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With the global surge in demand for metal resources and tightening environmental regulations, the efficient processing of complex lead-zinc ores has become a focal point in the industry. This article systematically analyzes several breakthrough process technologies and, in conjunction with the EPCM+O service model, provides mining enterprises with comprehensive solutions that enhance resource utilization by over 30% and reduce environmental costs by 40%.
In the field of complex lead-zinc ore processing, we employ a Dynamic Flotation Strategy Selection System (DFSS):
Priority Flotation Optimization Scheme: For ores with embedding particle size differences greater than 0.15mm, we utilize electrochemical control technology to achieve a lead-zinc separation accuracy of 92% through XRT pre-selection (traditional processes achieve <85%).
Innovative Application of Mixed Flotation: We have developed a pH adaptive adjustment system combined with a new type of zwitterionic collector, resulting in an 18% increase in the simultaneous flotation rate of coexisting minerals and reducing zinc loss in tailings to below 5%.
Revolutionary Reagent System: High-entropy alloy-based collectors enable simultaneous adsorption of multiple metals. Coupled with micro-interface reactors, reagent consumption is reduced by 35%, while lead recovery remains stable at over 94.5%.
By interlocking an online particle size analyzer with high-pressure roller mills, we have constructed a three-stage grinding system:
Coarse Grinding Stage (-200 mesh 50%): Utilizing precise media ratio technology, energy consumption is reduced by 25%.
Medium Grinding Stage (-325 mesh 75%): An AI grinding expert system is introduced, maintaining an over-grinding rate of <3%.
Fine Grinding Stage (-400 mesh 90%): A nano-bubble generator is applied, increasing liberation to 98%.
Additionally, an online XRF sorting machine has been developed to achieve real-time grade feedback adjustments, saving water and electricity costs by 12-15 yuan per ton of ore processed.
Our eco-friendly mineral processing system consists of three core modules:
Low-Carbon Flotation Workshop: Organic depressants are used instead of lime, stabilizing pH between 7.5 and 8.2 and reducing sulfur ion emissions by 60%.
Biological Enhancement System: Acidophilic microbial communities (A. ferrooxidans) are introduced for pre-oxidation, improving gold/silver leaching rates by 22% and 18%, respectively.
Water Treatment Hub: A three-stage membrane separation device (UF+NF+RO) achieves 95% wastewater reuse, with heavy metal retention rates exceeding 99.9%.
The intelligent control platform built on Industry 4.0 concepts features:
Digital Twin Modeling: Real-time simulation of over 20 key process parameters.
Online Monitoring Network: Equipped with sensor arrays at 32 critical control points.
Energy Efficiency Optimization Algorithm: Dynamically adjusts equipment loads, reducing overall energy consumption by 18-22%.
Cloud Platform Access: Supports remote diagnostics and process parameter optimization.
Data from a polymetallic mine project in Tibet:
Original Ore Grade: Pb 2.1% / Zn 3.8% / Ag 58g/t
Utilizing a combined process: high-pressure roller milling + mixed flotation + bio-leaching.
Technical Indicators:
Pb concentrate grade: 63.2% (industry average: 58%)
Zn recovery rate: 92.7% (traditional processes: 85%)
Cyanide usage reduced by 80%
Annual cost savings of processing: ¥4.2 million
As a professional provider of EPCM+O services for mineral processing, our continuously developed patented technologies have been successfully applied in over 100 countries' mining areas. For customized lead-zinc ore processing solutions or to visit demonstration plants, please contact our technical team to obtain a complete process package that includes economic analysis.
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