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With the explosive growth of new energy batteries, sealing materials and other industries, the annual growth rate of graphite concentrate demand is over 12%. As a service provider with 18 years of experience in mineral processing EPCM+O, we for you the 8 key steps of modern graphite ore processing and show how to achieve 95% recovery rate and 20% reduction in tonnage cost through precise process control.
Coarse crushing: Jaw crusher hydraulic system pressure up to 18MPa, processing 300-500mm raw ore to 80-150mm.
Medium crushing: Multi-cylinder hydraulic cone crusher realizes laminated crushing and produces 25-50mm standard material.
Fine crushing: Vertical shaft impact crusher + high frequency screen closed circuit system, final particle size 0-15mm (screening ratio ≥ 85%)
Technical highlights: Our intelligent crushing control system can monitor the current load in real time, automatically adjust the feed rate, reduce the idle time of equipment by 40%.
Equipment selection: ball mill (capacity 5-200t/h) is suitable for cryptocrystalline graphite; rod mill to protect the scale structure
Key parameters: grinding concentration 65-75%, fineness -0.074mm accounting for 60-70% of the dissociation degree of the optimal
Innovative solution: steel ball intelligent replenishment system, reducing grinding media consumption by 15 tons per year.
Case data: a flake graphite project through the optimization of steel ball gradation, monomer dissociation degree from 84% to 92%, concentrate grade increased by 3 points.
| Type of drug | Dosage (g/t) | Mode of action | Innovative technology |
|---|---|---|---|
| Kerosene | 200-300 | Hydrophobicity enhancement | Nano emulsification technology to improve adsorption efficiency 30% |
| 2# oil | 50-80 | Stabilize foam layer | Micro bubble generator produces 0.5-1mm uniform bubbles |
| Lime | 800-1200 | Silicate inhibition | pH intelligent regulation system ±0.3 precision |
1. primary selection: remove more than 60% of mica impurities
2. secondary selection: separation of quartz and other silicate minerals (magnetic field strength of 0.8-1.2T)
3. three-level selection: filling flotation column to achieve 96-99% of fixed carbon content
Comparison of benefits
Traditional process: 3 times selection, 88% recovery rate
Optimized process: 5 times of selection + medium ore circulation, recovery rate of 95%↑.
Intelligent return system: according to the online analyzer data, automatically select the treatment mode
- The grade of medium ore >20%: directly return to roughing
- 15-20%: enter regrinding circuit (grinding to -0.038mm)
- <15%: independent flotation circuit
| Stage | Equipment | Moisture Content | Energy Consumption | Applicable Scenarios |
|---|---|---|---|---|
| Primary | Deep Cone Thickener | 45-50% | 0.7kW-h/t | Large Scale Concentrator |
| Intermediate | Ceramic Filter | 18-22% | 3.8kW-h/t | Long Distance Transportation Needs |
| Ultimate | High Pressure Filter Press | 8-12% | 3.8kW-h/t | Long Distance Transportation Needs |
Hydrofluoric acid method: 99.99% purity, suitable for nuclear industry-grade graphite
- Temperature: 80-90℃
- Time: 4-6 hours
- Waste acid recovery rate: 85%↑
High temperature method: 99.9% purity, 40% cost reduction
- Temperature: 2500-3000°C
- Inert gas protection
Dry discharge system: belt vacuum filtration + solar drying, tailings water content <15
Resource utilization:
- Preparation of lightweight building materials (dosage 30-50%)
- Soil conditioner (pH 6.5-7.5)
- Underground filling material (compressive strength 5-8MPa)
Modern graphite ore processing has entered the era of precise control. By choosing our equipment and services, you will not only receive a proven process package that has been validated in 200+ mines, but also an online process optimization system and full lifecycle technical support - the core code for maximizing the value of graphite resources.
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