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Before a mineral processing plant goes into production, it conducts a laboratory mineral processing test. But why might the concentrate grade and recovery be so impressive in the lab, yet fall short of expectations once the project is operational? This is precisely the "amplification effect" of mineral processing technology. To mitigate this risk, it is recommended to conduct a pilot-scale mineral processing test after the laboratory test but before the project launch. This scientific simulation compensates for the limitations of lab-scale tests and provides precise guidance for industrial production.
Pilot tests are a cross between small-scale laboratory tests and full-scale industrial trials. They are continuous (generally requiring 72 hours of uninterrupted operation), with core equipment scaled down to an industrial-grade level and featuring a complete closed-loop process.
Pilot tests validate the results of small-scale tests and optimize process flows under simulated industrial conditions. They accurately capture key engineering parameters and operational data, making them essential for large-scale projects with processing capacities exceeding 10,000 tons per day.
The core value of pilot testing lies in verification, identifying and resolving issues, and optimization.
Verification: The 72-hour continuous, stable testing process validates the laboratory process. Only by scaling up the pilot test and conducting it continuously can its true feasibility be determined.
Identifying and resolving issues: Pilot testing exposes problems not encountered during laboratory testing. Common issues include poor process integration, slurry transport blockages, water balance fluctuations, and ineffective concentration control. Discovering these issues after production inevitably impacts project progress and economic benefits. Identifying and resolving issues during pilot testing ensures that production targets and stable operation are achieved after commissioning.
Optimization: Pilot testing uses near-realistic operating conditions. The test results are used to optimize key parameters such as grinding fineness, flotation reagent system, regrinding time, and magnetic field strength, finding a balance between economic efficiency and technical performance.
Pilot testing places key equipment in a realistic slurry environment to test its processing capacity, separation efficiency, specific energy consumption, and wear life, providing real-world data for industrial production.
It accurately measures the consumption of water, electricity, reagents, grinding media, and wear parts. It also captures actual grinding cycle load, flotation circulation volume, pump head, and flow requirements. Real-time monitoring is achieved through intelligent equipment such as online XRF analyzers, particle size analyzers, and slurry potentiometers to ensure data integrity.
For difficult-to-process ores characterized by high argillaceous content, polymetallic intergrowth, extremely fine intercalation, high oxidation rates, and widely varying floatability, pilot testing offers a comprehensive validation solution. It can promptly identify persistent issues such as mud capping, soluble salt interference, and ion effects caused by slurry composition, and propose customized solutions.
Representative samples produced by pilot testing can be directly sent to smelters and chemical plants for trial use, obtaining quality approval certificates that can be used in negotiations with customers and pre-sales discussions. Pilot testing also provides real-world atomization data to support sales contracts.
Pre-Test Preparation
Ore Sample Preparation: Based on the geological model and ore type, a scientific sampling plan is developed to ensure representative samples. Multi-point sampling and testing are performed to ensure consistent composition within and between batches, with an error of less than ±5%.
Customized Process Design: Analyze the closed-loop test results from the laboratory test to determine the basic process structure. When implementing engineering simulation, a continuous, closed-loop test process should be designed first. Core equipment should be scaled down to industrial scale, and auxiliary facilities such as slurry pumps, agitation tanks, buffer tanks, and valves should be precisely configured.
Core Process Flow
Crushing → Grinding and Classification → Separation → Concentrate Dewatering
Crushing: Performed using small jaw crushers, cone crushers, and other equipment, with strict control of feed size and feed rate.
Grinding and Classification: A small ball mill and hydrocyclone form a closed circuit. Overflow fineness is measured using an online particle size analyzer to dynamically adjust feed rate, slurry concentration, and hydrocyclone pressure.
Separation: After the slurry reaches a stable concentration in the slurry conditioning tank, it is continuously and stably pumped into the separation process. An automated dosing system is deployed to precisely control reagent dosage and total consumption.
Flotation: The froth thickness, color, and fluidity of each tank should be recorded. Aeration volume, liquid level, and scraper speed should be optimized based on the concentrate and tailings grades.
Magnetic Separation: The effects of magnetic field strength, separation gap, and flushing water volume on concentrate grade and recovery should be continuously monitored.
Gravity Separation: Bed thickness, water flow rate, and stroke frequency should be controlled.
Concentrate Dewatering: A small, high-efficiency thickener is used to verify settling performance and obtain underflow concentration and overflow turbidity data. The concentrate is then filtered using a filter or filter press to obtain a filter cake. The filter cake’s moisture content, filtration rate, and filtrate clarity are tested and recorded to provide data support for industrial-scale selection.
During pilot testing, key data should be automatically recorded every 5–15 minutes. Intelligent online instruments all have this function. In addition, samples should be collected at each node at a set frequency for chemical element analysis, particle size analysis, and mineral liberation analysis. Operation logs should be maintained as a basis for parameter adjustments.
Under optimized parameters, continuous production should be conducted for at least 72 hours, simulating a factory shift schedule. During the test, a stress test should be conducted simultaneously to record the system’s disturbance resistance and recovery speed. Core indicators such as concentrate grade, recovery rate, and specific energy consumption should be calculated to provide a basis for industrial operation.
After the pilot test, high-confidence engineering parameters should be provided, including a balance sheet, consumption indicators, and equipment compliance data. An optimized process flow diagram and equipment selection proposal should also be delivered to the customer. Key operational guidelines should be offered, and product samples should be provided for further verification or market promotion.
Xinhai Mining offers customers both ore dressing tests and pilot-scale tests. Our advantages include:
1.Seamless integration of the entire process, ensuring that the data is representative of industrial conditions;
2.Intelligent control systems enable automatic closed-loop regulation of key parameters, reducing human error;
3.AI-powered analysis tools determine optimal process flows;
4.Capable of simulating complex operating conditions—including high clay content, high salinity, and variable feed rates—to proactively identify critical post-production issues and propose solutions.
Xinhai Mining provides each customer with a customized pilot testing solution, building a "micro-factory" that simulates real-world conditions, minimizes risk, and provides precise technical support for your large-scale ore dressing plant.
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