We can supply crushing, grinding and beneficiation equipment for processing copper ore, and technological lines, DSK provide comprehensive solutions

Processing complex copper ore
Crushing and screening complex for processing copper ore

Crushing and grinding equipment for sale

Various crushing, milling and screening equipment produced by Shiban solve problems in processing copper ore.

Peculiarities:

• High performance;
• Services for selection, installation, training, operation and repair;
• We supply high-quality spare parts from the manufacturer.

Copper Ore Crushing Equipment:

Various crushing, milling, screening equipment such as rotary crusher, jaw crusher, cone crusher, mobile crusher, vibrating screen, ball mill, vertical mill are designed to process copper ore in a production line to produce copper concentrate, etc.

In an open pit, raw materials are first transported in the main impact crusher and then transferred to the cone crusher for secondary crushing. According to customer requirements, the stone crushers can be equipped with a tertiary crushing stage, which allows crushing copper ore below 12mm. Once sorted into a vibrating screen, suitable crushed materials are released as a finished fraction or sent to a further process to produce copper concentrate.

As a major manufacturer of crushing equipment and milling equipment in China, SBM offers various solutions for copper ore mining and processing: crushing, milling and screening. During the primary crushing process, copper ore is crushed into small pieces less than 25 mm in diameter. To obtain a finer finished products You need to buy secondary or original crushers. Overall energy consumption is reduced significantly. Comparing the work efficiency and , we find that it does the job more efficiently in tertiary crushing. And if the installation has the same number of secondary and tertiary crushers, the operation is transferred from the tertiary and secondary crushers, where the liner wears three times less, which significantly reduces the cost of the crushing process.

The crushed copper ores are then sent to a storage hopper via a conveyor belt. Our ball mills and others provide grinding of copper ores to the required fraction.

Mining and processing of copper ore:

Copper ore can be mined either from open pit mines or underground mines.

After the quarry explosion, the copper ores will be loaded by heavy trucks, then transported through the primary crushing process to be crushed copper ore to 8 inches or less. The vibrating sieve screens the crushed copper ores, according to the customer's requirement, which through the conveyor belt come out as a finished fraction; if you need powders, then the crushed copper ores are sent to the milling equipment for further grinding.

In a ball mill, the crushed copper ore will be processed to about 0.2 mm using 3-inch steel balls. The copper ore slurry is finally pumped into the flotation deck with fine sulfide ores (about -0.5 mm) to recover the copper.

Review of DSO for copper ore:

"We purchased stationary crushing and screening equipment for large-scale copper ore processing." ---- Client in Mexico

Ores or technogenic raw materials extracted from the earth's interior in most cases cannot be directly used in metallurgical production and therefore undergo a complex cycle of successive operations preparation for blast furnace smelting. Note that in open-pit ore mining, depending on the distance between blast holes and the size of the excavator bucket, the size of large blocks iron ore can reach 1000-1500 mm. For underground mining maximum size piece usually does not exceed 350 mm. In all cases, the extracted raw materials contain a large number of small fractions.

Regardless of the subsequent scheme for preparing ore for smelting, all mined ore first goes through the stage primary crushing, since the size of large pieces and blocks during mining far exceeds the size of a piece of ore, the maximum allowable under the conditions of blast furnace smelting technology. The technical conditions for lumpiness, depending on reducibility, provide for the following maximum size of ore pieces: up to 50 mm for magnetite ores, up to 80 mm for hematite ores and up to 120 mm for brown iron ores. The upper limit of the size of agglomerate pieces should not exceed 40 mm.

Figure 1 shows the most common crusher installation layouts in crushing and screening plants. Schemes a and b solve the same problem of crushing ore from

Figure 1. Iron ore crushing scheme
a - “open”; b - “open” with preliminary screening; c - “closed” with preliminary and calibration screening

In this case, the principle “do not crush anything unnecessary” is implemented. Schemes a and b are characterized by the fact that the size of the crushed product is not checked, i.e. the schemes are “open”. Experience shows that the crushed product always contains a small number of pieces, the size of which is slightly larger than the specified size. In “closed” (“closed”) circuits, the crushed product is again sent to the screen to separate insufficiently crushed pieces and then return them to the crusher. With “closed” ore crushing schemes, compliance with the upper limit of the size of the crushed product is guaranteed.

The most common types of crushers are:

• conical;
• jaw crushers;
• roller;
• hammer

The structure of crushers is shown in Fig. 2. The destruction of pieces of ore in them occurs as a result of crushing, splitting, abrasive forces and impacts. In the Black jaw crusher, the material introduced into the crusher from above is crushed by oscillating 2 and stationary 1 cheeks, and in the McCooley cone crusher - by stationary 12 and rotating internal 13 cones. The cone shaft 13 enters the rotating eccentric 18. In a jaw crusher, only one stroke of the movable jaw is working; during the reverse stroke of the jaw, part of the crushed material manages to exit the working space of the crusher through the lower outlet slot.

