Tailored Processing Flows: How Xinhai Solved Mixed Ore Challenges at the Tanzania 1200t/d Gold Plant

 Mining projects often face their biggest hurdles not in construction, but in designing a processing flow that can adapt to complex ore characteristics. The Tanzania 1,200t/d gold mineral processing plant is a perfect example of this, where the ore’s dual sulfide and oxide composition required a fully customized solution to maximize gold recovery. This project highlights Xinhai Mining’s strength in developing tailored processing flows that meet the unique needs of each deposit.

At the start of the project, the ore analysis revealed two distinct fractions: sulfide ore with a gold grade of 10.7g/t and oxide ore with 2.4g/t. With Au as the only valuable element, the challenge was to create a flow that could handle both materials efficiently, ensuring consistent leaching rates regardless of ore type. The answer was an all-slime cyanidation process, chosen for its proven ability to deliver high recovery rates across mixed ore compositions. This process would become the backbone of the plant, guiding every stage from crushing to tailings management.


The processing flow was structured in four key stages, each optimized for the Tanzania site’s specific conditions:
  1. Crushing Stage: A single open-circuit crushing process was implemented to reduce the ore to a manageable size, preparing it for efficient grinding.
  2. Grinding and Classification Stage: A closed-circuit grinding system paired with cyclone classification ensured the ore was ground to the precise particle size required for effective cyanidation, eliminating over-grinding and under-grinding issues.
  3. Separation Stage: The core of the process, the all-slime cyanidation system, allowed gold to leach into the solution, with gold-bearing carbon then sent to a desorption electrolysis system to extract the precious metal.
  4. Final Treatment: Extracted gold was smelted into gold slime, while tailings were thickened and dewatered before safe stacking, meeting environmental and operational standards.
The result of this tailored flow was remarkable: leaching rates of 93.75% for sulfide ore and 91.58% for oxide ore. These figures are a testament to how a customized processing flow can unlock value from even the most challenging ore bodies. For mining operators, this means moving beyond one-size-fits-all solutions to partner with teams that understand the nuances of their deposit.
To dive deeper into how we designed this flow for the Tanzania project, explore the full case study:
https://www.fewstern.org/cases/Tanzania-1200t-Gold_11.html
Beyond the processing stages, the project also required careful planning to address construction and operational challenges. Most of the plant’s equipment was constructed from thin steel, making it vulnerable to deformation during lifting and transportation. Xinhai’s team implemented rigorous measures to protect these components, ensuring they arrived at the site in perfect condition and could be installed without issues. We also developed contingency plans to address shortages of materials, machinery, and technicians, keeping the project on schedule even when unexpected hurdles arose.
For mining projects, the processing flow is more than a technical design—it’s the blueprint for success. The Tanzania gold plant shows how a tailored flow, combined with proactive construction planning, can turn mixed ore challenges into a high-performing, long-term operation.

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