Green Ngoria Gold Processing Projects

Engineering Case Studies & Project Portfolio

Explore verified gold extraction flowsheet designs, turnkey CIP/CIL installations, high-pressure Zadra elution retrofits, and metallurgical recovery improvements delivered safely, on schedule, and on budget.

50+
Turnkey Projects Delivered
Across Kenya, Tanzania & East Africa
94.5%
Average Gold Recovery
Optimized CIL/CIP cyanidation kinetics
12,500+
TPD Capacity Installed
Cumulative daily milling & leach feed
Zero LTI
Safety Compliance Record
Strict OSHA / Mining Act standards
Showing 8 case studies
8-Stage Agitated CIL Leach Circuit & Steel Gantry
94.2% Overall Au Recovery
Commissioned
Turnkey CIL / CIPMigori County, Kenya500 TPD (Medium Scale)GN-MIG-500

500 TPD Turnkey CIL Gold Processing Facility

Client: South Nyanza Gold Fields Ltd · Commissioned: 2025

Engineered and constructed a full-scale Carbon-in-Leach plant replacing artisanal vat leaching. Delivered comprehensive mineral processing scope: primary jaw crushing, 1.8m × 3.6m overflow ball mill, closed-circuit hydrocyclones, 8 agitated CIL tanks, Zadra pressure elution, electrowinning cells, and induction smelting furnace.

Artisanal / Previous Baseline: 58%Green Ngoria CIL: 94.2% (+36.2% Delta)
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Agitated CIP Adsorption Tanks with Carbon Air-Lifts
89.5% Au from Historic Tailings
Commissioned
Tailings ReprocessingKakamega County, Kenya300 TPD (Medium Scale)GN-KAK-300

300 TPD Tailings Reprocessing CIP Circuit

Client: Western Kenya Mineral Resources · Commissioned: 2024

Designed, fabricated, and commissioned an agitated Carbon-in-Pulp circuit to reprocess 1.25 g/t refractory legacy stamp-mill tailings. Integrated hydraulic monitor reclamation, ultra-fine regrinding, high-activity coconut shell carbon, automated lime dosing, and filter-press dry tailings stacking.

Artisanal / Previous Baseline: 42%Green Ngoria CIL: 89.5% (+47.5% Delta)
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High-Pressure Zadra Desorption Column & Electrowinning Unit
98.8% Desorption Efficiency
Commissioned
Elution & SmeltingLake Victoria Goldfields, Tanzania1.5-Tonne Batch CapacityGN-TZ-150

1.5-Tonne Pressure Zadra Elution & Carbon Kiln Retrofit

Client: Geita Gold Corridor Mining Consortium · Commissioned: 2025

Engineered an advanced elution retrofit replacing an inefficient 48-hour atmospheric Anglo American (AARL) circuit with a rapid 12-hour high-temperature Pressure Zadra stripping plant (140°C, 450 kPa), complete with stainless electrowinning cells and a diesel-fired rotary reactivation kiln.

Artisanal / Previous Baseline: 76%Green Ngoria CIL: 98.8% (+22.8% Delta)
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Agitated Froth Flotation Cells & Concentrate Launders
92.4% Sulfide Gold Recovery
Commissioned
Flotation & DewateringKisumu / Siaya County, Kenya250 TPD (Modular Scale)GN-KIS-250

250 TPD Gold Flotation & Tailings Dewatering Facility

Client: Nyanza Mineral Ventures · Commissioned: 2024

Turnkey engineering and mechanical erection of an agitated froth flotation plant for pyritic gold ores. Included rougher-scavenger-cleaner flotation bank, high-rate thickener with automated flocculant dosing, and membrane chamber filter press for dry tailings management.

Artisanal / Previous Baseline: 52%Green Ngoria CIL: 92.4% (+40.4% Delta)
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2.4m × 4.2m Grinding Mill with High-Chrome Liners
P80 75μm at 99.2% Uptime
Commissioned
Crushing & MillingBondo-Nango, Siaya County, Kenya750 TPD (Industrial Scale)GN-SIA-750

750 TPD Closed-Circuit Ball Mill & Hydrocyclone Grinding Station

Client: Bondo Gold Enterprises Ltd · Commissioned: 2025

Engineered, fabricated, and installed an industrial-scale 2.4m × 4.2m overflow discharge ball mill driven by a 315 kW motor, complete with rubber-lined slurry sump, dual variable-speed feed pumps, and a radial 6-way hydrocyclone cluster for sharp classification.