Figure 2. Design diagrams of crushers a - cheek; b - conical; c - mushroom-shaped; g - hammer; d - roller; 1 - fixed cheek with an axis of rotation; 2 - movable cheek; 3, 4 - eccentric shaft; 5 - connecting rod; 6 - hinged support of the rear spacer cheek; 7 - spring; 8, 9 - mechanism for adjusting the width of the unloading slot; 10 - rod of the closing device; 11 - bed; 12 - fixed cone; 13 - movable cone; 14 - traverse; 15 - suspension hinge of the movable cone; 16 - cone shaft; 17 - drive shaft; 18 - eccentric; 19 - shock-absorbing spring; 20 - support ring; 21 - regulating ring; 22 - cone thrust bearing; 23 - rotor; 24 - impact plates; 25 - grate; 26 - hammer; 27 - main frame; 28 - crushing rollers

The productivity of the largest jaw crushers does not exceed 450-500 t/h. Typical for jaw crushers are cases of pressing of the working space when crushing wet clay ores. In addition, jaw crushers should not be used for crushing ores that have a platy shale structure of the piece, since individual tiles, if their long axis is oriented along the axis of the crushed material delivery slot, can pass through the working space of the crusher without being destroyed.

The feeding of jaw crushers with material must be uniform, for which a plate feeder is installed on the side of the fixed jaw of the crusher. Typically, jaw crushers are used to crush large pieces of ore (i= 3-8). Electricity consumption for crushing 1 ton of iron ore in these installations can range from 0.3 to 1.3 kWh.

In a cone crusher, the axis of rotation of the internal cone does not coincide with the geometric axis of the fixed cone, i.e., at any moment, ore crushing occurs in the zone of approaching the surfaces of the internal and external fixed cones. At the same time, in the remaining zones, the crushed product is released through the annular slot between the cones. Thus, the crushing of ore in the cone crusher is carried out continuously. The achieved productivity is 3500-4000 t/h (i = 3-8) with an electricity consumption for crushing 1 ton of ore of 0.1-1.3 kWh.

Cone crushers can be successfully used for ores of any type, including those with a layered (platy) structure of the piece, as well as for clay ores. Cone crushers do not require feeders and can operate “under the block”, i.e. with a working space completely filled with ore coming from a bunker located above.

The Simons short cone mushroom crusher differs from a conventional cone crusher in that it has an extended dispensing zone for the crushed product, ensuring complete crushing of the material to a given size of pieces.

IN hammer crushers crushing of ore is carried out mainly under the influence of blows from steel hammers mounted on a rapidly rotating shaft. At metallurgical plants, limestone is crushed in such crushers, which is then used in sintering shops. Brittle materials (such as coke) can be crushed in roller crushers.

After primary crushing, rich low-sulfur ore of a fraction > 8 mm can be used by blast furnace shops; a fraction of the fine fractions is still absorbed by the furnace, sharply worsening the gas permeability of the charge column, since small particles fill the space between larger pieces. It must be remembered that separating fines from the blast furnace charge in all cases gives a significant technical and economic effect, improving the progress of the process, stabilizing dust removal at a constant minimum level, which in turn contributes to constant heating of the furnace and a reduction in coke consumption.

Machines used for crushing - crushers - can reduce the size of pieces to 5-6 mm. Finer crushing is called grinding and is carried out in mills.

In most cases, crushing together with grinding are preparatory operations before ore beneficiation. Although it is possible to crush in one unit from 1500 mm, for example, to 1-2 mm or less, practice shows that this is economically unprofitable, therefore, at crushing and processing plants, crushing is carried out in several stages, using the most suitable type of crusher for each stage: 1) coarse crushing from 1500 to 250 mm; 2) average crushing from 250 to 50 mm; 3) fine crushing from 50 to 5-6 mm; 4) grinding to 0.04 mm.

Most crushers used in industry operate on the principle of crushing pieces of ore between two steel surfaces approaching each other. For crushing ores, jaw crushers (coarse and medium crushing), cone crushers (coarse, medium and fine crushing), roller and hammer crushers (medium and fine crushing) are used.

Jaw crusher(Fig. 1, a) consists of three main parts: - a fixed steel vertical plate, called a fixed cheek, - a movable cheek suspended in the upper part, - a crank mechanism that imparts oscillatory movements to the movable cheek. The material is loaded into the crusher from above. When the cheeks come together, the pieces break apart. When the moving jaw moves away from the fixed one, the crushed pieces fall under the influence of their own weight and exit the crusher through the discharge hole.

