Concentrator design

Beneficiation plant design concentrator design (engineering design of mineral processing plant) ore or other material with physical and chemical methods, make useful minerals and gangue or impurity cost-effective separation, or to meet other users smelter product requirements Factory design. Catalogue according to mineral processing method

Design main content

A brief history of development at home and abroad

Principles for determining the size of a concentrator

Product solutions

Conventional grinding process

Selection process design basis

Design specifications

Device Selection

Automatic control

Storage facility

According to the method of mineral processing

There are re-election, flotation, magnetic separation and chemical beneficiation process; including roasting, leaching, adsorption, displacement, extraction and so on. The design scope mainly includes: comprehensive recycling design of the concentrator, design of the tailings facility of the concentrator, design of the pre-selected workshop of the ore, design of the washing workshop, design of the crushing and screening workshop, design of the magnetizing roasting workshop, design of the grinding and grading workshop, design of the re-election workshop, design plant flotation, magnetic separation plant design, the joint process of beneficiation plant design, design gold mineral concentrate concentrated filtration plant design, plant design and slag concentrate beneficiation plant design dried.

Design main content

Design scale and product plan, process flow, design index, work system and equipment operation rate, equipment selection, production inspection, automation,

Concentrator storage facilities, maintenance equipment and facilities, workshop composition, plant construction, equipment configuration, production safety and environmental protection, and engineering (pre-) calculations, technical and economic indicators.

A brief history of development at home and abroad

In the middle of the 19th century, some countries in Europe and the United States began to build re-election plants. At the end of the 19th century, they built magnetic separation plants and flotation plants. After the 1940s, they developed chemical beneficiation. Since the 1960s, fine-grain re-election, fine-grain flotation, The wet strong magnetic separation and metallurgical joint process was developed and built. Since the 1970s, new processes and new equipment have been continuously developed, and large-scale concentrating plants have been built abroad, such as the 15,000-ton ore dressing plant that has been processed daily in Papua New Guinea. In 1909, China designed and built the first re-election plant at Shuikoushan Mine in Hunan Province, and later changed it to a flotation plant. By 1949, there were only more than 20 concentrating plants in the country. After 1949, thousands of various types of beneficiation were designed and built. plant (including the re-election, flotation, magnetic separation and joint process concentrator), the third day of Dexing copper mine concentrator ore processing capacity 6000Ot. Since the 1980s, in the crushing and grinding design of the concentrator, in order to reduce the size of the broken product, save the grinding power consumption, and achieve more and more grinding, the United States uses the Lu 2100mm ultra-fine crushing cone crusher , the former Soviet Union adopted KH and one 2200 Inertial Cone Crusher , China's Jiangxi Dexing Copper Mine No. 3 Concentrator uses Lu 2100mm super heavy cone crusher, Shandong Zaozhuang Gold Mine adopts PYHD-900mm rotary disc type super fine cone crusher. In order to simplify the process, save steel consumption and reduce costs, the self-grinding process is adopted. In the United States, the bamboo-based nmX4.6m wet self-grinding machine is used. The first demineralization plant of Dexing Copper Mine in China adopts a wet self-grinding machine. In the re-election plant design, the use of narrow-stage grading, multi-stage grinding, flow film dressing, especially the application of flow film dressing, changed the appearance of fine mud re-election. The United Kingdom uses a 40-layer turn-over bed and a cross-flow tape chute. China uses a centrifugal concentrator, a vibrating chute, and a double-layer tape chute. In the pre-selected workshop design, in addition to re-election, hand selection and heavy medium beneficiation, laser, radiation and conductance/magnetic sorting were developed. In the flotation plant design, equal floatation, string branching, flocculation flotation, Carrier flotation and flash flotation processes. Flotation equipment is available in both pneumatic and mechanical agitation, such as the Finnish loom "flotation machine and the former Soviet Union 100m" flotation column. In the design of magnetic separation plant, there are permanent magnet, electromagnetic, strong magnetic and high gradient magnetic separation, especially the application of strong magnetic and high gradient magnetic separation, so that weak magnetic minerals can be effectively recovered, and superconducting magnetic separation is more open. Selected new areas. Comprehensive recovery associated components, up to 74 kinds of the former Soviet Union, Japan, 85% to 95%; China's overall recovery, gold 25% of a total 33%, 65% white silver, platinum group metals and scattered elements almost Up to 100%. In addition, the dispersion of small mines, the design of mobile concentrators, the original ore to achieve long-distance transmission of tape, concentrate and tailings to achieve long-distance, high-concentration pipeline transportation, the automation of the mineral processing process and computer-aided design, has achieved results. With the improvement of the technological level and the development of equipment, the processing objects of the concentrator are not only suitable for the original ore, but also for the treatment of tailings, smelting intermediate products or slag. The design basis is mainly the design tasks and related documents issued by the superior authorities, and the approved geological exploration reports. The mineral processing test report and engineering geological report, topographic map, equipment map, etc., identified and approved by the competent department. Industrial test reports using new technologies and new equipment shall be subject to technical appraisal and approval by the competent department, and individual large-scale new equipment shall be approved by the competent department when it is used for industrial production. Beneficiation tests include optional tests, laboratory tests, laboratory extended continuous tests, semi-industrial tests, industrial tests and individual tests. The scope of adaptation should be listed in Table 1. Table 1 Classification of mineral processing test and adaptation scope The design scale and product plan are demonstrated by feasibility study and determined by the competent authority in the design task. The design scale is usually expressed in terms of the number of raw ore processed annually or daily, and is divided into large, medium and small scales according to national regulations.

