Processing of copper ore. Ore crushing - jaw cone hammer and roller crushers

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 movable 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 moving cone approaches some part of the fixed one, the 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 journal, 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, particles are automatically sorted 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.

Processing plant copper ore in mining, beneficiation, smelting, refining and casting

Crushing and screening complex for processing copper ore

Copper ore processing plant is a crushing plant specially designed for crushing copper ore. When the copper ore comes out of the ground, it is loaded into a 300-ton truck to transport the crusher. The complete copper crushing plant includes jaw crushers like main crusher, impact crusher and cone crusher. Once crushed, the copper ore must be screened by size by screening machine and distributing the classified ore to a series of conveyors, for transportation to the mill for further processing.

Copper ore processing complex

The process of extracting copper from copper ore varies depending on the type of ore and the required purity of the final product. Each process consists of several steps in which unwanted materials are physically or chemically removed and the copper concentration is gradually increased.

Firstly, the copper ore from the open pit is crushed, loaded and transported to the primary crusher. The ore is then crushed and screened, with fine sulfide ore (< 0.5 мм) собирается пенной флотации клеток для восстановления меди. Крупные частицы руды идет в кучного выщелачивания, где меди подвергается разбавленного раствора серной кислоты, чтобы растворить медь.

The alkaline solution containing dissolved copper is then subjected to a process called solvent extraction (SX). The SX process concentrates and purifies the copper leach solution, so the copper can be recovered with high efficiency electrical current through cell electrolysis. It does this by adding a chemical to the SX tanks that selectively binds to and extracts the copper, easily separating it from the copper, recovering as much of the reagent as possible for reuse.

A concentrated solution of copper is dissolved in sulfuric acid and sent to electrolytic cells to restore copper plates. From copper cathodes, it is made into wires, devices, etc.

SBM can offer types of crushers, screening and grinding machine, copper ore flotation plant, processing plant in USA, Zambia, Canada, Australia, Kenya, South Africa, Papua New Guinea and Congo.

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

Copper ore processing complex
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. After screening in 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 product, you need to buy secondary or primary 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

In the bowels of the earth there is quite a large number of various minerals that can be used to produce various materials. Copper ore is quite widespread - it is used for processing and producing various substances that are used in industry. It is worth considering that such ore, which contains copper, may also contain other minerals. It is recommended to use earthen rock that contains at least 0.5-1% metal.

Classification

A huge number of different copper ores are being mined. The classification is carried out according to their origin. Highlight the following groups copper ores:

1. Pyrite has become quite widespread. The rock is a compound of iron and copper and has a large number of various inclusions and veins of other impurities.
2. Stratiform is represented by a combination of copper shales and sandstones. This kind of the breed has also become widespread, as it is represented large deposit. The main characteristics include a simple sheet shape, as well as a uniform distribution of all useful components. Due to this, copper rock of this type is most in demand, as it allows for productivity at the same level.
3. Copper-nickel. This ore is characterized by massive texture inclusions of cobalt and gold, as well as platinum group metals. The deposits are in vein and sheet form.
4. Porphyry copper or hydrothermal. Copper ore deposits of this kind contain a large concentration of silver and gold, selenium and other chemical substances. Besides this, everything useful material are in higher concentration, due to which the breed is in demand. It is extremely rare.
5. Carbonate. This group includes iron-copper and carbonatite ore. It is worth considering that this breed was found only in South Africa. The mine being developed is classified as massive alkaline rock.
6. Skarn is a group that is characterized by a local location in a wide variety of rocks. Characteristic properties can be called small sizes and complex morphology. It is worth considering that in this case the ore containing copper has a high concentration. However, the metal is unevenly distributed. The rocks being mined have a copper concentration of about three percent.

Copper practically does not occur, for example, like gold, in the form of massive nuggets. The largest such formation can be called a deposit in North America, whose mass is 420 tons. With 250 types of copper, only 20 of them are widely used in pure form, others are used only as alloying elements.

Copper ore deposits

Copper is considered the most common metal, which is used in a wide variety of industries. Deposits of copper ore are found in almost all countries. An example is the discovery of deposits in Arizona and Nevada. Copper ore is also mined in Cuba, where oxide deposits are common. In Peru, chloride formations are being mined.

The use of the mined copper mixture is associated with the production of various metals. There are two main copper production technologies:

1. hydrometallurgical;
2. pyrometallurgical.

The second method involves fire refining of metal. Due to this, ore can be processed in almost any volume. In addition, exposure to fire allows almost all useful substances to be extracted from the rock. Pyrometallurgical technology is used to isolate copper from rocks that have a low degree of metal enrichment. The hydrometallurgical method is used exclusively for processing oxidized and native rock, which also have low copper concentrations.

In conclusion, we note that copper today is included in almost all alloys. Its addition as an alloying element allows you to change the basic performance properties.

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 building 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 loop.

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 an important role in the 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 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.