Rice. 1 Crushers: a – jaw; b – conical; c – hammer; g – roller

Cone crushers They work on the same principle as cheek ones, although they differ significantly from the latter in design. A cone crusher (Fig. 1, b) consists of a fixed cone and a movable cone suspended in the upper part. The axis of the movable cone with its lower part enters eccentrically into the rotating vertical glass, due to which the movable cone makes circular movements inside the large one. When the movable cone approaches some part of the fixed one, pieces are crushed, filling the space between the cones in this part of the crusher, while in the diametrically opposite part of the crusher, where the surfaces of the cones are removed to the maximum distance, crushed ore is unloaded. Unlike jaw crushers, cone crushers have no idling, due to which the productivity of the latter is several times higher. For medium and fine crushing, short cone crushers are used, operating on the same principle as cone crushers, but slightly different in design.

IN roll crusher crushing of ore occurs between two horizontal steel parallel rolls rotating towards each other (Fig. 1, c).

For crushing brittle rocks of low and medium strength (limestone, bauxite, coal, etc.) hammer crushers, the main part of which (Fig. 1, d) is a rotor-shaft rotating at high speed (500-1000 rpm) with steel hammer plates attached to it. Crushing of material in crushers of this type occurs under the influence of numerous hammer blows on falling pieces of material.

Commonly used for grinding ores ball or rod mills, which are cylindrical drums with a diameter of 3-4 m rotating around a horizontal axis, in which steel balls or long rods are located along with pieces of ore. As a result of rotation at a relatively high frequency (~20 min -1), the balls or rods, having reached a certain height, roll or fall down, grinding pieces of ore between the balls or between the balls and the surface of the drum. The mills operate in a continuous mode - loading with ore occurs through one hollow axle, and unloading through another. Typically, grinding is carried out in aquatic environment, due to which not only dust emissions are eliminated, but also the productivity of the mills is increased. During the grinding process there is automatic sorting particles by size - small ones become suspended and in the form of a pulp (a mixture of ore particles with water) are removed from the mill, and larger ones, which cannot be suspended, remain in the mill and are crushed further.

Copper can be produced as a main product or as a co-product with gold, lead, zinc and silver. It is mined in the Northern and Southern Hemispheres and primarily consumed in the Northern Hemisphere with the United States as the main producer and consumer.

A copper processing plant processes copper from metal ore and copper scrap. The leading consumers of copper are wire mills and copper mills, which use copper to produce copper wire etc. End uses of copper include Construction Materials, electronic products, transportation and equipment.

Copper is mined in quarries and underground. The ores typically contain less than 1% copper and are often associated with sulfide minerals. The ore is crushed, concentrated, and suspended with water and chemicals. Blowing air through the mixture attaches the copper, causing it to float at the top of the slurry.

Crushing complex for copper ore

Large raw copper ore is fed into the copper ore jaw crusher, evenly and gradually, by vibrating feeder through the copper ore primary crushing hopper. Once separated, the crushed pieces of copper ore can meet the standard and will be taken as the final product.

After the first crushing, the material will be transferred to the copper ore impact crusher, copper ore cone crusher, secondary crushing conveyor. Then the crushed materials are transferred to the vibrating sieve for separation. The final production of copper ore will be taken away, and other copper ore parts will be returned to the copper ore impact crusher, forming a closed circuit.

The dimensions of the final copper ore product can be combined and rated according to customers' requirement. We can also equip ash removal systems to protect the environment.

Mill complex for copper ore

After primary and recycling in the copper ore production line, it can enter the next stage to grind the copper ore. The final copper ore powder produced by Zenith copper ore milling equipment typically contains less than 1% copper, while sulfide ores have moved to the beneficiation stage, while oxidized ores are used for leach tanks.

The most popular copper ore milling equipment is ball mills. Ball mill plays important role in copper ore grinding process. Zenith ball mill is an effective tool for grinding copper ore into powder. There are two grinding methods: dry process and wet process. It can be divided into table type and flow type according to various forms unloading material. Ball Mill is a crucial equipment for grinding after crushed materials. It is an effective tool for grinding i various materials into powder.

It can also use mills such as MTW European type trapezoidal mills, XZM ultrafine grinding mills, MCF coarse powder grinding mills, vertical mills, etc.

Copper ore has a different composition, which affects its quality characteristics and determines the choice of method for enriching the feedstock. The composition of the rock may be dominated by sulfides, oxidized copper, or a mixed amount of components may be present. At the same time, for ore mined in the Russian Federation, the flotation enrichment method is used.

