Modular Recovery Plants

Since 1972, KCA has fabricated portable / modular carbon adsorption, carbon desorption, carbon stripping, and Merrill-Crowe plants. Our plants have earned an outstanding reputation for quality, simplicity, ease of start-up, and fail-safe operation.

74

Plants delivered

4,000 TPD

Largest modular

Multiple

Models

Why Modular

Rapid installation at remote sites, easily relocatable, high resale value, single-source supply. Modular plants serve gold operations treating up to 4,000 tonnes of ore per day. Above that size, plants are typically built on-site.

KCA Modular ADR Plant Models

KCA Model 20 (15 m³/h), Model 30, Model 50, Model 150, and Model 250. All models include adsorption columns, acid wash, pressure strip, electrowinning, and carbon regeneration. Fully tested and commissioned at the KCA Reno facility before shipping. Download the model brochures below for full specifications.

Modular Merrill-Crowe

Pre-coat filter, vacuum tower, zinc powder addition, clarifier filters, sludge filtration. Available in skid-mounted modules from 100 to 1,200 m³/h.

Delivery & Commissioning

KCA pre-assembles, tests, and trial-runs every modular plant in our 20,000 ft² Reno fabrication shop before disassembly and shipping. On-site re-assembly and commissioning by KCA technicians.

Download Brochures

📄 KCA Model 20 ADR Plant Brochure ↓ PDF 📄 KCA Model 30 ADR Plant Brochure ↓ PDF 📄 KCA Model 50 ADR Plant Brochure ↓ PDF 📄 KCA Model 150 ADR Plant Brochure ↓ PDF 📄 KCA Modular Merrill-Crowe Brochure ↓ PDF

Project Receipts

Precious Metal Plants Delivered

A partial list of operations where KCA has delivered modular recovery plants since 1972.

Operation	Location	Type	Size (m³/hr)
Afema	Ivory Coast	Carbon Adsorption & Ethanol Strip	50
Afema II	Ivory Coast	Carbon Adsorption & Ethanol Strip	100
Afema II	Ivory Coast	Carbon Regeneration	25 kg/hr
Al Hajal	Saudi Arabia	Carbon Adsorption & Ethanol Strip	15
Ashanti	Ghana	Carbon Adsorption & Ethanol Strip	125
Aurex	Peru	Merrill-Crowe	30
Aurora	United States	Carbon Adsorption & Ethanol Strip	50
Bolnisi	Georgia, CIS	Carbon Regeneration	25 kg/hr
Bolnisi	Georgia, CIS	Carbon Adsorption & Ethanol Strip	50
Cetco Mill	Russia	Vacuum/Deaeration Circuit	250
Choquelimpie	Chile	Carbon Adsorption & Ethanol Strip	225
Cripple Creek	United States	Carbon Adsorption & Ethanol Strip	55
El Cubo Phase I	Mexico	Merrill-Crowe	120
El Cubo Phase II	Mexico	Merrill-Crowe	121
El Magistral	Mexico	Carbon Adsorption	70
El Plomo	United States	Carbon Adsorption & Ethanol Strip	15
Essakan	Burkina Faso	Carbon Adsorption & Ethanol Strip	30
Fazenda Nova	Brazil	Carbon Adsorption	450
Getchell	United States	Carbon Adsorption & Ethanol Strip	45
Gilbert	United States	Carbon Adsorption & Ethanol Strip	50
Gordex	New Brunswick	Carbon Adsorption & Ethanol Strip	30
Hassai	Sudan	Carbon Adsorption & Ethanol Strip	20
Hassai	Sudan	Carbon Regeneration	25 kg/hr
Hayden Hill	United States	Carbon Adsorption	45
Ivrindi	Turkey	Carbon Adsorption	3,200
La Sorpresa	Mexico	Merrill-Crowe	65
Little Bald Mtn.	United States	Carbon Adsorption & Ethanol Strip	20
Magistral	Mexico	Carbon Adsorption & Ethanol Strip	70
Marvel Loch	Australia	Carbon Adsorption & Ethanol Strip	35
Mascota	Mexico	Carbon Adsorption	340
Newmont Tailings	United States	Carbon Adsorption	22
San Antonio	Mexico	Merrill-Crowe	70
San Martin	Mexico	Merrill-Crowe	70
Santiago de Chuco	Peru	Carbon Adsorption & Zadra Strip	20
Santiago de Chuco	Peru	Carbon Regeneration	42 kg/hr
Scott-European	Russia	Carbon Adsorption & Zadra Strip	20
Seligdar	Siberia	Carbon Adsorption & Zadra Strip	50
SSATE	Saudi Arabia	Carbon Adsorption & Ethanol Strip	125
Sterling	United States	Carbon Adsorption & Zadra Strip	35
Sterling II	United States	Carbon Adsorption & Ethanol Strip	200

Recent KCA Projects

See this capability in action.

Selected recent projects where KCA delivered this service. All from our portfolio of 500+ engineering projects.

Camino Rojo

Zacatecas, Mexico · ORLA Mining

18,000 TPD Heap Leach · $125M EPCM

La India

Sonora, Mexico · Agnico-Eagle

17,250 TPD Heap Leach · 13-month EPCM

Soledad Mountain

Mojave, CA · Golden Queen

14,000 TPD · 600 m³/h Merrill-Crowe

View All Projects →

Common Questions

Frequently asked.

How long does a typical KCA testwork campaign take?

Bench-scale programs take 4–8 weeks; column leach campaigns 3–6 months depending on heap height and ore character; full bankable feasibility-level testwork can span 9–18 months. Every campaign begins with a metallurgical interview to set the scope, schedule, and budget against your project milestones.

Can KCA take a project from testwork through commissioning?

Yes — this is KCA's defining capability. Most EPCM firms outsource testwork; KCA self-performs the lab, engineering, and (in EPCM mode) construction management. The flowsheet you sign off on is designed by the same team that builds the plant. One handoff. Fewer surprises.

Where does KCA work geographically?

KCA's Reno, Nevada headquarters serves projects in the Americas, Asia-Pacific, and Africa. Our Chihuahua, Mexico affiliate (Kappes Cassiday del Norte) supports operations across Mexico and Central America. Our Perth, Western Australia affiliate (KCAA) serves Asia-Pacific. Over 500 projects across six continents since 1972.

What types of ore does KCA test and engineer?

Primary expertise is gold and silver — both heap leach and milling/agitated cyanide processes. We also work on copper, lithium, and base metals. The KCA lab routinely runs HPGR, gravity, flotation, cyanide, and Merrill-Crowe campaigns across all commodity classes.

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