Principles for determining the size of a concentrator

(1) Satisfy the country's needs for products and rational use of geological resources, ore mining and mineral processing technical conditions; (2) mineral resources and mineral sites are far apart,

The ore dressing plant should be decentralized to build a factory; when the ore points are close to each other and the ore properties are basically the same, the plants can be built in a centralized manner. However, whether centralized or decentralized construction, it depends on specific conditions, determined by technical and economic comparison, and is compatible with the scale of mining; (3) Reasonable service years.

Product solutions

According to the quality standards of the concentrates issued by the state and the requirements of users for product quality. The principle is to recycle as much of the national resources as possible, to obtain maximum economic benefits, and to pay attention to the comprehensive recovery of associated useful components. Therefore, the main product in the product plan can be a single concentrate or a mixed concentrate. It can even separate some high-purity high-quality concentrates, some grades with lower concentrates, semi-finished products (for semi-finished products for smelting) or medium mines. , sent to the smelting plant for treatment; associated components depending on the specific conditions, can also be separated from the concentrate, can also be concentrated in the main metal concentrate. The main production processes of process beneficiation generally include crushing, sorting and concentrate processing.

Conventional grinding process

The medium crushing design usually uses a two-stage or three-stage closed-circuit crushing process and is considered in combination with grinding. Conditional has adopted "multi-breaking and less grinding" that is more broken, reducing the grinding burden, mainly the crushing particle size from the past 15 ~ 20mm to 9 ~ 15mm, improve grinding efficiency, reduce grinding energy consumption. When the design adopts the self-grinding process, only one section of crushing is required, and the crushing particle size is 0-350mm; when the ore contains mud and water, the washing process must be increased in the crushing process; the ore depletion rate is large, and the pre-selected discarded waste rock needs to be added. The grinding process depends on the ore size, the useful mineral inlay size characteristics and the degree of ore mud. In general, the useful mineral particle size is unevenly embedded with stage grinding; when the ore is easy to be pulverized, the rod grinding (open circuit) plus ball milling (closed circuit) process is commonly used; the ore contains more mud, and the washing is difficult and self-grinding The self-grinding, semi-self-grinding or ABC process can be used. ABC is the abbreviation of Autogenus, Ballmill and Crusher. The United States, Canada and other countries first adopted [ores self-grinding (A) and then ball milling (B) and difficult-to-wear particles back to break (C)]. The selection process depends on the nature of the ore.

Selection process design basis

When the difference in floatability between the useful mineral and the gangue mineral is large, the design usually adopts flotation, and the re-election is used when the density difference is large; when the magnetic difference is large, the magnetic separation is used; when the difference in conductivity is large, the electric selection is used. Black magnetic iron ore metal ores using weak magnetic; weak magnetic ore or ore mixed with strong magnetic separation, flotation, roasting or reselection process and a magnetic joint process. When there is a large amount of sulfide ore in the non-ferrous metal ore, direct preferential flotation is used; when a small amount of disseminated ore or a high-sulfur sulfide containing a small amount of non-ferrous metal is used, the whole flotation is used; the oxidized ore is commonly used in flotation, re-election or floatation. Select a water and metallurgical joint process; re-election of tungsten, tin , and button minerals, tungsten, tin, polymetallic sulfide ore, re-election, flotation, magnetic separation, and electro-election combined process; flotation and re-election of gold and silver ore Combined with the selection of a metallurgical process; low-grade gold ore and low-grade copper ore, using heap leaching or bacterial leaching; comprehensive recovery of associated useful components, using re-election, flotation or combined processes. Process design should consider product quality, comprehensive recycling, poor and poor sorting, mud and sand sorting, difficult to sort, early harvest and more useful ore, early loss of waste rock or tailings. In the re-election process, the particle size segmentation, the secondary concentrate re-election, and the fine mud concentration are separately treated; in the flotation process, if the concentrate grade is required to be high, the number of selections is increased, the ore grade is high, and the recovery rate is required to be increased. Increase the number of sweeps; in the magnetic separation process, the impurities are removed before the strong magnetic separation, and the ferromagnetic minerals are removed by weak magnetic separation. The design of the concentrate dewatering process depends on the user's requirements for the moisture content of the product and the characteristics of the concentrate. Generally, a two-stage dehydration process of concentration and filtration is used. Re-select a part of the coarse-grained concentrate, using a sedimentation tank, dewatering tank, dewatering screen or filtration, etc.; a fine-grained concentrate produced by flotation, commonly used in two stages of dewatering and filtration, and individual products require moisture. When less than 8%, a three-stage dewatering process of concentration, filtration and drying is used.

