1. Common Crusher Types for Gold Ore

• Jaw Crusher
  • Stage: Primary Crushing
  • Best For: Large, hard ore (compressive strength ≤320MPa).
  • Key Points: Simple, robust, high capacity. Produces coarse output (typically 10-350mm). Works best with low-clay ore.

• Cone Crusher
  • Stage: Secondary/Tertiary Crushing
  • Best For: Medium to hard ore (e.g., quartz vein gold).
  • Key Points: High efficiency, low energy consumption, produces uniform product with minimal overgrinding. Hydraulic models allow easy adjustment.

• Impact Crusher (Vertical Shaft Impactor – VSI)
  • Stage: Tertiary Crushing / Sand Making
  • Best For: Medium hardness, brittle ore.
  • Key Points: High reduction ratio, good grain shape. Supports “more crushing, less grinding” for energy savings. Prone to clogging with high-clay ore.

• High-Pressure Grinding Rolls (HPGR)
  • Stage: Fine/Ultra-fine Crushing
  • Best For: Medium-hard ore with fine-grained gold.
  • Key Points: Highly energy-efficient, promotes early mineral liberation, significantly reduces grinding load. Higher initial investment, suitable for large-scale operations.
• Hammer Crusher
  • Stage: Secondary/Tertiary Crushing
  • Best For: Soft, brittle ore (e.g., oxidized ore).
  • Key Points: High reduction ratio and capacity. Rapid wear with hard ore and prone to clogging with clay.

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2. Key Selection Factors

• Ore Properties: Hard ore → Jaw + Cone crusher combo. High clay content → Consider pre-washing or clog-resistant designs.
• Product Size: Target >100mm after primary → Jaw crusher. Target <10mm for grinding → Cone crusher or HPGR.
• Capacity: Small plant (<500 t/d) → Jaw + Hammer/Impact crusher. Large plant (>2000 t/d) → Jaw + Cone + HPGR.
• Process Flow: Traditional: Three-stage closed circuit (Jaw + Cone + Screen). Energy-saving: Jaw + HPGR (replaces multiple stages).

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3. Example Flowsheets

• Hard Quartz Vein Gold Ore:
  Primary: Jaw Crusher (<150mm)
  Secondary: Cone Crusher (<50mm)
  Tertiary: Cone Crusher or HPGR (<10mm)
  Closed-circuit with vibrating screens.
• Soft Oxidized Ore (High Clay):
  Primary: Jaw Crusher (with grizzly for clay removal)
  Secondary: Impact or Hammer Crusher (<8mm)
  Wet screening may be necessary.

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4. Important Considerations

• Wear: Quartz is highly abrasive. Use wear-resistant materials (e.g., manganese steel liners).
• Clogging: For clayey ore, include washing or pre-screening.
• Automation: For large plants, automated control systems optimize performance.

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Recommendation Summary

• Small Operations: Jaw + Hammer/Impact crusher for low cost and easy maintenance.
• Large Operations: Jaw + Cone + HPGR for maximum efficiency and energy savings (“more crushing, less grinding”).
• Fine-Grained Ore: Prioritize HPGR for early liberation.