Manual of Operation for the SYOGM Rothensteed Mill


Manual of Operation

for the SYOGM Rothensteed Mill

Table of Contents

  1. Description of the SYOGM Rothensteed Mill
  2. Machine Parts
  3. Capacity
  4. Water Input
  5. Wear Parts
  6. Motor Operation and Maintenance
  7. Operating the Feeder
  8. Screen Information
  9. Improving Gold Recovery
  10. Safety Precautions
  11. Installation and Commissioning
  12. Daily Operator Checks
  13. Lubrication Schedule
  14. Troubleshooting Guide
  15. Maintenance Schedule
  16. Storage and Decommissioning
  17. Technical Specifications
  18. Spare Parts List
  19. Operator Log Sheet

1. Description of the SYOGM Rothensteed Mill

The SYOGM Rothensteed Mill is purpose-built for the efficient milling of half-inch particles to pass through a 1.5 mm screen, drawing upon established research published in the Journal of the South African Institute of Mining and Metallurgy. This research demonstrated that gold recoveries in the range of 75 to 80 percent could be achieved at relatively coarse grinds. Notably, Vaal Reefs ore yielded a 75 percent gold recovery with no milling at all—merely crushed to pass 1.5 mm—and recovery increased marginally to 79 percent at 93 percent passing 74 microns as milling continued.

The mill is designed for direct integration with fine gold recovery sluices, including those utilizing Cleangold technology and methods. This configuration eliminates the need for material transport, minimizes dust generation, and enables immediate gold recovery upon milling. With trained operators, full gold recovery potential may be realized.

Detailed documentation regarding the fine gold recovery system, associated management policies, and operator training is provided in separate attached documents.

2. Machine Parts

  1. Support stand with legs – Provides structural foundation for the mill assembly.
  2. 10 HP motor, 3 phase, 1440 RPM – Main power unit. Full load amperage: 15.6 A at 415 V.
  3. Motor starter assembly – Includes starter unit, control wiring, ammeter, overload relay set to 15.6 A, and safety key switch.
  4. Three Type A V-belts – Power transmission from motor to rotor.
  5. Main milling assembly – Housed within the stand, comprising rotor, rotating impact plates, and 16 static impact plates; complete with safety covers.
  6. Feed hopper – Accepts input of half-inch sized rock material.
  7. Output screen – Positioned atop the discharge chute for particle size classification.
  8. Discharge sluice – Directs milled material to the gold recovery system.
  9. Plummer block bearings – Heavy-duty split-type bearing housings supporting the main rotor shaft. Designed to accommodate misalignment and withstand continuous impact loads. Require periodic greasing and inspection.

3. Capacity of SYOGM Rothensteed Mill

Under optimal operating conditions—including appropriate feed rate, particle size consistently smaller than half-inch, adequate water flow, correctly sized screen, and full motor power at rated speed—the SYOGM Rothensteed Mill consistently processes between 3 and 5 tonnes per hour.

It is important to note that feed rate significantly influences throughput; both underfeeding and overfeeding can negatively impact capacity. Operators should monitor and maintain steady feed delivery to achieve rated performance.

The use of dirty or turbid water may cause fine particles to cement inside the machine, leading to reduced efficiency and potential blockages. It is strongly recommended to clean the mill thoroughly using a pressure washer after each production shift and prior to any extended storage period.

4. Water Input

The SYOGM Rothensteed Mill is capable of operating in both dry and wet modes. Wet operation is strongly preferred for dust suppression, particle suspension, and optimal material flow.

A water flow rate of 1000 liters per hour is recommended for standard operation. The machine may function at reduced flow rates down to 500 liters per hour; however, operators should anticipate reduced throughput and increased dust generation under such conditions.

Water should be introduced at the feeder inlet simultaneously with the feed material to ensure uniform moisture content throughout the milling chamber.

5. Wear Parts

The following components are subject to wear and require periodic inspection and replacement:

Wear parts should be replaced immediately upon noticing a measurable decline in milling capacity, increased processing time to achieve target particle size, or visible degradation of the impact surfaces.

Additional replaceable items include:

Standard wear parts are provided sufficient for approximately three months of continuous operation under normal conditions.

