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Molybdenum plays a key role in high-strength alloys, corrosion-resistant materials, electronic components, catalysts, and other fields. However, molybdenum occurs in low and dispersed concentrations in the Earth's crust, primarily in the form of molybdenite. Extracting molybdenum from molybdenite requires a scientific and precise beneficiation process. Xinhai Mining, with over 30 years of experience in the mineral processing industry, has conducted extensive research on molybdenum beneficiation and has rich experience in EPC project execution.
Before entering the separation process, molybdenite must be crushed and ground to achieve a high degree of monomer dissociation, ensuring efficient molybdenum recovery.
Crushing: This typically involves two or three stages, including coarse, secondary, and tertiary crushing. Jaw crushers are used for coarse crushing, while cone crushers are used for secondary and tertiary stages. Vibrating screens assist with classification during the crushing process.
Grinding: This typically involves one or two stages. Grid ball mills are used for coarse grinding, while overflow ball mills are used for fine grinding. A classifier is essential during grinding. Depending on the required particle size, either a spiral classifier or hydrocyclone can be used.
Once the minerals reach sufficient dissociation, the core beneficiation stage—flotation—can begin. Key flotation steps include:
Roughing: pH regulators maintain an alkaline environment. Lime is typically used to adjust pH to around 9 to suppress gangue minerals such as pyrite. During roughing, collectors and frothers are added, and the aeration rate and slurry concentration are carefully adjusted.
Cleaning & Scavenging: Multiple cleaning stages are used to improve concentrate grade, typically aiming for >45% Mo. Scavenging reduces losses in tailings. An XCF/KYF combined flotation cell is recommended for high flotation efficiency and high-grade concentrate production.
Difficulties in flotation: The main challenges include separating easily floatable gangue (e.g., talc, carbonaceous materials) and improving recovery of fine-grained molybdenum particles.
Xinhai Solution:
Representative ore samples are collected for beneficiation testing. Following the principle of “one ore, one strategy,” flotation reagent schemes and process designs are customized based on ore properties.
Advanced Process Control: Online analyzers and model predictive control (MPC) systems are used to stabilize flotation performance and optimize recovery and concentrate grade.
If the flotation concentrate contains excessive impurities, further treatment is necessary. Common methods include:
Leaching (Acid/Alkaline): Acid or alkaline leaching can selectively remove impurities. For example, oxidative roasting followed by acid leaching is used to eliminate copper and iron.
Regrinding and Re-flotation: When flotation performance is suboptimal, the concentrate can be re-ground and re-floated to enhance the grade.
Roasting: MoS₂ is oxidized to MoO₃ (industrial-grade molybdenum oxide), enabling downstream hydrometallurgical processing or direct use in industrial applications.
What is EPC:
Molybdenum ore processing involves multiple complex steps. Xinhai's full-process EPC (Engineering, Procurement, and Construction) service covers the entire mining industry chain — from feasibility study, mineral processing test, mine design, complete equipment manufacturing and procurement, civil construction, equipment installation and commissioning, to employee training and final production. Also known as a turnkey project, this model helps customers save time and effort.
Advantages of Xinhai's EPC Service
(1) Reliable Mineral Processing Tests
Xinhai provides customers with exploratory tests, conditional tests, closed-circuit flotation tests, and pilot tests (semi-industrial scale). After determining the process flow through small-scale testing, pilot tests are carried out to verify the feasibility of the process. Pilot test results are more accurate and closer to actual production conditions.
(2) Extensive Project Database
Since its establishment over 30 years ago, Xinhai has undertaken dozens of molybdenum ore processing projects. With a rich database of completed projects, Xinhai can deliver accurate designs, helping customers minimize risks and optimize investment returns.
(3) Core Equipment Guarantee
Xinhai owns independent intellectual property rights for key equipment such as flotation machines, crushers, and energy-saving ball mills. These core pieces of equipment are independently developed and manufactured by Xinhai, ensuring high quality and reliable after-sales service. We do not offer a patchwork production line — all key equipment in the system is manufactured in-house by Xinhai.
Tenfold Expansion and Reconstruction Project of a Molybdenum Mine in Inner Mongolia
Ore Properties: Medium- to fine-grained interbedded ore; molybdenum grade: 0.06–0.11%; main minerals: molybdenite, pyrite, and quartz
Original Process: Two-stage, one closed-circuit crushing → stage grinding → stage flotation
Customer Pain Points: Long process flow; high energy consumption and operating costs in the second-stage grinding and flotation stages
Xinhai Solution
(1) Process Reconstruction
Based on experimental verification, the original two-stage ball milling and classification operations were eliminated. A single-stage grinding with full-size flotation was adopted. All flotation operations after the second-stage grinding were removed. The roughing process was optimized into a four-stage high-efficiency cleaning process.
(2) Reagent System Upgrade
Composite Collector XH-Mo03 was developed to enhance molybdenite selectivity and suppress pyrite flotation.
A new synergistic system of foaming agent and modifier was introduced. This improved foam stability by 30% and increased the roughing recovery rate by 5.2%.
Project Results
Concentrate Grade: Improved from 42–45% to 45.55%, an increase of 3–8%
Recovery Rate: Increased from 85% to 89.26%, an improvement of 7.26%
Process Optimization:
Before: Two-stage grinding + multi-stage flotation
After: Single-stage grinding + four-stage concentration
Equipment usage reduced by 35%
Processing Capacity: Increased from 1,000 t/d to 10,000 t/d — a tenfold improvement
Molybdenum extraction involves the integration of geology, chemistry, physics, and engineering. Every step in the process—design, reagent selection, equipment configuration, and operation—affects the environmental impact and overall economic performance of the project. Therefore, it is essential to choose a contractor with extensive experience, solid technical strength, and integrated service capabilities.
Xinhai Mining, with over 30 years in the mineral processing industry, brings together advanced process technology, reliable equipment manufacturing, and strong engineering capabilities. We are committed to building efficient, stable, eco-friendly, and profitable molybdenum beneficiation projects for our clients.
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