TIER 04 / TURNAROUND & UPGRADES

+5% to +18% Au • Rapid Diagnostic Audit

Plant Optimization & Turnaround

Diagnostic Audits, Tailings Recovery & Circuit Debottlenecking

Comprehensive diagnostic audits, kinetic leach profiling, carbon circuit remediation, and mechanical retrofits for operational plants suffering from gold loss, carbon fouling, or bottlenecks.

Request Feasibility for Plant Optimization & Turnaround Run Plant Recovery Calculator

+5% – 18% AuRecovery UpliftImmediate Revenue Increase

< 0.15 g/t AuTailings TargetRemediates Gold Leakage

15% – 30%Reagent SavingsCyanide & Lime Optimization

5 – 10 DaysAudit DurationComprehensive Field Metallurgical Review

Engineered For Your Scale

Operational Architecture & Mineralogy Fit

Many operating gold plants in East Africa operate far below their metallurgical potential, leaving valuable gold in tailings dams (>0.4 g/t Au) due to poor grind liberation, carbon passivation, insufficient dissolved oxygen, or improper agitation hydraulics. Green Ngoria’s diagnostic optimization engineering identifies exact root causes of gold leakage and implements high-impact mechanical and chemical retrofits that yield immediate recovery uplifts within days.

Target Operator ProfileOperating gold processing plants experiencing high tailings grade, carbon loss, low throughput, high reagent costs, or frequent mechanical downtime.

Systematic diagnostic audit targeting recovery uplifts, chemical reduction, and mechanical uptime.

Circuit Flowsheet Walkthrough

Step-by-Step Mineral Extraction Flow

How ore advances through crushing, closed-circuit milling, agitated leaching, carbon adsorption, and final gold bullion smelting.

Full Circuit Sampling & Metallurgical Profiling

Our metallurgists collect and analyze stream samples across crushing, classification, each leaching stage, and tailings discharge.

Root-Cause Bottleneck Diagnosis

We perform diagnostic leach tests, size-by-size assays, and carbon activity tests to pinpoint the exact source of gold loss.

Immediate Chemical & Hydraulic Tuning

We adjust cyanide dosing, oxygen sparging, pulp density, and cyclone pressures on site to unlock rapid recovery gains.

Mechanical Retrofits & Long-Term Monitoring

We install high-capacity interstage screens, low-shear impellers, and reliable slurry pumps, followed by monthly performance tracking.

Hardware & Machinery

Core Equipment Package Included in This Tier

Every mechanical component is fabricated with high-wear metallurgy and pressure-tested before shipment.

Field Metallurgical ProfilingDiagnostic Leach & Titration Kit

Mobile kinetic bottle roll apparatus, digital dissolved oxygen and cyanide titration probes

Carbon Retention RetrofitHigh-Efficiency 316L Interstage Screens

Air-swept or mechanical wiped cylindrical screens to prevent slurry blinding and carbon overflow

Circuit Flow StabilizationHigh-Chrome Slurry Pump Upgrades

Heavy-duty AH slurry pump assemblies with precision laser alignment

Mixing & Carbon PreservationLow-Shear Hydrofoil Agitator Retrofit

Energy-saving dual hydrofoil impellers preventing carbon abrasion and breakage

Engineering Data Sheet

Technical Parameters & Operating Specifications

Diagnostic Audit Scope

Sampling PointsCrusher feed, Mill discharge, Cyclone overflow, Tank 1-8, Tailings

Laboratory TestworkDiagnostic cyanide leaches, size-by-size gold assays, carbon loading kinetics

Hydraulic AnalysisSlurry rheology, residence time distribution, agitator power draw

Audit OutputCertified Mass Balance & Chemical Kinetic Turnaround Dossier

Common Problem Areas Remediated

High Tailings Grade (>0.4 g/t)Identified whether due to coarse locking, slow kinetics, or carbon fouling

Carbon Loss & AttritionEliminated through agitator hydrofoil retrofits and screen slot corrections

Cyanide OverconsumptionSolved via dissolved oxygen sparging and pH buffer stabilization

Pump Blowouts & BlockagesRemediated via slurry velocity calculations and high-chrome wet end retrofits

Expected Results Timeline

Field Audit Duration5 to 10 Days on site with lead metallurgists

Quick-Win AdjustmentsImplemented within 48 hours of audit commencement

Hardware Retrofits1 to 3 weeks with parts dispatched from Migori spares hub

FIELD CASE STUDY • Narok / Migori Gold Belt, Kenya

Operating 200 TPD CIP Plant Recovery Turnaround

The Operational Challenge: Operating plant was suffering from 0.72 g/t Au gold loss in tailings (only 82.4% recovery) and excessive carbon attrition from worn agitators.

Green Ngoria Solution: Green Ngoria conducted a 7-day metallurgical audit, calibrated grind P80 from 120µm to 75µm, upgraded interstage screens to 316L wedge-wire, and added oxygen sparging.

Verified Field Metric

+13.1% Recovery Increase (Recovery jumped from 82.4% to 95.5%)

Tailings gold dropped from 0.72 g/t to 0.18 g/tOre: Quartz-pyrite gold ore (4.1 g/t Au)

Certified Engineering Output