Copper ore flotation plant optimizes grinding and grading operations to achieve standard production

A copper ore selection plant encountered problems during the production and commissioning phase.The design production capacity of the selected plant is 4500t/d, and the processing capacity is 187.5t/h at Taiwan time.In the early stage of commissioning, when the processing capacity of the ball mill was 140t/h, the indicators were better, but when the processing capacity was increased to 187t/h, the copper recovery rate decreased significantly.In order to solve this problem, the selection plant optimized the grinding and grading process, and finally achieved the standard production.Let's take a look at the optimization plan together.

1.Copper ore grinding and grading process flow

Process overview: The grinding stage of the copper ore selection plant adopts a closed-circuit grinding process, and the ball mill model is MQY5074 overflow ball mill.In the grading stage, the FX-500 cyclone group is used to complete the grading operation.Flotation adopts a two-thick, three-sweep and one-fine process.

Equipment parameters: The graded overflow concentration is designed to be 28%-33%, and the fineness of -200 mesh accounts for about 72%; the size of the mixing barrel is Φ3550×3550mm; XCFII-40 and KYFII-40 flotation machines are used for coarse and sweeping selection, and XCFII-16 and KYFII-16 flotation machines are selected.

2.Status quo and problems of grinding and grading process

The grinding effect is not ideal: When the processing capacity of the ball mill is increased to 187t/h, the ball mill is prone to spitting coarse particles and belly swelling. The grinding effect is not good, and the processing capacity of the ball mill cannot be increased.

The process is not smooth: debris and hard-to-grind particles in the ball mill discharge easily clog the mixing barrel, sand sinking nozzle, pipeline and copper concentrate pump.

Overflow pump problem: The flow rate of the overflow pump is not stable, and the pump pool is prone to diffuse phenomenon.

The work of the cyclone is unstable: the pressure of the cyclone fluctuates greatly, the fineness of the overflow is polarized, and under-grinding and over-grinding exist at the same time.

The effect of the mixing barrel is not good: The mixing effect of the mixing barrel is not good, and the coarse-grained minerals are easy to sink into the tank, resulting in frequent dropping and diffuse tank phenomena in the first two tanks of the flotation rough selection, the flotation liquid level is unstable, and the index declines.

3.Optimization and transformation of grinding and grading process

Change the supplementary ball system: increase the single consumption of supplementary balls, only Φ100 steel balls are selected, the filling rate of ball milled steel balls is increased, the ball mill no longer spits coarse particles, and the processing capacity of Taiwan meets the production requirements.

Replace the cylindrical screen for ball milling and ore discharge: replace the polyurethane strip hole cylindrical screen with a perforated cylindrical screen made of steel plate to solve the problem of clogging of coarse particles and debris.

Replace the graded overflow slag removal equipment: replace the linear screen with a cylindrical screen to meet the quality requirements of the slurry and solve the problem of debris entering the flotation.

Retrofit the overflow pump slurry pipeline: Redesign and rectify the slurry pipeline to solve the problem of clogging and unstable flow of the spare pump, and improve the processing capacity of the ball mill and the feeding stability of the cyclone.

Optional cyclone sedimentation nozzle: All 7 cyclone sedimentation nozzles are replaced with Φ90mm size, the cyclone works stably, and the overflow concentration and fineness meet the design requirements.

Optimize the flotation dosing point: Move the flotation agent of the mixing barrel forward to the overflow port of the cyclone to add it manually, and then add it to the overflow pump tank of the ball mill. The copper selection index has recovered, and the recovery rate is stable at more than 92.70%.

4.Comparative analysis before and after optimization and transformation

Analysis of grinding effect: After the transformation, the fineness and concentration of the cyclone overflow have been improved, the grading quality efficiency has been improved, and the grinding and grading effect is better.

Comparison of Taiwan-time processing capacity: After the optimization and transformation, the Taiwan-time processing capacity has been increased from about 140t/h to more than 187t/h, and the processing capacity has been achieved to the standard.

Analysis of flotation indicators: After optimizing the flotation dosing point, the grade of tailings is reduced, and the recovery rate of copper selection is increased by more than three percentage points, and the economic benefits are obvious.

5.conclusion

Through the optimization and transformation of the grinding and grading process, the grinding effect has been enhanced and good conditions have been created for subsequent flotation; the problems of ball mill rising belly and pump tank diffuse volume have been solved, and the processing capacity at Taiwan time is up to standard; after the flotation dosing point is optimized, the flotation index has been significantly improved, and the production standard has been achieved.

In the actual production process, production may not be up to standard due to various reasons. Xingmuang Group has extensive experience in the design of mineral processing technology and the selection of mineral processing equipment, and it can basically achieve one-time production up to standard. If you have mineral processing needs, please contact us.