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In the process of copper ore beneficiation and extraction, particle size control is the core technical parameter that determines production efficiency, metal recovery rate and operating cost. As an equipment manufacturer with 20 years of experience in mineral processing EPC services, we systematically analyze the deep impact mechanism of particle size on copper extraction efficiency through this article and provide feasible solutions.
When copper ore is crushed to -0.074mm (200 mesh), the monomer dissociation degree of copper minerals and gangue minerals can reach more than 85%. However, our industrial test data shows that when the particle size is lower than -0.010mm (1250 mesh), the ore mud content exceeds 15%, which will cause the flotation foam stability to decrease by 30% and the reagent consumption to increase by 25%. For example, in a porphyry copper mine project, after optimizing the grinding fineness from P80=150μm to P80=75μm, the copper recovery rate increased by 12.8%, but when it was further refined to P80=38μm, the concentrate grade decreased by 4.3%.
The SmartGrind intelligent grinding system we developed can dynamically adjust the grinding parameters according to the characteristics of the ore:
- Impregnated ore: P80=106-75μm
- Dense block ore: P80=75-45μm
- Complex symbiotic ore: P80=45-20μm
According to the monitoring of laser particle size analyzer, the ideal flotation particle size distribution should meet the following requirements:
- +150μm particle proportion <5%
- -10μm ore mud content <12%
- The main flotation section is concentrated in 38-106μm
The case we implemented in a copper mine in Peru shows:
(1)Adopting a dual classification system of hydrocyclone + high-frequency screen
(2)The coarse particle size (+75μm) enters the regrinding circuit
(3)The medium particle size (38-75μm) uses a fast flotation process
(4)The fine particle size (-38μm) uses a nanobubble generator
This solution increases the flotation recovery rate by 9.2% and reduces the reagent cost by 18%.
According to JKSimMet simulation data, when the grinding fineness is reduced from P80=150μm to P80=75μm:
- Grinding energy consumption increases by 42%
- Flotation recovery rate increases by 15%
- Comprehensive net income increases by 23%
Our recommended mill configuration:
The three-dimensional model established by the MLA mineral dissociation analysis system shows:
- When the degree of copper mineral dissociation reaches 90%:
- +150μm particle copper loss rate 38%
- 75-150μm loss rate 12%
- -75μm loss rate 5%
- The correlation coefficient between concentrate copper grade and particle size is 0.87
The intelligent control system we configured for the EPC project includes:
1. Online particle size analyzer (Malvern Insitec)
2. Adaptive grinding expert system
3. Flotation foam image analysis module
4. Real-time energy consumption monitoring platform
In the application case of a copper-cobalt mine in the Democratic Republic of the Congo, the system automatically adjusted the grinding fineness from P80=106μm to P80=82μm, stabilizing the copper recovery rate at 93.5±0.8%, with an annual efficiency increase of more than US$12 million.
Particle size control is the core technical link between geological resource characteristics and mineral processing economic benefits. Our engineering practice shows that by:
- Establishing a three-dimensional model of ore hardness-dissociation degree-energy consumption
- Configuring an intelligent grinding-classification closed-loop system
- Adopting particle size classification flotation process
The copper recovery rate can be increased by 8-15% and the operating cost can be reduced by 10-20%. If you need a customized particle size control solution, please contact our mineral processing engineering team for on-site diagnosis and process optimization.
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