6. Motor Operation and Maintenance

The mill is designed for use with a 7.5 kW (10 HP), 3-phase, 4-pole electric motor operating at 1440 RPM, constructed with full copper windings. Full load amperage: 15.6 A at 415 V.

This manual does not cover detailed motor maintenance or repair procedures; refer to the motor manufacturer’s documentation for servicing instructions.

Starter Operation

The motor starter unit is equipped with a clear control interface:

Only trained and authorized operators shall operate the starter or access the key-locked controls.

Overload Relay

The thermal overload relay is factory set to 15.6 A. Do not adjust. If the relay trips:

  1. Switch off and isolate power.
  2. Allow motor to cool for 15 minutes.
  3. Investigate cause of overload (excessive feed rate, screen blinding, mechanical binding).
  4. Rectify fault.
  5. Reset overload relay by pressing reset button.
  6. Restart per normal procedure.

Repeated tripping indicates a serious problem; do not bypass or increase overload setting.

7. Operating the Feeder

The feeder is designed to accept material from a conveyor belt system. It performs best under a balanced, consistent feed rate, synchronized with water addition.

Operators should be aware that improperly fed material or excessive air movement may cause fine particles to be expelled from the feeder opening. It is the final operator’s responsibility to adapt the feeder configuration to site-specific conditions.

Once the conveyor belt is installed and aligned, all unnecessary openings on the feeder should be securely closed or covered to contain dust, prevent spillage, and protect personnel from flying debris.

Feed rate guidelines:

Signs of incorrect feed rate:

Symptom Probable Cause Action
Amperage <10.0 A Underfeeding Increase feed rate
Amperage >15.6 A Overfeeding Reduce feed rate immediately
Fluctuating ammeter Surge feeding Stabilize feed rate
Mill plugging Feed rate too high Stop feed; clear mill; reduce rate

8. Screen Information

The SYOGM Rothensteed Mill is designed to accommodate a range of screen sizes, offering operational flexibility. When configured with appropriately sized screens, the mill can function as a mid-stage crusher reducing material to 3/8 inch, or as a fine grinder achieving products as fine as 30 mesh.

For gold liberation applications, a 1.5 mm screen opening is strongly recommended. This configuration aligns with the published research indicating near-optimal gold recovery at this particle size with minimal over-grinding.

Screen Replacement Procedure

To replace the screen:

  1. Stop mill and isolate power. Remove key from starter.
  2. Allow rotor to come to complete stop.
  3. Remove bottom output chute assembly:
    • Release clamps or undo retaining bolts.
    • Carefully lower chute; support weight.
  4. Remove worn screen:
    • Note orientation for correct reinstallation.
    • Remove retaining bars or wedges.
  5. Inspect screen frame and gasket; clean sealing surfaces.
  6. Install new screen:
    • Ensure correct mesh size.
    • Seat fully in frame.
    • Secure with all retainers.
  7. Reinstall output chute:
    • Check gasket condition; replace if compressed or torn.
    • Tighten fasteners evenly.
  8. Rotate rotor by hand; confirm no contact with screen.
  9. Restore power; perform test run.

Screen life log: Record installation date, operational hours, and reason for replacement.

9. Improving Gold Recovery

Operators seeking to maximize gold recovery may integrate additional classification equipment downstream or in closed circuit with the mill. Suitable options include:

These devices enable tighter control over particle size distribution and improve recovery efficiency by ensuring optimal feed to concentration equipment. Separate instruction manuals and operational guidelines are provided with each supplementary component.

10. Safety Precautions

The safety of all personnel is paramount. The following precautions must be observed at all times:

Personal Protective Equipment (PPE)

Operational Safety

Electrical Safety

Housekeeping

Emergency Procedure:

  1. Push emergency stop.
  2. Call for assistance.
  3. Administer first aid if trained and safe to do so.
  4. Isolate power at main switch.
  5. Report incident to supervisor.

11. Installation and Commissioning

Site Preparation Requirements

The SYOGM Rothensteed Mill requires a level, reinforced concrete foundation capable of supporting the combined static and dynamic loads of the machine, motor, and feed system. A minimum concrete thickness of 150 mm with appropriate reinforcement is recommended.

