Typical Process Flow of Copper Ore Flotation Production Line
Raw Ore → Crushing → Grinding and Classification → Flotation Operation → Dewatering → Copper Concentrate
1. Crushing and Screening
Raw ore is processed by jaw crusher + cone crusher/impact crusher, and screened in a closed circuit to below 12-15mm.
Target: Uniform particle size for improved grinding efficiency.
2. Grinding and Classification
Ball mills and spiral classifiers/hydrocyclones form a closed circuit, grinding to -200 mesh (60%-75%).
Controlling grinding fineness: Too coarse, difficult to classify; too much grinding, high power consumption.
3. Flotation Operation
Core section. Generally consists of roughing, scavenging, and cleaning.
Roughing: Rapidly captures most of the copper minerals, obtaining a rough concentrate.
Scavenging: Recovers residual copper from the roughing tailings, improving the overall recovery rate.
Cleaning: Multiple enrichment of the rough concentrate to improve the concentrate grade.
Flotation machines are available in SF/KYF/XCF models, equipped with automatic dosing and aeration regulation systems.
4. Dewatering and Drying
Concentration: Concentrate slurry enters a thickener, underflow settles, and overflow is reused.
Filtration: Dewatering is performed using a ceramic filter/filter press, with the filter cake containing less than 10% moisture.
Drying (Optional): Further dewatering is performed to meet standards for easy transportation and sales.
5. Tailings Treatment
Tailings slurry enters a thickener + filter press, and is either dry-piled or backfilled; the water system is closed-loop, with near-zero discharge.
