TRX Gold Corporation is transforming its Buckreef Gold Mine in Tanzania into a mid-tier gold producer through a phased expansion of its processing facility. Starting with a modest 60 tpd pilot plant in 2020, the operation has grown to 1,750 tpd in 2024 and is now implementing a technical overhaul to reach 3,000 tpd by 2025. The expansion, designed by Orway Mineral Consultants, introduces a sophisticated hybrid flowsheet combining flotation with carbon-in-leach (CIL) technology to optimize recovery from both oxide and fresh sulphide ores.
This expansion represents a strategic shift in African gold processing, demonstrating how modular growth paired with advanced metallurgy can economically unlock complex ore bodies. The project’s innovative approach to phased capital deployment – adding flotation ahead of full sulphide commissioning – provides a blueprint for junior miners transitioning to intermediate producers while managing risk.
The upgraded circuit features several technological advancements:
- Comminution: Transition from 3-stage crushing to SAG mill primary grinding (7.32m x 3.75m, 3,500 kW) with existing 3.2m ball mill retained for secondary grinding
- Concentration: New 6 x TankCell e40 flotation circuit (35m³ cells) targeting 13.1% mass pull at 91.3% recovery
- Ultra-Fine Grinding: HIG700 regrind mill reducing flotation concentrate to P80 15µm
- Leaching: Split-circuit design with dedicated concentrate leach tanks (2 x 335m³) feeding into expanded 11-tank CIL circuit
- Elution: New split AARL circuit with 200kg/hr regeneration kiln to reduce soluble gold losses
| Parameter | Phase 1 (2,000 tpd) | Phase 2 (3,000 tpd) |
|---|---|---|
| Annual Throughput | 636,738 tpa | 1,095,000 tpa |
| Overall Recovery | 88.2% | 87.5% |
| Water Demand | 3,800 m³/day | 5,200 m³/day |
| Power Demand | XX kW | XX kW |
According to Orway Mineral Consultants’ January 2025 report, “The incorporation of flotation with intensive leaching of the concentrate provides optimal economics for the transitional ore types expected during ramp-up.” The design specifically addresses the challenge of declining oxide reserves by ensuring the circuit can maintain +87% recovery when processing 100% fresh sulphide ore.
Environmental considerations include a comprehensive water recycling system that recovers 85% of process water, with plans for cyanide destruction ahead of underground development. The phased approach also allows for operational learnings to be incorporated between expansion stages – a strategy TRX CEO Stephen Mullowney describes as “building the muscle before adding more weight.”
As the gold industry faces increasing pressure to improve recovery rates from complex ores while controlling capital intensity, Buckreef’s hybrid flotation-CIL approach may set a new standard for African gold expansions. With commissioning of the 3,000 tpd circuit expected in late 2025, all eyes will be on whether this innovative flowsheet delivers its promised 15% improvement in sulphide recovery compared to conventional CIL alone.
Based on filing data from 2024-2025.