Design specifications

The ore grade is provided by the mining department. Concentrate grade and recovery rate are generally determined according to the recommended indicators of the mineral processing test report approved by the competent authority, combined with national standards and user requirements for concentrate quality, taking into account the differences between the test and production and the indicators that may be achieved by production. When the difference between the original ore grade and the ore selectivity in the initial stage and the later stage of production is large, the two sets of design indicators can be divided into the early stage and the latter stage. The design index is generally slightly lower than the test index, and the difference between the two depends on the depth of the test, the nature of the ore and the complexity of the process. Under normal circumstances, only when the laboratory process test, the difference should be large, when there is a semi-industrial or industrial test, the difference can be small; when the mineral is single, the ore is selectable, and the process is simple, the difference can be small. On the contrary, it should be large; if the ore is a sulfide ore, the difference can be small, and the difference should be large for the oxidized ore; the difference of the ferromagnetic iron ore can be small, and the difference of the weak magnetic iron ore should be large. When comprehensively recovering the associated elements in the metal concentrate, if the selected index is too high, it is not conducive to comprehensive recovery. The main metal concentrate grade may be appropriately reduced or measures such as changing the process loop or the chemical conditions may be adopted to improve the recovery rate and make the associated elements as much as possible. Enriched in the main metal concentrate. Generally, the concentrate grade of magnetite contains more than 65% iron, and the recovery rate is 68%~88%; the concentrate grade of hematite and limonite contains 60%-65% iron, and the recovery rate is 70%-80%; lead zinc ore concentrate grade of 57% - 72% lead, 45% zinc a 57%, a recovery rate of 80% lead 90%, a 82% zinc 92%; veins concentrate grade tin-containing tin n%~60%, the recovery rate is 65%-72%; the concentrate grade of gold mine contains 40-1709/t, and the recovery rate is 75%~95%.
The water and electricity consumption indicators should be listed in Table 2. Table 2 Water and electricity consumption indicators and working systems and equipment operating rates designed by the concentrator. The concentrating plant generally adopts a continuous working system. The crushing and screening workshop located in the mine should be the same as the mine working system. When the mine is in intermittent work, the crushing and screening workshop of the concentrator, depending on the setting of the storage silo, determine its working system, which is the same as the mine or the concentrator. The working system of the concentrator and the equipment operating rate of each workshop shall be listed in Table 3.

Device Selection

The main principles are as follows: (1) The type, specification and quantity of equipment should meet the design processing capacity, ore properties and requirements of various process operations; (2) efficient, energy-saving, economical and practical; (3) auxiliary equipment capacity and main equipment or The system capacity should be adapted; (4) The equipment load rate of the upper and lower processes should be balanced, the equipment type and specifications of the same operation should be the same, the number of equipment should be compatible with the set number of equipment series, and appropriate large equipment should be selected as much as possible; 5) Based on the selection of domestic stereotyped products, the new equipment must undergo technical appraisal to confirm that the technology is mature and reliable; (6) The processing capacity of the equipment is determined by calculation and with reference to the actual production quota of similar enterprises.

Automatic control

The test parameters to be considered in the production test design include ore amount, slurry volume, concentrate amount, grade, particle size, slurry concentration, moisture and pH value. The sampling process is usually designed. Dry metering medium balance, tape scale or other metering device, wet metering flow meter, density meter or slurry metering sampler; particle size and grade analysis, using sieve analysis, chemical analysis, instrumental analysis or flow-carrying particle size analyzer, online X-ray analyzer, isotope analyzer; level and liquid level are respectively used by level gauge and level gauge. On-line inspection of automated beneficiation processes is the basis for automation and is generally used in grinding-grade and flotation plants. The process of mineral processing is controlled by feedforward control, feedback control and feedback control, and comprehensive control of feedforward control. Feedforward control is to detect the relevant parameters before the interference factor enters the process, and use the relationship studied in advance to determine its impact on the production process and correct it as required. Feedback control, first measure the parameters of the controlled variable, feed back to the controller, compare it with the given value, and then adjust the controlled variable according to the comparison result until it is close to the given value. However, in the process of mineral processing, due to the complex and variable parameters such as mineral quantity, grade, particle size and dosage, it is difficult to obtain a more accurate relationship. The design should not adopt feedforward control. At the same time, due to the long lag time of the beneficiation process, it is difficult to receive good results if it is fully incorporated into the feedback control system. Therefore, the design usually adopts a comprehensive control method based on feedback control and supplemented by feedforward control. Such as the amount of ore, concentration, fineness control and power monitoring in the grinding circuit; the agent, grade and liquid level control in the flotation circuit.

