Project Overview
WSHT Mining Group successfully delivered a complete gold ore processing plant for a major gold mining operation in the Lake Victoria goldfields region of Tanzania. The project, valued at approximately USD 35 million, includes a 500 tph crushing and gravity concentration circuit designed to achieve 92% overall gold recovery.
Project Scope
Engineering:
- Process design based on ore characterization and testwork
- Plant layout optimized for existing site constraints
- Structural, electrical and instrumentation engineering
- Environmental impact assessment and permitting support
Procurement:
- Complete equipment supply including crushing, screening and gravity circuits
- Structural steel, piping and electrical materials
- Commissioning spares and initial operating consumables
Construction:
- Site civil works including foundations and drainage
- Structural erection and equipment installation
- Electrical and instrumentation installation
- Commissioning and operator training
Process Design
The plant processes free-milling gold ore using a combination of crushing, grinding and gravity concentration:
Crushing Circuit:
- Primary jaw crusher (1100 x 1200 mm) reducing feed to -200mm
- Secondary cone crusher achieving -50mm product
- Tertiary cone crusher for final -12mm product
- Pre-screening to remove fine fraction before grinding
Grinding and Recovery:
- SAB (SAG-Ball) grinding circuit with recycle crushing
- Knelson gravity concentrators for coarse gold recovery
- Intensive leaching reactor for gravity concentrate
- Acidic leaching and carbon-in-leach (CIL) for overall recovery
500 TPH Gold Processing Plant — Tanzania
Key Equipment Supplied
- Primary Jaw Crusher PE-900×1200
- Secondary Cone Crusher PYB-1750
- Tertiary Cone Crusher PYD-1750
- SAG Mill 5.5×2.5m (800 kW)
- Ball Mill 3.6×6.0m (1250 kW)
- Knockout screens and hydrocyclones
- Knelson KC-CD20MS gravity concentrators (3 units)
- Carbon-in-leach tanks and associated equipment
- Complete elution and gold room
Performance Results
- Throughput: 500 tph (design), achieved 520 tph (actual)
- Gold Recovery: 92% overall (97% gravity + 95% leaching)
- Availability: 92% since commissioning
- Product Grade: 99.9% dor bars meeting refinery specification
Project Execution
The project was completed in 18 months from contract award to commercial operation. Key factors in successful delivery:
Local Content: 65% local employment and procurement as per Tanzanian mining regulations, with comprehensive skills transfer program for local workforce.
Logistics: Equipment shipped via Dar es Salaam port with dedicated logistics team managing customs clearance and inland transport to site.
Commissioning: Sequential commissioning allowed initial gold production within 20 months, with full design capacity achieved during the optimization period.
The plant has now been in successful operation for over three years, producing approximately 45,000 ounces of gold annually.
