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With the increasing scarcity of copper ore resources, existing copper ore processing technologies are difficult to meet the processing needs of low-grade copper ore. In order to make better use of low-grade copper ore and maximize the grade of copper concentrate and the recovery rate of ore dressing, emerging copper ore processing technologies are gradually emerging. This article introduces eight new technologies and gives technical integration suggestions.
Good crushing effect is a necessary prerequisite for obtaining high-quality copper concentrate. Traditional crushing equipment has high energy consumption and low efficiency. Today, high pressure roller grinding technology has solved this problem well. Its working principle is to use the lamination crushing principle of 150-350 MPa to make copper ore produce "inter-particle crushing" effect between rollers. Compared with traditional crushing equipment, the product particle size of this process is more uniform and the energy consumption can be reduced by 30~50%. After the product enters the grinding process, the processing capacity of the grinding system can be increased by about 20%.
After the high-pressure roller grinding technology (HPGR) was applied to the Los Bronces copper mine in Chile, the processing cost of the copper mine was significantly reduced, with the processing cost per ton of ore reduced by US$1.2, and the equipment investment payback period was shortened to 18 months.
1. Innovative breakthroughs in the new generation of semi-autogenous grinding (SAG) and autogenous grinding (AG) systems
In modern mining production, efficient grinding of copper mines is a key link in improving overall production efficiency and reducing operating costs. The new generation of semi-autogenous grinding (SAG) and autogenous grinding (AG) systems have brought revolutionary changes to copper mine grinding operations with their advanced technical architecture and intelligent functions. These systems integrate a variety of high-precision sensors and advanced algorithms to achieve all-round, real-time monitoring and dynamic optimization of the grinding process, thereby significantly improving grinding efficiency and equipment maintenance level.
2. Multi-parameter online monitoring and dynamic optimization
The new generation of SAG and AG systems are equipped with advanced load sensors and acoustic monitoring devices, which can collect real-time operating data inside the mill. Through real-time analysis of these data, the system can accurately determine the operating status of the mill and adjust the mill speed in real time according to the actual working conditions.
3. AI algorithm helps improve equipment maintenance efficiency
In addition to adjusting the mill speed in real time, the new generation of SAG and AG systems also use advanced artificial intelligence (AI) algorithms to predict the wear cycle of the liner. By collecting and analyzing a large amount of liner wear data, the AI algorithm can establish an accurate wear model and predict the replacement time of the liner in advance.
4. Successful application case of Palabora Copper Mine in South Africa
As a world-renowned copper mining company, Palabora Copper Mine in South Africa took the lead in applying the intelligent SAG system. The system has achieved remarkable results in the operation of Palabora Copper Mine. Through the optimization control of the intelligent SAG system, the steel consumption of Palabora Copper Mine has been reduced by 25%, which not only greatly reduces production costs, but also reduces the impact on the environment. At the same time, the intelligent adjustment function of the system has increased the grinding processing capacity by 15%, significantly improving the production efficiency and economic benefits of the mine.
1. XRT intelligent sorting
As an advanced ore sorting method, XRT intelligent sorting technology can effectively separate more than 30% of waste rock in the crushing stage by using X-ray transmission technology. This method not only greatly reduces the processing volume of subsequent grinding and sorting links, reduces energy consumption and production costs, but also improves the resource recovery rate, reduces environmental pollution, and provides strong support for the sustainable development of the mining industry.
2. Selective crushing control
Selective crushing control technology is an advanced method to achieve the dissociation of copper minerals along the grain boundary by precisely controlling the stress field during the crushing process. This selective crushing method not only improves the dissociation degree of copper minerals, which is beneficial to the subsequent sorting process, but also reduces the occurrence of over-crushing, reduces energy consumption and equipment wear, improves production efficiency and product quality, and provides a strong guarantee for the efficient sorting of copper ore.
3. High-pressure water jet pretreatment
High-pressure water jet pretreatment technology is a method of pretreating ore using high-pressure water flow. By causing microcracks in the ore, it effectively reduces the grinding work index by 12-18%. The application of high-pressure water jet pretreatment technology not only significantly reduces the grinding work index and reduces energy consumption, but also improves grinding efficiency and product quality, reduces production costs, and provides strong support for efficient production and energy conservation and emission reduction in the mining industry.
1. Composite collector system: Thiocarbamide/xanthate combination reagent increases copper recovery rate by 2-3 percentage points
2. pH-responsive inhibitor: Intelligently regulate the slurry potential and selectively inhibit pyrite
3. Microbubble flotation technology: bubble size is controlled at 300-500μm, and drug consumption is reduced by 15-20%
Intelligent control system based on industrial Internet of Things realizes:
Closed-loop control of grinding-flotation-thickening links (error ≤ 0.5%)
Digital twin model predicts equipment failure (accuracy 92%)
After application in Antamina dressing plant in Peru, the grade of copper concentrate is stabilized at 28.5%±0.3%
1. Tailings re-selection system: new magnetic-flotation combined process to recover residual copper (recovery rate 8-12%)
2. Tailings building material application: preparation of geopolymer materials to replace 30% cement
3. Microbial mineralization technology: using Bacillus pasteurianus to solidify heavy metal ions
Genetically modified strains of Acidithiobacillus ferrooxidans achieve:
Copper leaching rate increased to 85% (conventional heap leaching 65-70%)
Leaching cycle shortened to 60 days (conventional process 120 days)
After application at Chambishi copper mine in Zambia, processing cost reduced by $15/ton
The latest XRT+LIBS combined sorting system has:
Atomic-level identification capability of ore components
Sorting accuracy of more than 95%
After application at Highland Valley copper mine in Canada, the grade of ore entering the mill increased by 2.3 times
Modern mineral processing EPC projects should build a technical matrix:
1. Front end: HPGR+XRT pre-waste disposal (30-40% waste rock rate)
2. Mid-end: Intelligent grinding + molecular flotation (copper recovery rate>92%)
3. Back-end: Tailings resource utilization + water circulation (water return rate>85%)
The copper ore processing technology revolution is driving the industry to transform towards "high efficiency-intelligent-zero waste". Choosing an EPC service provider with technical integration capabilities can help mining companies reduce processing costs by $5-8/ton and increase return on investment by more than 30%. Contact our technical team now to get a customized copper ore processing upgrade plan.
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