Tanzanian Gold Mine Boosts Recovery with Jaw Crusher and Wet Disc Grinder Combination

Case Study Title: Rock Gold Processing Plant in Tanzania – Integrated Application of Jaw Crusher and Wet Pan Mill

Executive Summary

Tanzania is one of Africa’s leading gold producers, with annual output ranking among the top on the continent. Most of its rock gold deposits are hosted in Archean greenstone belts around Lake Victoria in the north. The predominant ore types are altered rock‑type and quartz‑vein‑type gold ores, characterised by high hardness and high quartz content. For a 1,200 tpd rock gold processing project in Tanzania, we provided a complete beneficiation solution built around a Jaw Crusher and a Wet Pan Mill, achieving an efficient combination of primary crushing and fine grinding.

1. Project Background & Challenges

Tanzania is endowed with abundant mineral resources, and gold mining offers enormous potential. However, local mining operations face several difficulties:

• Hard, quartz‑rich ore – demanding crushers with high wear resistance and crushing efficiency.

• Harsh site conditions – hot climate, remote locations, complex logistics for equipment transport and installation.

• Strict production and cost targets – the client required a line that meets capacity expectations while keeping operating costs under control.

2. Solution: Jaw Crusher + Wet Pan Mill Integrated Process

Based on the ore characteristics and the client’s requirements, we designed a core process route of:

Primary Crushing (Jaw Crusher) → Secondary Crushing → Grinding (Wet Pan Mill) → Gravity Concentration

(A) Jaw Crusher – The First Crushing Stage

The Jaw Crusher handles the primary reduction of run‑of‑mine ore. For this project, a PE1200×1500 Jaw Crusher was selected to crush feed material up to 1000 mm down to <250 mm. Key features:

• Large feed opening – accepts lumps up to 1000 mm, suitable for coarse ore from Tanzanian mines.

• High crushing ratio – reduces ore to <250 mm in a single pass, providing ideal feed for the downstream wet pan mill .

• Robust construction – high‑manganese jaw plates offer excellent wear resistance, especially for hard quartz‑vein gold ores.

• Easy maintenance – simple structure ensures reliable operation even in remote sites with limited maintenance support.

In other Tanzanian projects (e.g., the ML644 graphite mine in Morogoro), jaw crushers have also been specified for primary crushing in three‑stage closed‑circuit flows. Additionally, adding a jaw crusher has significantly increased plant throughput at several gold operations in the country.

(B) Wet Pan Mill – Cost‑Effective Grinding Solution

After primary crushing, the ore is fed to the Wet Pan Mill for fine grinding. This mill is widely used in small‑ and medium‑scale gold projects across Africa and is particularly well‑suited for Tanzanian operations. In this case, the wet pan mill grinds the crushed ore to 100–150 mesh (approx. 0.1–0.15 mm), ensuring sufficient liberation of gold particles. Its advantages include:

• Low capital investment – significantly cheaper than ball mills, fitting the budget of mid‑tier miners in Tanzania.

• Simple operation and maintenance – few wearing parts; local technicians can easily handle routine servicing.

• Efficient wet grinding – eliminates dust and improves grinding efficiency.

• Excellent recovery – when combined with downstream gravity equipment (e.g., shaking tables), it achieves high gold recovery rates.

(C) Complete Process Flow

The full production line comprises:

Run‑of‑mine ore → Vibrating Feeder → Jaw Crusher (primary) → Belt Conveyor → Wet Pan Mill (grinding) → Shaking Table / Gravity Concentrator → Gold Concentrate

This flowsheet is low‑cost, quick to commission, and easy to operate – making it particularly suitable for African mining conditions.

3. Project Results

After commissioning, the plant delivered outstanding performance:

• Designed capacity achieved – the line consistently processes 1,200 tpd as required.

• High recovery – overall gold recovery exceeded 90%.

• Controlled operating costs – the jaw crusher + wet pan mill combination drastically reduced both initial investment and ongoing maintenance expenses.

• Client satisfaction – the customer praised the equipment quality and technical support provided.

4. Lessons Learned & Industry Insights

This successful Tanzanian project offers valuable takeaways for the mineral processing sector:

• Site‑adapted equipment selection – the jaw crusher proved to be the ideal choice for primary crushing of hard, quartz‑rich ores.

• Economical process combination – the “jaw crusher + wet pan mill” pairing balances capital cost and processing efficiency, making it an excellent option for small‑ to medium‑scale mines in Africa.

• Local service matters – dispatching an experienced engineering team for installation, commissioning, and on‑site training was critical to success.

• Replicable model – this solution has been successfully deployed at multiple sites, including Mpanda in Tanzania, and is now being adopted in West Africa and Nigeria.

5. Conclusion

The successful implementation of this rock gold processing plant in Tanzania clearly demonstrates the suitability and cost‑effectiveness of the Jaw Crusher + Wet Pan Mill integrated process for high‑hardness gold ores in Africa. As Tanzanian mining continues to expand, this proven, reliable equipment combination will create even more value for mine owners across the region.

For a detailed equipment configuration or a customised quotation for your gold processing line in Tanzania, please contact us for professional consultation.