Pilot Plant Design for Smelter Approval
This presentation outlines our strategy to produce high-grade gold and silver concentrate that will secure smelter approval for our full-scale operation.
We'll examine the required equipment, expected recovery rates, and processing methodology to efficiently transform 2,000 tons of ore into the 20-ton high-grade concentrate sample needed for Korean smelter testing. Our approach balances technical precision with practical implementation to ensure successful outcomes.
Project Requirements & Objectives
Smelter Approval
Secure Korean smelter acceptance
20-Ton Concentrate
High-grade sample for testing
2,000 Tons Processed
Raw ore processing requirement
Our primary goal is to generate a 20-ton high-grade concentrate sample that will meet Korean smelter specifications. This requires processing approximately 2,000 tons of our ore, which contains 10 grams of gold and 50 grams of silver per ton. With our target 1:100 concentration ratio, we'll effectively concentrate these valuable minerals for smelter evaluation.
Success in this phase will unlock the capital needed to develop our full-scale 2,000 tons per month processing plant, creating a sustainable operation with significant production capacity.
Ore Characteristics & Recovery Expectations
10g
Gold Content
Per ton of raw ore
50g
Silver Content
Per ton of raw ore
1:100
Concentration
Target ratio
75%
Max Recovery
For oxide gold
Our ore body presents both opportunities and challenges. The oxide components offer excellent recovery potential of 70-90% for both gold and silver using centrifugal concentration methods. The sulfide components are more challenging, with expected recovery rates of 40-60% without pre-treatment.
Using the equipment package provided, we anticipate achieving average recovery rates of 65-75% for gold and slightly lower for silver. The electrostatic dry washer will further enhance our recovery, particularly for the gold fraction, though its efficiency for silver recovery is somewhat limited due to the conductivity characteristics of oxidized silver minerals.
Processing Equipment Package
Tornado Mill
Efficient fine grinding capability with reduced power consumption compared to traditional ball mills. Produces optimal particle size for downstream concentration.
Centrifugal Concentrator
Primary recovery unit that uses centrifugal force to separate heavy gold and silver particles from lighter gangue materials. Achieves high recovery rates for free gold.
Electrostatic Dry Washer
Secondary recovery unit that uses electrostatic principles to capture additional values missed in primary recovery. Particularly effective for fine gold particles.
The provided equipment package forms the core of our pilot operation. Each component has been selected to maximize recovery while maintaining operational simplicity during the trial phase. These units represent the latest in small-scale mineral processing technology, offering efficiency comparable to much larger operations.
Process Flow Diagram
Crushing
Using existing system to reduce ore to -1/2 inch
Grinding
Tornado Mill reduces material to optimal liberation size
Primary Recovery
Centrifugal Concentrator captures majority of values
Secondary Recovery
Electrostatic Dry Washer recovers additional fine particles
Screening
Trommel separates final product by size fraction
Tailings Management
Storage for future reprocessing via flotation or roasting
Our process flow harnesses gravity and electrostatic principles to maximize recovery while minimizing operational complexity. The crushing system feeds the Tornado Mill, which produces finely ground material optimized for liberation of gold and silver particles.
This ground material passes through the centrifugal concentrator for primary recovery, followed by the electrostatic dry washer for secondary recovery of finer particles. The trommel provides final sizing, with tailings stored for potential future reprocessing using more advanced methods.
Recovery Rate Analysis
The chart illustrates the expected recovery rates for both gold and silver across our different processing methods and mineral types. Oxide minerals consistently show higher recovery rates due to their liberated state and superior response to gravity concentration.
Sulfide minerals present greater challenges, with recovery rates typically 20-30% lower than their oxide counterparts. The combination of centrifugal and electrostatic recovery methods will allow us to capture approximately 65-75% of the available gold and 50-65% of the silver, yielding a high-grade concentrate suitable for smelter evaluation.
Production Timeline & Metrics
Weeks 1-2
Equipment setup and calibration
Weeks 3-4
Initial processing at 25% capacity
Weeks 5-10
Full production at 50 tons/day
Week 11
Concentrate shipment to Korean smelter
Weeks 12-14
Smelter testing and approval
Our production timeline spans approximately 14 weeks from equipment setup to final smelter approval. The first two weeks focus on proper installation and calibration of all equipment, followed by a gradual ramp-up period to ensure optimal performance before reaching full production capacity.
At our target processing rate of 50 tons per day, we'll complete the required 2,000 tons of ore processing in approximately 40 working days (8 weeks). This timeline accounts for typical operational challenges while providing sufficient buffer to ensure timely delivery of the 20-ton concentrate sample to the Korean smelter.
Path to Full-Scale Production
Pilot Plant Success
Confirm recovery rates and concentrate quality
Smelter Approval
Secure offtake agreement and capital funding
Plant Expansion
Scale to 2,000 tons per month capacity
Success with our pilot operation creates a clear pathway to full-scale production. Once we've validated our recovery methods and received smelter approval, we'll leverage this credibility to secure the capital needed for our 2,000 tons per month processing plant.
The equipment provided for the pilot operation will be integrated into the larger facility, minimizing additional investment while providing immediate operational capability. We anticipate that expanding to full production would require approximately 4-6 months of construction and commissioning, with the potential to grow further based on market conditions and ore availability.
With smelter relationships established through this initial sample, we'll be well-positioned to negotiate favorable terms for ongoing concentrate sales, maximizing the value of our mineral resources.