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Brochure - Modular Systems

Gekko systems has supplied modular components and systems for gold applications worldwide.

Brochure - Unique Hardware

Smart technology for step change benefits

Applicable Minerals


Free gold is unbound to other materials and is easy to liberate.


Gold associated with sulphides requires a modified flowsheet.


Free silver and silver complexes behave unpredictably and contain impurities.

Applicable Minerals


Coal ore properties can be manipulated for efficient recoveries.


A combination of different metals in a single compound.


Such as tin/tantalum, diamond, garnet and other gemstone-containing material.

Applicable Processes


Saves energy by recovering material into small volumes.


Upgrades the material going forward for economic gains.


Innovative flowsheets for coarse crushing and optimal liberation.

Applicable Processes


Controlling viscosity and magnetics in gravity separation feeds.


A low-energy process to recover higher material grades.


A high cyanide and high oxygen reaction boosts recoveries.

Applicable Processes


Optimising the best way to recover minerals from solution.


High-volume electrowinning captures more metal with great efficiency.


Gekko use the latest technologies to design or improve a detox process.

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Modular Systems

Meccano™ For Miners

Ingenious designs and advanced technology drive Gekko's production of modular plant systems.

Offering significant cost benefits and a low environmental footprint; Gekko process designers customise self-contained high recovery plants for minimal start-up capital, using high-quality components and in-house expertise.

These flexible modular plants are engineered to deliver super-efficient, environmentally friendly recoveries, by cleverly combining Gekko's gravity pre-concentration, flotation and intensive leach technologies.

Gekko Modular Systems offer significant savings on capital investment, installation and operating costs


Gekko’s extremely compact modular systems fit into 40ft shipping containers, making them easy to move and transport around the world.

The innovative modular systems offer significant savings on capital investment, installation and ongoing operating costs.

Gekko Modular Systems contain high quality, fully integrated Gekko components that are built to last.

Simple design features allow Gekko Modular Systems to be assembled and operated with ease.

Due to the flexible modular components of Gekko’s plant systems, flowsheets can be adapted to suit specific operational needs.

Pre-designed and fabricated in Gekko’s specialty workshops, the modular system is built economically and delivered quickly.

Modular System Specs

Beyond Tradition

Nowadays it's extremely expensive to build a new processing plant. Therefore mining operations are turning to modular plant systems that offer advantages such as:

  • Low capital costs that are reflected in a higher ROI
  • Improved cost to recovery ratios
  • Shipping to remote locations, compact modular systems are mobile and moveable
  • Quick and easy assembly on site by Gekko
  • Different modules can be used to customise a specific extraction process
  • Operational performance, quality and safety are upheld
  • Module throughputs are 2 t/hr, 50 t/hr, 100 t/hr - other tonnages available upon application
  • The best combination of modules for a specific operation will be recommended after initial ore testing by Gekko
  • Small environmental footprint due to the energy efficient design and operation
  • Off-site construction and pre-assembly by Gekko streamlines installation, commissioning and, therefore, cashflow generation.

Ores that can be concentrated by gravity or a combination of gravity and flotation processes are ideal for modular systems. Pre-concentration significantly reduces energy requirements and lowers the carbon footprint of plant operations.

Gekko's modular systems are used worldwide for free gold, complex gold, exploration, alluvial or hard rock, and diamond applications. Where appropriate, Gekko source and include processing equipment from other suppliers if required.

Typically, modular plants are designed and built by Gekko for a given mine operation with specific requirements. Gekko’s innovative core technologies and in-house process design expertise will produce an agile, effective modular plant. Contact a Gekko engineer today.

Innovative Gold Plant Design for Better Returns

Gekko also offer a ready-made modular plant known as the Gravity Flotation Intensive Leach (GFIL) system.

GFIL is a complete off-the-shelf gold processing modular plant designed to advance traditional whole ore cyanidation. It’s ideal for mines and ores with:

  • Restricted cyanide use permissions
  • Limited footprint space
  • A remote location
  • High forecast capital and operating costs
  • Sulphide-associated gold (complex ores)

The GFIL is backed by Gekko’s technological expertise and in-depth knowledge of gravity separation, flotation and intensive leaching systems for efficient gold recoveries

How the GFIL Works

The GFIL uses a Vertical Shaft Impactor (VSI) and High Pressure Grinding Roll (HPGR) to liberate mineral at a coarse grind size, which reduces energy costs.

The InLine Pressure Jig (IPJ) recovers a coarse mineral concentrate. As the desired mineral gets concentrated to approximately 5% of the total mass, the standard practice of cyanide leaching 100% of the ore is eliminated.

This 5% ore is treated with cyanide in Gekko’s proprietary high-performance InLine Leach Reactor (ILR) for superior gold recovery. The ILR reduces the consumption and environmental impact of whole ore cyanidation.

The gold is then recovered using the G-Rex column and the gold-bearing solution sent to electrowinning for final extraction.

Commissioning And Operating Experience With Gekkos Gold Ore Treatment Plants

Technical Papers (3 of 50)

More Technical Papers
technical paper
Technical Paper 031 - Commissioning And Operating Experience With Gekkos Gold Ore Treatment Plants

AusIMM - Metallurgical Plant Design and Operating Strategies Conference. A.H. Gray, S. Gannon, J. Abols and T. Hughes. | 04 March 2006

technical paper
Technical Paper 034 - A Focus On Gravity Recovery Improves Environmental And Cost Outcomes

AusIMM World Gold Conference, Cairns Australia. A.H. Gray and T. Hughes. | 01 October 2007

technical paper
Technical Paper 043 - New Developments IPJ And ILR Systems

ALTA International Gold Ore Processing Symposium, Perth, Australia. M. Braaksma and T. Bell. | 01 May 2010

The complete Woolshed Gully gold processing plant - designed and installed by Gekko

Case Studies (3 of 14)

More Case Studies
case study
Case Study - Ballarat Goldfields

Gekko Systems have recently designed, engineered and built the Stage 1 process plant for Ballarat Goldfields (BGF). | 01 April 2006

case study
Case Study - BHP Billiton Temco

BHP Billiton's Tasmanian Electro Metallurgical Company Pty Ltd (TEMCO) is Australia's only producer of manganese ferroalloy. | 01 July 2008

case study
Case Study - Argyle Diamonds

Gekko Systems recently successfully trialed a 20 tonne per hour Modular Diamond Pilot Plant at the Argyle Diamond Mine in Western Australia. | 01 January 2005

Gekko Modular Plant for REO Mongolia

Articles (3 of 37)

More Articles
Gekko Modular Plant for REO Mongolia

Another first for Gekko Systems is the recent installation of a gravity plant for REO LLC in Mongolia, the country’s only gold mining company with an underground operation. | 01 October 2013

Gekko Gravity Box Package for Gold Fields’ Agnew

After eight years of reliable ILR success, Gold Fields has upgraded its Agnew ILR2000 Batch Automatic unit. | 01 September 2012

Positive Recovery Results from Python at Kloof

Gekko Systems was contracted by Gold Fields in June 2010 to design, build, install and commission a Python 500 modular plant for its Kloof GROWTH project in South Africa. | 01 July 2011

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