Copper Ore Beneficiation Solutions

Copper Ore Beneficiation Solution

I. Solution Overview: Precise Separation, Maximize Value

This copper ore beneficiation solution is a total solution for all kinds of copper ores ( sulfide ores, oxide ores, mixed ores and complex polymetallic ores ). Adhering to the design concept of " flotation as the main method, wet method as a supplement, high efficiency recovery, green environmental protection ", we overcome the problems of fine-grained embeddedness, mineral symbiosis and other beneficiation problems through the customized process and advanced equipment configuration, aiming at achieving the highest copper recovery rate, optimal concentrate grade and the lowest operating costs for customers, and ensuring that the project economic benefits are maximized. Maximize the economic benefits of the project.

II. Detailed explanation of the core process

A set of efficient and mature copper ore dressing process mainly includes the following four precisely connected sections:

1. Crushing and screening section - laying the foundation for efficient milling and beneficiation

• Flow: The classic " three stages and one closed-circuit crushing " process is adopted.

  • Rough crushing: hydraulic jaw crusher, handling large pieces of raw ore with strong impact resistance.

  • Medium crushing: multi-cylinder hydraulic cone crusher, realizing medium and fine crushing with stable operation.

  • Fine crushing: high-pressure roller mill or fine crushing cone crusher, realizing "more crushing and less grinding", significantly reducing energy consumption.

• Closed Circuit: Vibrating screen and fine crushing equipment form a closed circuit to ensure that the particle size of grinding ≤ 12mm, creating the best conditions for efficient grinding.

2. Grinding and classifying section - realizing full dissociation of copper minerals

• Flow: " Stage grinding - stage separation " strategy is adopted.

  • One-stage grinding: energy-saving ball mill and spiral classifier or cyclone group form a closed circuit, and the output of preliminary dissociated products into the roughing.

  • Second stage grinding: regrind the coarse concentrate or medium ore, adopt ball mill and high-efficiency cyclone group closed circuit, precisely control the fineness, completely break the contiguous body, and release the micro-fine-grained copper minerals.

• Advantages: classification efficiency ≥85%, avoiding over-grinding, low energy consumption, and good dissociation effect.

3. flotation sorting section - the heart and soul of the recovery process
According to the nature of the ore, we provide the most suitable flotation technology:

• Copper sulfide ore flotation:

  • Preferential flotation: suitable for ores with simple mineral composition, adopting high selective collector to float copper minerals preferentially.

  • Mixed flotation: applicable to copper and sulfur and other minerals closely symbiotic ores, first mixed flotation to get copper and sulfur mixed concentrate, and then copper and sulfur separation (using special inhibitors to inhibit pyrite).

  • Features: adopts inflatable mechanical stirring flotation machine with strong pulp suction capacity, low power consumption and precise customization of pharmaceutical system.

• Oxidized Copper Ore / Difficult Ore Treatment:

  • Sulfide-flotation method: add activator such as sodium sulfide to sulfide the surface of copper oxide minerals, and then recover it by conventional flotation method.

  • Combined process: For extremely difficult to select ores, the combined process of " flotation + hydrometallurgy " (leaching-extraction-electrowinning) is adopted to ensure the recovery rate.

• Comprehensive recovery of polymetallic ores:

  • At the same time of recovering the main metal copper, we can simultaneously and comprehensively recover valuable elements such as molybdenum, gold, silver, etc. We design parallel or serial separation processes to maximize the value of resources.

4. Concentrate dewatering section - producing qualified products

• Concentration: Adopt high-efficiency deep cone thickener to concentrate the flotation concentrate to the bottom stream concentration ≥65%.

• Filtration: adopting ceramic vacuum filter, the moisture of the filter cake is as low as ≤12%, which greatly reduces the transportation cost.

• Drying (optional): for customers with special requirements, equipped with steam drying system, can further reduce the moisture of concentrate to ≤8%.

III. Recommended configuration of core equipment

Fourth, the core advantages of the solution

• Leading technology, high recovery rate:

  • By virtue of the exclusive pharmaceutical formula and multi-stage selection + sweeping process, it has remarkable effect on the recovery of copper minerals of micro-fine grains and ensures that the copper recovery rate is ≥92%.

  • Proficient in the separation technology of complex polymetallic ores, which can realize the efficient synergistic recovery of copper, molybdenum, gold, silver, etc.

• Energy saving and excellent cost:

  • The application of high-pressure roller mill process can save 40% energy compared with traditional crushing.

  • Optimized design of flotation machine impeller and high-efficiency wear-resistant materials can reduce power consumption by more than 25%.

  • Heat recovery system can reduce drying energy consumption by 30%.

• Green environmental protection, sustainable development:

  • Wastewater recycling rate ≥95%, realizing near-zero emission.

  • Promote dry storage and comprehensive utilization technology of tailings to reduce environmental footprint and risk.

  • Equipped with perfect exhaust gas treatment system to ensure that the emission standards are met.

V. Typical Successful Cases

• Case 1: Large porphyry copper sulfide mine

  • Raw ore grade: 0.75% Cu

  • Flow: rough crushing + semi-autogenous grinding + ball milling → copper and molybdenum mixed flotation → copper and molybdenum separation

  • Final index: copper concentrate grade 25.5%, copper recovery rate 93.2%; molybdenum concentrate grade 48%, molybdenum recovery rate 86%.

• Case 2: Complex and difficult to select oxidized copper ore

  • Raw ore grade: 1.2% Cu (oxidation rate>60%)

  • Adopted process: sulfidation-flotation combined process (leaching is adopted for some difficult ore)

  • Final index: total copper recovery rate of 88.5%, with remarkable economic benefits.

VI. Our customized services

We provide full life cycle services from "ore" to "product" to ensure project success:

1. Ore characterization: process mineralogical analysis, selectivity test, extended continuous test.

2. Solution design and optimization: process configuration, equipment selection calculation and 3D layout design based on test results.

3. Equipment Supply and Integration: Provide all core host machines and intelligent control systems to ensure quality and compatibility.

4. Construction and operation support: engineers on-site to guide the installation and commissioning, production technology training, provide long-term process optimization services.

Your ore is unique, and so are our solutions.
Please contact us for an initial evaluation and customized solution for the most economical and efficient beneficiation of your ore, providing exclusive copper mining technology solutions and detailed quotations!