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As global lead-zinc ore production decreases and ore grades continue to decline, efficient mining technologies have become crucial for enhancing economic benefits. Gravity concentration, with its low cost and high reliability, plays an indispensable role in the separation of lead-zinc ores. This article systematically analyzes the innovative applications of gravity concentration technology from its principles to equipment selection and process optimization.
Technical Essence: Achieves preliminary separation of minerals based on differences in density by adjusting the flow state and settling characteristics of the pulp.
Core Value:
Increases the concentration of the pulp before flotation or leaching (up to 40%-60%).
Reduces the load on subsequent dewatering equipment by 30%-50%.
Decreases overall energy consumption in mineral processing by 15%-25%.
Lead-zinc ores often contain a large amount of gangue minerals (such as quartz and calcite) and fine mud (-0.015mm), which can lead to loss of valuable minerals and equipment clogging in traditional processes. Gravity concentration optimizes solid-liquid separation paths, creating ideal conditions for high-precision mining.
Key Processes:
Crushing and Screening: Three-stage crushing (jaw crusher → cone crusher → impact crusher) controls the ore particle size at -5mm.
Desliming System: High-frequency vibrating screen + hydrocyclone combination removes -0.045mm fine mud (desliming rate >90%).
| Equipment Type | Technical Features | Applicable Scenarios |
|---|---|---|
| Cylindrical Thickener | Low cost, simple maintenance | Small to medium-sized mines (<500 t/h) |
| High-Efficiency Deep Cone Thickener | Large settling area (Φ6-12m) | Large mines (>1000 t/h) |
| New Rake-Type Thickener | Adjustable stirring intensity | High-viscosity pulp treatment |
Technological Breakthroughs:
Use of variable frequency speed-regulating motors (energy-saving by 30%).
Installation of ultrasonic anti-clogging devices.
Intelligent monitoring system (real-time collection of density and flow data).
Operational Points:
Concentration Control: Maintaining underflow concentration at 38%-45% through an automatic dosing system.
Flow Rate Adjustment: Setting surface flow rate at 0.2-0.5 m/s based on ore properties.
Underflow Discharge: Using pneumatic valves for stepless speed regulation.
Pre-Flotation Concentration System:
Concentrated pulp (40%) directly enters the flotation machine.
Reduces flotation reagent usage by about 12%-18%.
Avoids contamination of flotation froth by fine mud.
Pre-Leaching Concentration Scheme:
Concentrates lead-zinc ore to 55% before acid leaching.
Reduces impurities in leachate by 20%.
Increases extraction recovery rate by 8%-10%.
Tailings Concentration Process:
Concentrated tailings pulp with a moisture content ≤25%.
Can be directly used for tailings paste backfill or transportation.
1.Dust Control: Enclosed feeding system + pulse reverse blow dust removal (PM2.5 emissions<10 mg/m³).
2.Wastewater Reuse: Configuring three-stage settling tanks + filtration systems to achieve a recycling rate >95%.
3.Digital Twin Technology: Optimizes equipment operation parameters through virtual simulation.
In the context of green mining and intelligent upgrades, gravity concentration is evolving from an auxiliary process to a core process node. It is recommended that companies customize personalized concentration schemes through mineral processing tests and digital simulations. As a comprehensive solution provider for mining equipment, we offer services from equipment selection to system integration and remote operation, helping clients achieve a 20% reduction in energy consumption and a 30% increase in benefits.
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