Applicable Material: Copper ores (including bornite/chalcopyrite)
Application: Copper concentrate production
Equipment Configuration:
Vibrating Feeder → Jaw Crusher (Primary) → Impact Crusher (Secondary) → Ball Mill → Spiral Classifier → Wet Drum Magnetic Separator → Flotation Cells → Thickener → Rotary Dryer
Total Reserves: 62.43 million tonnes (7th globally, USGS 2023)
High-Grade Ores: 35% of proven reserves (≥1% Cu)
Geographic Distribution: Present in all provinces except Tianjin/Hong Kong
Grinding Target: 50-70% passing 74μm (-200 mesh, ASTM E11)
Flotation Circuit: 1 Rougher + 2-3 Cleaners + 1-2 Scavengers
Applicability: Copper grain size >30μm
Primary Grinding: 45-50% passing 74μm
Regrinding of Bulk Concentrate: 90-95% passing 74μm (liberation d₈₀=75μm)
Flotation Sequence:
✓ Bulk Flotation: Amyl xanthate (50-80g/t) at pH 8.5-9.5 (lime-controlled)
✓ Sequential Separation:
Bornite activation: Na₂S (200g/t) + CuSO₄ (150g/t)
Selective collector: Dithiophosphate
1. Crushing Section
Objective: Reduce run-of-mine ore to ≤25mm
Equipment:
Jaw Crusher: CSS 150mm, ≤1200mm feed
Impact Crusher: Output P₉₀≤25mm
2. Grinding & Classification
Ball Mill: Processes ≤25mm feed
Discharge specification:
Conventional flow: 50-70% passing 74μm
Stage-grinding: 45-50% passing 74μm (primary)
Spiral Classifier: Cut size 74μm (ISO 13320)
3. Concentration & Dewatering
| Process | Equipment | Key Parameters |
|---|---|---|
| Magnetic Separation | Wet drum separator | 0.8-1.2T field intensity |
| Flotation | Mechanical flotation cells | 28-32% pulp density |
| Thickening | High-rate thickener | Underflow density ≥65% solids |
| Drying | Rotary dryer | Product moisture ≤8% (ISO 589) |
| Parameter | Value | Standard |
|---|---|---|
| Concentrate Grade | ≥45% Cu | ISO 12743:2021 |
| Recovery Rate | 85-88% (conv.) / 92-95% (stage) | ASTM E1915-07 |
| Energy Consumption | 18-22 kWh/t ore | ISO 50001 |
| Water Consumption | 3.5-4.2 m³/t ore | ICMM Water Stewardship |
| Tailings Cyanide | <0.2 ppm | ICMM 2020 Guidelines |
Crushing: PE1200×1500 Jaw Crusher (160kW) + PF1520 Impact Crusher (400kW)
Grinding: Φ4.5×6.5m Ball Mill (2800kW)
Flotation: 16× JJF-20 cells
Dewatering: NT-45 Thickener (Ø45m) + Φ2.4×18m Rotary Dryer (110kW)
Dexing Copper Mine Case (Jiangxi, 2023):
Ore: Bornite-chalcopyrite ore (1.8% Cu)
Flowsheet: Stage-grinding with sequential separation
Results:
✓ Concentrate: 46.2% Cu
✓ Recovery: 94.3%
✓ Power: 20.1 kWh/t ore
Environmental Compliance:
Dust emissions: ≤10mg/m³ (ISO 9096)
Noise: ≤85dB(A) at 1m (ISO 4871)
Tailings: Zero-discharge water recycling (85% reuse rate)
