This setup is for a 500 TPD rock copper sulfide ore processing plant. Also suitable for lithium ore, rock gold sulfide ore, etc,
There are 4 parts in a full processing plant including a crushing system, grinding system, flotation beneficiation system, and copper concentrate dewatering system.
High recovery ratio for copper concentrate. Grade can reach about 30-35% maximum after processing,
Process Description
The total Input capacity of the plant is 500 TPD, the crushing system works 10 hours a day, so 50 TPH input capacity, ball mill flotation system works 24 hours a day, so 21 TPH input capacity.
Main machines include a raw material feeding hopper, vibration feeder, Primary Jaw crusher, Cone crusher, vibration screen, belt conveyor, small vibration feeder, storage bin, Ball mill, spiral classifier, mixing tanks, flotation machines, slurry pump, thickener, disc vacuum filter machine, etc.
1. Feeding and Crushing System: work 10 hours a day, 50 TPH Input Capacity
We use a vibration feeder for feeding raw material(below 300-500mm) to the primary jaw crusher stably and evenly.
The Primary jaw crusher is for primary crushing big stones below about 150mm, then output from the primary jaw crusher will go to the cone crusher for secondary crushing.
The output from the cone crusher is about below 20mm will go to the vibration screen (with one layer screen 20mm mesh size, ), screen out 0-20 mm fine material go to stockpile on the ground, larger than 20mm goes to cone crusher for crushing again, so the crushing system can work separated from the grinding system.
2. Ball Mill Grinding System: work 24 hours a day, 21 TPH input capacity
The 0-20mm powder material will first be stocked on the ground, and we will install a storage bin and vibration feeder underground to feed 0-20mm powder material to the transfer bin before the ball mill. There is a small vibration feeder fixed under the transfer bin, and Then powder material is smooth to the ball mill through a belt conveyor. The ball mill is for grinding material to small fine powder below 200 mesh
In order to get fine powder size, the ball mill needs to work together with a spiral classifier, The overflow of the classifier is fine slurry around 200 mesh, and the underflow coarse particles will go back to the ball mill grind again, to be closed-circuit. So from this grinding system will get 200 mesh slurry.
3. Flotation System:
The 200 mesh slurry will be firstly sent to mixing tanks for mixing material and Relevant chemicals completely.
The flotation processing includes roughing flotation, scanning flotation, and cleaning flotation. Adjust the number of chutes of the flotation machine according to the raw material grade of the copper ore
4. Copper Concentrate Ore Dewatering System to get dry concentrate:
After getting the copper concentrate slurry from the flotation system, it is with water, so I need to dewater it. because the size is very small, fine 200 mesh, firstly use thickener to primarily thicken concentrate, make higher density, then use a disc vacuum filter machine to filter water, and dry copper concentrate ore with very low moisture, then can go to the packing system.
The water after the thickener and vacuum filter can be reused to process the plant.
This Setup is also suitable for 1000 TPD, 240TPD,120TPD, etc minerals flotation beneficiation processing plants. But this Setup does not include a tailing dewatering system, if you need we can design and update for you.
We also can send our engineers to mine sites to help you with installation and commissioning guidance.