Clearance requirements:

Drainage:

Anchor bolts shall be cast into the foundation according to the mounting footprint diagram provided in Appendix A. Allow minimum 7 days curing time before placing equipment.

Lifting and Handling Instructions

Machine weight: Approximately 850 kg (motor not included).

Lifting points:

Procedure:

  1. Use spreader bar with chains or synthetic slings rated minimum 2 tonnes capacity.
  2. Attach all four lifting points evenly; adjust sling lengths to maintain level lift.
  3. Lift slowly; clear floor by 100 mm and check stability before proceeding.
  4. Guide machine onto foundation bolts; lower carefully and engage nuts finger-tight.

Moving without crane:

Alignment Procedure between Motor and Mill Pulleys

Correct pulley alignment is critical for belt life, power transmission, and bearing longevity.

Tools required: Straightedge, steel rule, or laser alignment tool.

Procedure:

  1. Rough alignment:

    • Mount motor on slide rail base; leave bolts snug but movable.
    • Install motor pulley and mill pulley; ensure both are fully seated on keyways and shaft ends are flush with pulley hubs.
    • Place motor pulley approximately 5–10 mm closer to motor than mill pulley to allow for belt tensioning take-up.

  2. Angular alignment:

    • Place straightedge across outer faces of both pulleys.
    • Adjust motor position until straightedge contacts both faces evenly across full width.
    • Repeat at top, centre, and bottom positions.

  3. Parallel alignment:

    • Measure distance between pulley centre lines at both front and back of pulleys.
    • Adjust until both measurements are equal within 0.5 mm tolerance.

  4. Final torque:

    • Tighten motor mounting bolts to specified torque (refer to motor manufacturer data).
    • Re-check alignment; slight shift may occur during tightening.

Belt Tensioning Procedure

Belts supplied: 3 × Type A V-belts.

Procedure:

  1. Install belts over pulleys by hand; do not roll or pry belts into grooves with tools.
  2. Adjust motor position outward on slide rail until belts are snug.
  3. Apply tension:
    • Correct deflection: 10–12 mm downward force at belt mid-span when pressed firmly with thumb.
    • Alternative method: Belt should not slip under full load but should not run hot.
  4. Run machine for 15 minutes; stop and re-check tension.
  5. Re-tension after first 8 hours of operation as initial bedding-in occurs.

Caution: Over-tensioning shortens bearing and belt life. Under-tensioning causes slippage, glazing, and capacity loss.

Electrical Connection Requirements

Motor specifications:

Connection requirements:

  1. Supply cable:

    • Minimum 4 mm² × 4 core armoured cable (3 phases + earth) – suitable for 15.6 A continuous duty.
    • Cable entry via base of starter enclosure; use appropriate gland.

  2. Earthing:

    • Dedicated earth conductor required.
    • Earth continuity must be maintained from mains supply to motor frame.
    • Supplementary earth bond between motor body and mill frame required.
    • Earth resistance: Less than 1 ohm.

  3. Isolation:

    • Lockable isolating switch must be installed adjacent to machine, visible from starter position.
    • Switch rating: Minimum 20 A.

  4. Protection:

    • Thermal overload relay correctly set to 15.6 A (motor nameplate FLA).
    • Short circuit protection via MCB or fuse rated 20 A, Type C or as advised by starter manufacturer.

All electrical work shall be performed by licensed electricians in compliance with local regulations.

First Start-Up Checklist

Before starting, verify the following:

Mechanical:

Electrical:

Water (if operating wet):

Run-in procedure:

  1. Dry run (no load, no water):

    • Start motor; observe rotation direction (arrow marked on mill cover).
    • If incorrect, isolate supply and swap any two phases at starter.
    • Run for 5 minutes; listen for unusual noise, check vibration, monitor bearing temperatures.
    • Stop; check belt tension and bolt torque.

  2. Wet run (water only, no feed):

    • Start water flow at 500 L/hr.
    • Start mill.
    • Confirm water flows through screen and discharge sluice without leakage.
    • Check for misting or spray from seals; adjust water rate if required.

