cyanide, flotation reagents, flocculants and other chemicals.
- Water circuits: Clarified-water tanks, reclaim pumps, fresh-water supply, return lines and water-quality monitoring balance process demand and minimize discharge.
- Tailings transport and storage: Pipelines, pumps, thickened-tailings or filtered-tailings systems and the tailings facility receive material that has passed through recovery. Design must account for geotechnical stability, seepage control, stormwater and closure requirements.
The Troilus flowsheet shows concentrate and tailings thickeners, a concentrate filter, a tailings facility and water return. The Arthur report describes filtered-tailings handling. Those examples demonstrate the equipment categories needed to close the solids and water loops, not a single mandatory tailings design.
How engineers choose a flowsheet
Equipment selection starts with representative sampling and metallurgical testwork rather than with a preferred machine. The key questions are:
- Where is the gold? Determine whether it is liberated and coarse, locked in sulfides, associated with tellurides or distributed through fine particles. Free gold supports gravity; sulfide association may support flotation or a concentrate-treatment route.
- How hard and variable is the ore? Abrasion, competency and clay content affect crusher type, mill power, liner wear, screen performance and pump selection. Blending and stockpile capacity may be needed when ore types change.
- What grind unlocks the value? Establish the liberation size through mineralogical and recovery tests. A finer grind can improve liberation but increases power, media consumption, classification load and sometimes reagent use.
- Which recovery combination works? Compare gravity alone, gravity plus leach, flotation plus concentrate treatment, CIL, CIP or a hybrid. Evaluate recovery, concentrate mass, residence time, reagent consumption, water use, tailings chemistry and capital cost together.
- How will every stream be handled? Account for carbon, concentrate, pregnant solution, barren solution, recycle water, filter cake and final tailings. A flowsheet is incomplete if it has no practical route for a by-product or upset condition.
SGS describes the selection of energy- and cost-effective equipment for primary and secondary crushing and milling as part of a broader gold-processing design. Its guidance reinforces that sizing and configuration must follow the ore and the process objective, not a generic equipment list (SGS Gold Processing).
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What the named project examples show
| Source example | Equipment or figure reported | How to interpret it |
|---|---|---|
| Rosebel Gold Mines | Gyratory crusher, coarse-ore stockpile and feeders, grinding, gravity recovery, leaching, CIL, carbon stripping and refinery; 80% passing 75 microns; 70% of feed gold leached in described tanks | Operating-site description and figures; neither percentage nor grind size is a universal target |
| Arthur Gold Project | 42-by-65 gyratory primary crusher, MP1000 cone secondary crusher, vibrating screens, pressure elution, electrowinning, carbon acid washing and regeneration, smelting and filtered tailings | Technical-report design details for that project, not standard plant sizing |
| Troilus 2022 design | Grinding, gravity, rougher and cleaner flotation, concentrate and tailings thickeners, concentrate filter, water return and tailings facility | Illustrates a combined gravity/flotation route with dewatering and water-management equipment |
Reading these examples side by side shows why “the gold plant” is an unsafe singular concept. Two plants may both produce doré yet use different crushing, grinding, flotation, leach, carbon and tailings arrangements because their ores and site constraints differ.
Common equipment and design pitfalls
Using a project number as a rule
A crusher dimension, grind target or leach percentage from one operation cannot be copied into a new plant without ore characterization and testwork. Treat published figures as evidence of what that project selected or achieved under its stated conditions.
Ignoring circulating loads
Screen oversize, cyclone underflow and scavenger streams return material to earlier equipment. Conveyors, pumps, chutes and bins must be sized for these circulating loads, not only for fresh ore feed.
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Underestimating water and fines
Clay-rich ore can blind screens, upset cyclones and increase thickener demand. Fine particles can slow settling and make filtration difficult. Pilot or variability testing should cover wet-season water quality and the full ore envelope.
Letting valuable material escape
Missing carbon screens, poor concentrate containment, leaking pumps or inadequate sampling can turn a technically sound recovery circuit into a metal-loss problem. Install sampling points, screen inspections, secure launders and appropriate standby equipment where the mass balance requires them.
Designing recovery without the tailings route
Tailings density, chemistry, transport distance and storage method feed back into thickener, pump, filter and water-circuit choices. The tailings facility and reclaim-water system should be developed with the process plant, not added after the recovery equipment is selected.
Bottom line for a plant-equipment list
Start with crushers, screens, stockpiles, feeders, conveyors, mills and classifiers. Add gravity equipment when free gold justifies early recovery; add flotation when sulfides carry the gold; use CIL or CIP with activated carbon for a suitable leach feed. Complete the route with carbon stripping or elution, electrowinning, smelting and doré handling, then specify the pumps, reagent systems, thickeners, filters, water return and tailings equipment that make the circuit operable. The correct list and sizes come from the ore’s mineralogy, liberation testwork and site design—not from a generic catalog.
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