Innovation and Future Prospects of Copper Ore Beneficiation Equipment

Innovation and Future Prospects of Copper Ore Beneficiation Equipment
——High Efficiency and Energy Saving Drive Industrial Upgrading

Introduction

Copper, known as the lifeblood of modern industry, plays an irreplaceable role in power, electronics, construction, and new energy due to its excellent conductivity, ductility, and corrosion resistance. With the growing global demand for copper resources, how to extract copper minerals efficiently and environmentally has become a core concern. Beneficiation equipment and processes, as the heart of copper production, directly determine resource utilization, productivity, and environmental impact. In recent years, China has narrowed the gap with developed countries through technology imports, independent innovation, and equipment upgrades. This article explores the current status and future directions of copper ore beneficiation equipment, focusing on breakthroughs in crushing, grinding technologies, and novel processes.

I. Technological Breakthroughs in Core Beneficiation Equipment

1. Crushing Equipment: Multi-Crushing with Less Grinding

The concept of multi-crushing with less grinding has become key to improving efficiency by reducing energy consumption in grinding. Domestic crushing technology advancements include:

·         Popularization of Compound Pendulum Jaw Crushers
Compared to traditional simple pendulum crushers, compound pendulum crushers optimize the dynamic jaw trajectory, achieving higher crushing ratios and more uniform particle size distribution. For instance, the PEWD400×750 fine crusher developed by the Beijing Mining and Metallurgy Research Institute reduced final product size in small-scale plants while cutting energy consumption by 15%~40%.

·         Localization of Roller Presses
Based on layer crushing theory, domestic roller presses now handle 120 tons/hour of iron ore (Protodyakonov hardness 16), with a 30% reduction in wear and extended service life. For example, a Shandong iron mine reported a 30%~40% productivity increase post-upgrade.

Additionally, imported advanced equipment (e.g., TSHD short-head crushers) has further upgraded domestic technology, pushing product size closer to international standards (<12 mm).

2. Grinding Equipment: Precision and Intelligence

Grinding fineness is critical to copper concentrate grade. Innovations in materials and processes have addressed traditional inefficiencies:

·         Revolutionary Magnetic Liners
Magnetic liners, replacing heavy manganese steel plates, feature lightweight designs and easy installation. They reduce energy consumption by 0.66 kW·h per ton and extend service life by 20%. At Shandong Jinling Iron Mine, liner wear decreased by 8.43%, and grinding efficiency improved by 4%~10%.

·         Hard Alloy Grinding Balls
Hard alloy balls co-developed by Jinchuan Group and Tsinghua University reduced ball consumption from 1.87 kg/t to 1.04 kg/t. Optimizing pulp concentration (below 50%) maximizes crushing probability and stabilizes slurry thickness on ball surfaces.

II. Novel Beneficiation Processes: Green and Efficient

1. Flotation-Regrinding Integrated Process

Traditional sulfide copper flotation faced challenges in grade stability and impurity removal. The flotation-regrinding process dynamically adjusts parameters (e.g., lime conditioning, pH control), achieving a stable concentrate grade above 65% while recovering associated metals like gold and silver. Shougang Group reduced tailings to 15% with an annual throughput of 14 million tons.

2. Air Cushion Belt Conveyors

Replacing traditional roller-based systems, air cushion conveyors use blowers to create frictionless transport. Advantages include:

·         30% energy savings (one blower per 100 meters);

·         Eliminated material stratification;

·         40% lower maintenance costs and 50% longer lifespan.
The technology also reduces noise pollution, aligning with green mining initiatives.

III. Future Directions: Intelligence and Sustainability

1. Mechatronics and Automation

IoT and AI enable remote monitoring and intelligent control. For example, Ansteel’s Swedish Swedia ball mill (206.6 m³, 410 kW) uses automation to optimize grinding parameters, boosting productivity by 20%. Future systems will integrate fault prediction and adaptive control.

2. Low Energy Consumption and Material Innovation

R&D focuses on ultra-fine crushers (<10 mm) and wear-resistant materials. Ceramic-metal composite liners and nano-coated balls may extend equipment life by 30%.

3. Circular Economy and Environmental Upgrades

Priorities include reducing toxic chemicals, wastewater recycling, and tailings utilization. Bio-flotation reagents, for instance, can minimize environmental risks.

Conclusion

Technological innovation in copper beneficiation equipment drives high-quality industry development. Through advancements in crushing, grinding, and novel processes, China is transitioning from a follower to a leader. Continuous innovation and global collaboration will secure a competitive edge, balancing economic and ecological benefits.