Processing of disseminated and continuous copper sulfide ore, which contains no more than a quarter of oxidized copper, is carried out in Russia at processing plants:

• Balkhash;
• Dzhezkazgan;
• Sredneuralskaya;
• Krasnouralskaya.

The technology for processing raw materials is selected in accordance with the type of source material.

Working with disseminated ores involves extracting sulfides from the rock and moving them into depleted concentrates using chemical compounds: blowing agents, hydrocarbons and xanthate. The primary method used is fairly coarse grinding of the rock. After processing, the lean concentrate and middlings undergo an additional process of grinding and cleaning. During processing, copper is freed from intergrowths with pyrite, quartz and other minerals.

The homogeneity of the porphyritic ore supplied for processing makes it possible to flotate it at large processing plants. High level productivity allows you to reduce the cost of the enrichment procedure, as well as accept ore with a low copper content (up to 0.5%) for processing.

Flotation process diagrams

The flotation process itself is built according to several basic schemes, each of which differs in both the level of complexity and cost. The simplest (cheapest) scheme involves switching to an open ore processing cycle (at the 3rd stage of crushing), grinding the ore within one stage, as well as carrying out a subsequent additional grinding procedure to obtain a result of 0.074 mm.

During the flotation process, the pyrite contained in the ore is subjected to depression, leaving in the concentrates a sufficient level of sulfur necessary for the subsequent production of slag (matte). To carry out depression, a solution of lime or cyanide is used.

Solid sulfide ores (cuprous pyrites) are distinguished by the presence of a significant amount of copper-containing minerals (sulfates) and pyrite. Copper sulfides form thin films (covellite) on pyrite, and due to the complexity chemical composition the floatability of such ore is somewhat reduced. An effective beneficiation process requires careful grinding of the rock to facilitate the release of copper sulfides. It is noteworthy that in a number of cases, thorough grinding is not economically feasible. We are talking about situations where pyrite concentrate, subjected to a roasting process, is used in blast furnace to extract precious metals.

Flotation is carried out by creating an alkaline environment of high concentration. The following are used in the process in specified proportions:

• lime;
• xanthate;
• fleetoil.

The procedure is quite energy-intensive (up to 35 kW h/t), which increases production costs.

The ore grinding process is also complex. As part of its implementation, multi-stage and multi-stage processing of the source material is provided.

Intermediate ore beneficiation

Processing of ore with a sulfide content of up to 50% is similar in technology to the processing of solid sulfide ore. The only difference is the degree of its grinding. Material of a coarser fraction is accepted for processing. In addition, the separation of pyrite does not require the preparation of an environment with such a high alkali content.

At the Pyshminsky concentrating plant, collective flotation followed by selective processing is practiced. The technology makes it possible to use 0.6% ore to obtain 27% copper concentrate with subsequent extraction of over 91% copper. Work is carried out in an alkaline environment with different levels intensity at each stage. The processing scheme allows reducing the consumption of reagents.

Technology of combined enrichment methods

It is worth noting that ore with a low content of clay and iron hydroxide impurities lends itself better to the beneficiation process. The flotation method allows you to extract up to 85% of copper from it. If we talk about refractory ores, then the use of more expensive combined enrichment methods, for example, the technology of V. Mostovich, becomes more effective. Its use is relevant for the Russian industry, since the amount of refractory ore makes up a significant part of the total production of copper-bearing ore.

The technological process involves crushing raw materials (fraction size up to 6 mm) followed by immersing the material in a sulfuric acid solution. This allows sand and sludge to be separated and free copper to go into solution. The sand is washed, leached, passed through a classifier, crushed and flotated. The copper solution is combined with the slurry and then subjected to leaching, cementation and flotation.

In work using the Mostovich method, sulfuric acid is used, as well as precipitating components. The use of technology turns out to be more expensive compared to standard flotation.

The use of Mostovich's alternative scheme, which involves the recovery of copper from the oxide with flotation after crushing the ore subjected to heat treatment, makes it possible to reduce costs somewhat. The technology can be made cheaper by using inexpensive fuel.

Flotation of copper-zinc ore

The process of flotation of copper-zinc ore is labor-intensive. Difficulties explained chemical reactions, occurring with multicomponent raw materials. If the situation with primary sulfide copper-zinc ore is somewhat simpler, then the situation when exchange reactions began with the ore already in the deposit itself can complicate the enrichment process. Selective flotation may not be possible when dissolved copper and cavellin films are present in the ore. Most often, this picture occurs with ore mined from the upper horizons.

In the beneficiation of Ural ore, which is quite poor in copper and zinc content, both selective and collective flotation technologies are effectively used. At the same time, the method of combined ore processing and the scheme of collective selective enrichment are increasingly used at leading enterprises in the industry.