  3. Load introduction:

    • Begin feeding clean, sized rock (half-inch minus) at approximately 1 tonne per hour.
    • Gradually increase to full rated feed rate over 30 minutes.
    • Monitor motor amperage; do not exceed 15.6 A.
    • Observe product discharge; verify particle size passing screen.

Commissioning sign-off:

Date: Installed by: Verified by: ______________

12. Daily Operator Checks

Pre-Start Inspection

Before starting the SYOGM Rothensteed Mill each shift, the operator shall verify the following:

Guards and Covers:

Obstructions and Foreign Material:

Belt Condition:

Fasteners:

Water Supply (wet operation only):

Work Area:

Documentation:

If any deficiency is identified, do not start the machine. Report to supervisor and rectify before operation.

Monitoring Motor Amperage During Operation

Motor current is the primary indicator of mill loading and must be observed continuously during operation.

Procedure:

  1. Observe ammeter at starter enclosure during:

    • Start-up (brief inrush current expected).
    • Steady-state operation.
    • Feed rate changes.

  2. Normal operating range:

Parameter Value
Motor nameplate FLA 15.6 A
Recommended continuous operating range 70–90% of FLA (10.9–14.0 A)
Maximum continuous 100% FLA (15.6 A) – do not exceed
Overload trip setting 15.6 A (class 10 or 20)
  1. Operator actions based on amperage reading:
Amperage Condition Action Required
Below 10.0 A Underloaded Increase feed rate gradually to improve efficiency.
10.9–14.0 A Optimal Maintain current feed rate.
14.0–15.6 A High load Monitor closely; reduce feed rate if sustained.
Above 15.6 A Overload Immediately stop feed; reduce feed rate; if persists >5 seconds, stop mill and investigate.

  1. Log ammeter reading at start of shift, mid-shift, and end of shift in operator logbook.

  2. Erratic ammeter movement:

    • Fluctuating needle indicates uneven feed rate.
    • Steady climb indicates screen blinding or material buildup.
    • Sudden drop may indicate belt slippage or feed interruption.

Never leave a running mill unattended without ammeter observation capability.

Checking for Unusual Noise or Vibration

The trained operator’s critical diagnostic tools are hearing and touch. Stop and investigate if any of the following are detected:

Noise:

Sound Likely Cause Action
Squealing Belt slippage Stop; re-tension belts.
Rhythmic tapping Loose impact plate or foreign object Stop immediately; inspect rotor and static plates.
Grinding or scraping Rotor contacting stationary parts Stop immediately; check wear part clearance.
Rumbling Worn bearings Stop; check Plummer blocks for heat/play.
Popping Material backing up at feeder Clear obstruction; reduce feed rate.
High-pitched whine Over-tensioned belts or motor bearing issue Check tension; listen at motor bearings.

Vibration:

Procedure if abnormal vibration detected:

  1. Stop feed immediately.
  2. Allow mill to run empty (30–60 seconds).
  3. If vibration ceases with load removed: Feed-related imbalance – check for tramp metal, oversized feed, or uneven distribution.
  4. If vibration continues empty: Mechanical issue – stop mill, lock out power, inspect:
    • Buildup on rotor faces.
    • Missing or broken impact plates.
    • Loose Plummer block bolts.
    • Worn belts causing uneven pulley loading.

Record all noise and vibration events in operator logbook.

Screen Condition and Cleanliness

The output screen directly controls product particle size and mill capacity. A compromised screen renders the mill ineffective.

Inspection Frequency:

What to look for:

  1. Tears or holes:

    • Allows oversize particles to pass.
    • Action: Replace screen immediately.

  2. Blinding (plugged apertures):

    • Fine, damp material wedged in screen mesh.
    • Indicators: Reduced throughput, elevated motor amperage, clean oversize in product.
    • Action:
      • Stop mill; flush screen with pressure washer from underside.
      • If wet operation: Increase water flow rate.
      • If persistent: Screen may require replacement with anti-blinding type or larger opening.

  3. Wear thinning:

    • Screen wire visibly worn, especially at impact zone.
    • Action: Replace during next scheduled maintenance; monitor closely.

  4. Loose fit or bypass:

    • Material escaping around screen edges.
    • Action: Re-seat screen; check gasket condition; tighten retainers.

