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In the field of copper ore beneficiation, processing high-hardness ore has long been recognized as a major industry challenge. Difficult ore grinding, frequent equipment wear, insufficient processing capacity, and substandard flotation indicators directly affect the mine's productivity and benefits. Many projects, despite favorable resource conditions, fail to achieve the ideal recovery rate and grade due to mismatched processes and equipment.
To address this issue, Xinhai Mining has developed a specialized beneficiation process suitable for high-hardness copper ore based on years of mineral processing experience. The 1500t/d copper ore processing plant project in Pakistan undertaken by Xinhai, despite the high ore hardness and complex on-site conditions, still achieved a copper concentrate grade of over 20% and a stable recovery rate of 90%+, providing a mature and replicable solution for the efficient beneficiation of high-hardness copper ore.
The 1500t/d copper ore project in Pakistan is an EPC general contracting project undertaken by Xinhai Mining, covering the entire process of construction drawing design, equipment manufacturing, installation guidance, and other services. The mine is a typical sulfide copper ore with a raw ore copper grade of 0.8%, accompanied by valuable elements such as gold and silver, which has good recovery value.
During the project implementation, several prominent difficulties were encountered:
The ore hardness is relatively high, and the conventional grinding process is difficult to reach the designed processing capacity, with the actual stable production capacity of about 1200t/d.
The requirement for grinding fineness control is high, which is directly related to the flotation effect and makes the process design difficult.
The implementation standards for overseas projects are strict, requiring complete sets of Chinese and English construction drawings to adapt to the on-site water and electricity conditions.
Combined with the ore characteristics and on-site conditions, Xinhai Mining has tailored an optimized full-process crushing-grinding-flotation-dewatering process for the project, focusing on solving the problems of difficult grinding and separation of high-hardness ore.
1. Crushing Process: Two-and-a-Half-Stage Closed Circuit for Efficient Crushing Reduction
The two-and-a-half-stage closed-circuit crushing process is adopted, equipped with a jaw crusher, a cone crusher, and a heavy-duty circular vibrating screen, realizing the closed-loop operation of coarse crushing, semi-stage crushing, fine crushing, and screening. The final crushed product size is controlled at -12mm, creating good conditions for subsequent grinding and effectively reducing grinding load and equipment loss.
2. Grinding and Classification: Stable Fineness to Adapt to High-Hardness Ore
According to the characteristics of high-hardness ore, the one-stage closed-circuit grinding + controlled classification process is adopted, combined with a wet grid-type ball mill and a hydrocyclone group, which accurately stabilizes the grinding fineness at 68% passing -200 mesh, ensuring sufficient monomer dissociation of minerals and laying a foundation for efficient flotation recovery.
3. Flotation Process: One Roughing, Two Scavenging, and Two Cleaning to Improve Grade and Increase Income
The flotation link adopts the process of one roughing, two scavenging and two cleaning, equipped with Xinhai's special flotation equipment. Roughing strengthens recovery, scavenging fully recovers residual minerals, and cleaning improves grade, realizing efficient recovery of copper minerals and minimizing metal loss.
4. Concentrate Dewatering: Two-Stage Dewatering to Meet Storage and Transportation Requirements
The two-stage dewatering process of concentration + filter pressing is adopted. After dewatering, the moisture content of copper concentrate is about 20%, which is convenient for storage, transportation, and sales, meeting the actual production needs of customers.
Under the condition of high-hardness ore, the project still achieved very excellent beneficiation indicators:
Actual stable processing capacity: 1200t/d
Copper concentrate grade: ≥20%
Copper recovery rate: ≥90%
The project delivered a complete set of Chinese and English construction drawings, and the equipment was successfully shipped and completed on-site installation and commissioning. After commissioning, it has been operating stably for a long time, winning high recognition from the owner. As an overseas project with high reliability requirements, its stable operation has fully verified the maturity of Xinhai's processes and equipment.
In-depth process adaptation: Special optimization for hard and difficult-to-grind ore, with a higher matching degree of crushing, grinding, and flotation processes.
Stable and controllable indicators: Industrial verification shows that the grade exceeds 20% and the recovery rate is 90%+, ensuring more secure benefits.
Full-chain EPC capability: One-stop delivery from testing, design, equipment, to installation and commissioning;
Rich experience in overseas projects: Can provide Chinese and English drawings to adapt to on-site conditions and standards of different countries.
High-hardness copper ore is not a "hard nut to crack". As long as the right process and service provider are selected, efficient beneficiation and stable profitability can be achieved. Xinhai Mining focuses on solving the beneficiation pain points of various refractory copper ores. We have mature processes and reliable equipment, providing customers with end-to-end beneficiation services to help them increase production capacity, optimize indicators, and improve profitability.
If you are operating or planning a high-hardness copper ore project and care about recovery rate, grade, and stable commissioning, please contact Xinhai Mining via WhatsApp at +8613811510145. We use real cases and professional technology to provide you with efficient, reliable, and implementable beneficiation solutions for your copper ore project.
+86 13811510145