FV3000

The first block in the process line. It receives the run-of-mine material through a feed hopper fitted with grizzly bars that reject oversize, and delivers it into a tyre-driven rotary scrubber. Inside the rotating drum with lifter bars the material is intensively washed and disintegrated — clay agglomerates are broken down and heavy mineral grains are liberated.

An integrated trommel is fitted at the drum discharge, with an installed aperture of 5 mm. The undersize (below 5 mm) flows by direct gravity discharge into the sump, where it is made into slurry and pumped to the vibrating screen. The oversize of 5–100 mm is discharged to waste; a deep-fill sluice can be installed on this outlet to catch coarse gold. The module is mounted on a dedicated transport frame.

A self-contained classification block with its own slurry preparation. Slurry from the scrubber sump is fed onto a vibrating screen with an installed aperture of 2 mm. The undersize (below 2 mm) enters the built-in sump, where it is mixed with water to the required slurry density; slurry pumps installed in the same block deliver the prepared slurry directly to the concentrator block.

The oversize of 2–5 mm passes through a vibrating sluice adjustable for inclination (height/angle) as well as vibration frequency and amplitude. The module carries a water distribution manifold with control valves and pressure gauges. Screening, slurry preparation and slurry delivery are therefore performed within one module.

A separate, self-contained module in which the slurry is formed: a conical receiving sump takes the trommel undersize (below 5 mm), mixes it with water to the required density, and a centrifugal slurry pump delivers the prepared slurry to the next block through flexible reinforced hoses — in the current layout, to the vibrating screen. The pump wet end is manufactured from wear-resistant materials.

A particular feature of this module: it is used together with the scrubber–trommel block (receiving the trommel discharge and preparing slurry from it) and can additionally be used as an independent element in various process flowsheets wherever a standalone slurry preparation and pumping unit is required. Unlike the vibrating screen block, where the sump and pumps are built in, this module is supplied separately.

The core of the plant and its most densely equipped block. This is not simply two concentrators, but a complete concentration module on a common frame with a service platform and guard rails, comprising several subsystems:

• Two Falcon SB400 (Sepro) centrifugal concentrators — the gravity concentration itself, recovering free gold and other heavy minerals.
• Feed conditioning and distribution unit: a tank with a mechanical agitator providing uniform feed and stable slurry density to both machines.
• Pneumatic system with an Atlas Copco air compressor: supplies compressed air to the pneumatic actuator of the pinch valve on the concentrate discharge — during the rinse cycle the valve is opened under Auto-Pac control (bowl fluidisation itself is performed with water, not air).
• Control automation: variable frequency drives (VFD) / Auto-Pac system setting acceleration, centrifugal field and periodic automatic concentrate rinse.
• Flexible hose and manifold connections distributing slurry and fluidisation water, plus a service platform with stairs and guard rails.

At maximum operating settings (rotor speed and G-force, fluidisation water pressure) the Falcon SB400 concentrators — and the plant as a whole — recover gold particles down to 30 microns.

Two machines are installed in the block, connected in parallel and operating simultaneously, so the production figures of the block are the sum of both units. The table below gives values per single unit and for the block of two.

A separate block supplying water to all modules of the plant — scrubber and screen spray water, slurry preparation in the sumps, and concentrator fluidisation. The pump set is mounted on a common frame; the pump is centrifugal with a belt drive. It can be driven either by an electric motor or by a diesel engine, which secures water supply with or without a mains connection. The discharge line is fitted with shut-off valves and a pressure gauge.

A separate filter and hydrocyclone unit is connected to the pump set, allowing the water fed to concentrator fluidisation to be cleaned separately to the required level of purity.

The final block of the process line — a modular room for concentrate upgrading. In its compact (folded) state the room has the transport dimensions of a 40-foot container; once positioned on site, the side walls extend on dedicated built-in slides, increasing the total floor area by 70%.

The room equipment includes: shaking tables, a magnetic separator, a concentrate receiving hopper, a slurry preparation unit feeding the tables, specialised pumps, piping and other equipment. A separate area is also provided for weighing and storing the finished product after upgrading.