Screen Cleaning Procedure:

Screen Life Log:

13. Lubrication Schedule

Plummer Block Bearings (2 off)

Motor Bearings

Feeder Hinge Points (if fitted)

Belt Tensioning Slide Rails

Note: Keep a grease gun dedicated to this machine and stored clean. Contaminated grease destroys bearings.

14. Troubleshooting Guide

Problem Probable Cause Corrective Action
Mill will not start No power supply Check isolator; reset tripped breaker
Emergency stop engaged Twist to release; reset
Overload relay tripped Allow cooling; reset; investigate cause
Key switch off Insert key; turn to ON position
Motor fault Check connections; test motor insulation
Low capacity / throughput Feed rate too low Increase gradually; monitor amperage
Screen blinded Clean or replace screen
Worn impact plates Inspect; replace wear parts
Belt slippage Re-tension belts
Insufficient water flow Increase to 1000 L/hr
Feed too coarse Ensure <½" feed size
Oversize in product Screen torn or holed Replace screen
Screen bypass Re-seat screen; replace gasket
Incorrect screen fitted Verify mesh size; install correct screen
Motor overload / high amperage Excessive feed rate Reduce feed immediately
Screen blinded Clean screen
Material buildup inside mill Stop; clean mill interior
Belt tension too high Slightly reduce tension
Mechanical binding Check rotor clearance; inspect bearings
Excessive vibration Unbalanced rotor Clean buildup from rotor faces
Worn or missing impact plates Replace worn plates
Loose Plummer block bolts Tighten to torque
Worn bearings Replace Plummer block bearings
Foreign object inside mill Stop; remove object; inspect for damage
Belt squealing / slipping Insufficient tension Re-tension belts
Belts glazed or worn Replace belts
Oil or grease on belts Clean pulleys; replace belts
Overloaded mill Reduce feed rate
Bearing overheating Insufficient lubrication Grease bearings (2–3 strokes)
Over-greasing Clean excess grease; reduce strokes
Misalignment Check pulley alignment
Belt tension too high Reduce tension slightly
Bearing worn or damaged Replace bearing
Material backing up at feeder Feed rate too high Reduce feed rate
Screen blinded Clean screen
Discharge chute blocked Clear obstruction
Water flow insufficient Increase water rate
Erratic ammeter reading Uneven feed rate Stabilize feed; check conveyor
Intermittent belt slip Check tension; inspect belts
Electrical fault Check connections; consult electrician
Dust emission (dry mode) Enclosure not sealed Check covers; seal leaks
Excessive air movement Reduce airflow; improve shrouding
Dry operation without dust control Convert to wet mode or install extraction

15. Maintenance Schedule

Daily (Every Shift)

Weekly

Monthly

Quarterly (3 Months)

Annually

16. Storage and Decommissioning

Short-Term Storage (Up to 1 Month)

  1. Run mill empty to clear all material.
  2. Operate with water only for 5 minutes (wet mode) to flush system.
  3. Stop mill; isolate power; remove key.
  4. Clean exterior surfaces; remove accumulated dust and fines.
  5. Grease Plummer block bearings (3 strokes).
  6. Cover mill with breathable dust cover.
  7. Store in dry, sheltered area.

Long-Term Storage (More than 1 Month)

  1. Complete all short-term storage steps.
  2. Remove belts; store in cool, dark location away from direct sunlight.
  3. Apply light oil or rust preventative to:
    • Unpainted metal surfaces.
    • Pulley grooves.
    • Rotor shaft exposed areas.
  4. Grease Plummer block bearings thoroughly until fresh grease purges from seals.
  5. Seal all openings (feeder inlet, discharge chute) to prevent rodent entry.
  6. Wrap motor with plastic; include desiccant bag inside wrapping.
  7. Rotate rotor by hand monthly to redistribute lubrication.
  8. Inspect quarterly for corrosion or pest intrusion.

