For owners planning to invest in small- to medium-sized copper mine beneficiation projects, designing a production line with stable capacity, compliant output, and high return on investment is crucial for success. A typical and popular requirement is a production capacity of 10 tons/hour, equipped with a jaw crusher, and a product output particle size of 100 mesh. This article will provide an in-depth analysis of the core configuration of this production line.
I. Why is "Two-Stage Crushing + Closed-Circuit Grinding" the Golden Rule?
Directly using a jaw crusher to crush large pieces of ore before feeding them into a ball mill is a common misconception. This process is extremely inefficient and cannot achieve the target capacity. The most scientific and efficient solution is "two-stage crushing + one-stage closed-circuit grinding."
• Two-stage crushing: The jaw crusher handles coarse crushing, while the cone crusher/fine jaw crusher handles medium crushing. The purpose is to efficiently crush the raw ore (up to 300-350mm) to a smaller particle size of 10-20mm, laying a solid foundation for subsequent grinding and greatly reducing the load on the ball mill.
• Closed-circuit grinding: The ball mill and classification equipment (such as a spiral classifier) form a cycle. Qualified fine powder is separated in time, while coarse particles are returned for regrinding. This effectively avoids the phenomenon of "over-grinding," maximizing production capacity (10 tons/hour) while ensuring product particle size (100 mesh).
II. Core Equipment Selection List
The following is a classic equipment configuration suggestion for your reference.
1. Crushing Section: Providing "fine feed" for the ball mill
◦ Coarse crushing equipment - Jaw crusher
▪ Recommended model: PE-500×750
▪ Function: Crushes large pieces of raw ore to below 100mm. It is the first stage of the production line, with a simple structure and reliable operation.
◦ Medium crushing equipment - Cone crusher (essential)
▪ Recommended model: PYB1200 spring cone crusher
▪ Key function: Further processes the coarsely crushed material to 10-20mm. This is a key guarantee for achieving a ball mill capacity of 10 tons/hour, significantly reducing overall energy consumption.
2. Grinding and Classification Section: The "Heart" of the Production Line
◦ Core Equipment - Wet Grid Ball Mill
▪ Recommended Model: MQGg1530 (φ1500×3000mm)
▪ Advantages: The grid ball mill has a fast discharge speed, larger processing capacity, and is more energy-efficient, making it very suitable for relatively coarse grinding requirements such as 100 mesh.
▪ Matching Power: Approximately 110kW
◦ Classification Equipment - High-Weir Spiral Classifier
▪ Recommended Model: FG-12
▪ Function: Forms a closed-loop circulation with the ball mill, separating fine particles that meet the 100 mesh requirement, while returning coarse sand that does not meet the standard to the ball mill. This equipment operates stably and is easy to maintain.
III. Investment Recommendations and Precautions
• Ore Properties are Fundamental: The final selection of equipment strongly depends on the physicochemical properties of your copper ore, such as hardness and clay content. It is recommended to conduct ore grindability tests to obtain the most accurate solution.
• "One-stop" support: In addition to the core main unit mentioned above, auxiliary equipment such as feeders, belt conveyors, silos, and power control systems (total power approximately 250-350kW) also need to be planned.
• Professional installation and commissioning: Large equipment such as ball mills require professional concrete foundations and a professional team for installation and commissioning. The initial steel ball ratio is particularly crucial for rapid production capacity achievement after commissioning.
A well-designed production line is the cornerstone of profitability. We hope this detailed configuration guide will help you clearly plan your copper ore processing project. We recommend that you provide specific ore parameters to a professional equipment supplier to obtain a customized solution and quotation that best suits your needs.