Artisanal / Previous Baseline: 74%Green Ngoria CIL: 99.2% (+25.2% Delta)
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12m Diameter High-Rate Thickener with Auto-Dilution
96.2% Pregnant Solution Recovery
Commissioned
Plant Audits & RetrofitsMara Region, Tanzania600 TPD DewateringGN-MAR-600

High-Rate Thickener & Counter-Current Decantation (CCD) Retrofit

Client: North Mara Gold Producers · Commissioned: 2024

Following a comprehensive metallurgical plant audit, Green Ngoria engineered and erected a 12-meter diameter high-rate thickener with automated feedwell dilution and hydraulic rake lift, enabling efficient solid-liquid separation and recycling 40% of cyanide reagents.

Artisanal / Previous Baseline: 71%Green Ngoria CIL: 96.2% (+25.2% Delta)
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Primary Jaw & Secondary Hydraulic Cone Crusher Setup
98.6% Crushing Circuit Uptime
Commissioned
Crushing & MillingNarok County, Kenya450 TPD (Medium Scale)GN-NAR-450

450 TPD Multi-Stage Crushing & Screening Plant

Client: Kilimapesa Gold Corridor Miners · Commissioned: 2024

Engineered an aggressive hard-rock crushing plant featuring a heavy-duty primary jaw crusher, secondary hydraulic cone crusher, double-deck inclined vibrating screen, overhead self-cleaning tramp iron magnet, and high-pressure dust mist suppression system.

Artisanal / Previous Baseline: 72%Green Ngoria CIL: 98.6% (+26.6% Delta)
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Direct-Fired Rotary Thermal Reactivation Kiln at 750°C
99.1% Carbon Activity Restoration
Commissioned
Elution & SmeltingMigori County, Kenya100 kg/hr ContinuousGN-MIG-KILN

Rotary Carbon Reactivation Kiln & Acid Wash System

Client: Macalder Mining Consortium · Commissioned: 2025

Fabricated and commissioned a continuous horizontal rotary carbon reactivation kiln with 310-grade stainless steel retort operating at 650°C-750°C with steam activation, preceded by an acid-wash scaling column to strip foulants and restore gold adsorption kinetics.

Artisanal / Previous Baseline: 65%Green Ngoria CIL: 99.1% (+34.1% Delta)
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Operational Footprint

Active Engineering Corridors Across East Africa

Green Ngoria deploys dedicated metallurgists, mechanical fabricators, and commissioning engineers directly to mining operations throughout the region.

Migori Gold Belt

Kenya · South Nyanza

Hub for high-sulfide quartz vein deposits. Over 8 active CIL/CIP installations, including our dedicated Spares & Reagents Logistics Facility in Migori.

Active Plants: 500 TPD CIL, 1.5T Zadra Elution, Carbon Reactivation Kiln

Kakamega & Siaya Reefs

Kenya · Western Goldfields

Archaean greenstone belt mining. Specialized in refractory tailings reprocessing, ultrafine regrinding, and dry-stack tailings filtration systems.

Active Plants: 300 TPD CIP Tailings, 750 TPD Grinding, 250 TPD Flotation

Lake Victoria Goldfields

Tanzania · Geita & Mara

Major industrial gold corridor. Turnkey retrofits for high-efficiency pressure Zadra elution columns, thickening clarifiers, and rotary reactivation kilns.

Active Plants: 1.5T Zadra Retrofit, 600 TPD High-Rate Thickener CCD
Engineering Assurance

The Green Ngoria 6-Stage EPC Execution Standard

Every project follows strict quality control gates, ISO-aligned mechanical fabrication, and rigorous metallurgical startup protocols.

STAGE 01

Diagnostic Testwork

Bottle-roll cyanide kinetics, diagnostic leach, Bond Work Index grindability, and diagnostic mineralogy to determine exact gold liberation.

STAGE 02

Flowsheet & 3D Design

Custom PFDs, P&IDs, mass balances, structural steel stress calculations, and 3D plant arrangement drawings tailored to site terrain.

STAGE 03

Precision Fabrication

Heavy tank rolling, agitator shaft balancing, polyurethane interstage screen assembly, and ASME-certified pressure elution column welding.

STAGE 04

Civil & Mechanical Erection

Reinforced equipment plinths, structural gantry erection, slurry piping reticulation, valve manifolds, and electrical motor control centers (MCC).

STAGE 05

Cold & Hot Commissioning

Dry mechanical run-in, water leak testing, slurry hydraulic balancing, automated reagent calibration, and safe hot cyanidation startup.

STAGE 06

Metallurgical Handover

First gold bullion pour verification, operator standard operating procedure (SOP) training, and ongoing metallurgical warranty support.

Ready to Maximize Gold Recovery on Your Mining Concession?

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