Decommissioning

  1. Isolate and lock out all power sources.
  2. Disconnect electrical supply; remove cables.
  3. Drain and disconnect water supply.
  4. Remove belts and store (if reusable) or dispose.
  5. Remove motor; store or dispose per local regulations.
  6. Dismantle mill into major assemblies:
    • Stand
    • Main milling assembly
    • Feeder
    • Discharge chute
  7. Segregate components by material type for recycling.
  8. Dispose of wear parts, bearings, and electrical components per local environmental regulations.
  9. Paint or label “DECOMMISSIONED – NOT FOR OPERATION” on main frame if retained on site.

17. Technical Specifications

Parameter Specification
Model SYOGM Rothensteed Mill
Intended feed size ≤ ½ inch (12.7 mm)
Typical product size Passing 1.5 mm screen (adjustable)
Capacity 3–5 tonnes per hour (dependent on feed and screen)
Motor power 10 HP (7.5 kW)
Motor speed 1440 RPM
Motor current (FLA) 15.6 A at 415 V, 50 Hz
Motor protection Thermal overload relay set to 15.6 A
Power transmission 3 × Type A V-belts
Rotor speed Approximately 900–1000 RPM (driven)
Impact plates 16 static + 3 rotating (manganese-enhanced)
Bearings Plummer block split-type (2 off)
Water consumption Recommended: 1000 L/hr; Minimum: 500 L/hr
Screen options 1.5 mm (standard), 3/8", 30 mesh, others available
Machine weight (without motor) Approximately 850 kg
Total installed weight Approximately 950 kg
Dimensions (L × W × H) 1800 mm × 1200 mm × 1600 mm (approximate)
Foundation type Reinforced concrete, 150 mm min thickness

18. Spare Parts List

Part Number Description Quantity per Machine Recommended Stock Level
SY-WP-001 Static wear liner (set of 16) 1 set 2 sets
SY-WP-002 Static impact plate (manganese) 3 6
SY-BL-001 Type A V-belt 3 6
SY-BL-002 Type B V-belt (wear parts kit) 3 3
SY-SC-001 Screen – 1.5 mm 1 3
SY-SC-002 Screen – 3/8" 1 1
SY-SC-003 Screen – 30 mesh 1 1
SY-BR-001 Plummer block bearing assembly 2 2
SY-FT-001 Feeder hinge pin 2 2
SY-GS-001 Discharge chute gasket 1 2
SY-KT-001 3-month wear parts kit (liners + plates + belts) 1 kit 1 kit

Ordering Information:

Contact SYOGM Parts Department with machine serial number and part number. Emergency orders: Specify “URGENT” on purchase order.

19. Operator Log Sheet

Daily Operator Log

Machine Serial Number:
Date: Shift: Day / Night Operator: ______________

Check Item Status (OK / Not OK) Remarks / Action Taken
Pre-Start Checks
Guards and covers secure
Rotor free to turn
Belts condition and tension
Screen condition
Feeder clear
Water supply (wet mode)
Work area clear
Operational Data
Start-up amperage (A)
Mid-shift amperage (A)
End-shift amperage (A)
Water flow rate (L/hr)
Feed rate estimate (tph)
Observations
Unusual noise? (Y/N)
Unusual vibration? (Y/N)
Screen blinded? (Y/N)
Belt slippage? (Y/N)
End of Shift
Mill run empty
Screen cleaned
Power isolated
Key returned
Area swept clean

Supervisor Review: Date:

Document Control

Manual Title: Manual of Operation for the SYOGM Rothensteed Mill
Document Number: SYOGM-OM-2026-01
Revision: 1.0
Date of Issue: 12 February 2026
Prepared by: SYOGM Technical Publications
Approved by: ____________________

Important Notice:

The information contained in this manual is accurate at the time of publication. SYOGM reserves the right to improve, modify, or change specifications and components without notice and without incurring obligation to previously supplied units.

Copyright:

© 2026 Start Your Own Gold Mine. Permission is granted to copy, distribute and/or modify this document under the terms of the GNU Free Documentation License, Version 1.3 or any later version published by the Free Software Foundation; with no Invariant Sections, no Front-Cover Texts, and no Back-Cover Texts. A copy of the license is included in the section entitled “GNU Free Documentation License”

END OF MANUAL

The London or gold world market price as of Thursday, February 12 2026, 20:32:04 was US $150.19 per gram or US $150194.14 per kilogram.

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