Storage facility

There are mines, mines, intermediate mines or mines, buffers and distribution mines, grinding mines and product mines.

(l) Raw ore receiving mine

Generally use a rectangular funnel bin;

(2) Intermediate mine or heap

Large-scale concentrating plants and concentrators of two or more ores are commonly used in ground or semi-underground structures, and are more economical on the ground;

(3) Slowly matching the mineral warehouse with multi-purpose trough-shaped mine bins

Large ore is commonly used in flat-bottomed troughs. The ore with more ore is a three-sided or four-sided inclined bucket structure; the ore dressing plant generally consists of crushing, screening, pre-selection, grinding-grading, beneficiation, concentrate concentration, filtration, drying, etc. It consists of workshops and tailings, chemical storage and preparation, power supply, water supply, laboratories, laboratories, repair stations and warehouses. For large and complex process concentrators, the production workshop can be divided into smaller units according to the production process, such as coarse crushing, medium crushing, fine crushing, screening, washing, pre-selection, grinding, beneficiation, concentration, filtration, drying. Workshops such as ingredients (mixing) and packaging, concentrates, tailings ponds, etc. The slag beneficiation workshop is generally attached to the smelter. The conditions for the construction of the factory building include the flat construction of the plant and the construction of the hillside. When the terrain is suitable, it is more economical to use the hillside to build a factory.

(4) Grinding mine warehouse

Multi-purpose overhead structure, generally round or slot plant building has multiple layers, single layer, mixed type: (1) multiple layers. It is also a suspended parabolic shape. The storage bins in front of the self-grinding machine are small in area, but the building structure is complicated, and the drop between the units is large. It is mostly used for flat ground or semi-underground mining. The storage time is generally 24~36h. The size of the concentrating plant with large requirements for the construction and material self-flow slope and small return products in the process is small, and the equipment condition is poor, and the value is large; there is an intermediate mine bin or process, such as crushing sieve. Take small values ​​in the workshop, heavy medium pre-selection workshop, and re-election of the car, but not less than 16h. Between; (2) single layer. Large area, scattered management, but plant structure

(5) Product mine warehouse

With the overhead or grab mine tank structure, it is also simple and easy to install large-scale and vibration equipment. It is mostly used for hillside construction and storage. The storage time depends on the transportation conditions. The concentrating plant with small conveying slope, large returning operation and large returning amount; maintenance equipment and facilities including lifting equipment and maintenance site. Check the hybrid. There are single-layer and multi-layer, mostly used for re-election and other ore dressing lifting equipment, with the heaviest parts of the equipment being repaired or the joint process beneficiation workshop which is difficult to dismantle. The weight of the most reloaded parts to be unloaded shall be determined in the design.
(1) Fully satisfy the limit value of the process to be heavy tonnage, and it is also not allowed to deviate from the lifting range to hoist zero. And consider the possibility of reform process and expansion of scale; (2) the same type of parts, the lifting height should be within the allowable range of the crane. The equipment should be concentrated as much as possible, and can be concentrated in stages if necessary; (3) The distance between equipments must meet the requirements of production operation and maintenance to ensure production safety and smooth flow; (4) Reasonably determine the platform elevation to meet the pipeline self-flow slope requirements. The flotation plant is generally not less than 4%, the re-election plant is not less than 14%, and the magnetic separation plant is not less than 10%; (5) determining equipment installation, transportation channels and sewage facilities; (6) fully considering the civil column modulus, and Appropriate maintenance sites are required as required; (7) When there are two cranes in the same span, the same elevation shared track should be used; (8) Laboratory, laboratory and technical checkpoints can be combined. The laboratory can also be constructed separately and kept at a distance greater than som from the grinding and crushing plant to avoid vibration.
The configuration is widely used in electronic computers for auxiliary design. The former Soviet Union carried out model design, that is, pre-modeled various devices, and then moved the model to make various solutions. In the design of production safety and environmental protection concentrator, the dust, waste water, waste gas and waste slag generated in the production process need to adopt comprehensive treatment measures. The discharge of dust, wastewater, waste gas and waste slag must comply with the discharge standard and meet the design of industrial enterprises. Relevant safety regulations. Production safety (including installation, maintenance, operation), in addition to meeting the equipment installation rules, the factory door is generally larger than the external dimensions of the installation equipment, the passage of the transportation equipment should be compatible with the equipment dimensions; the maintenance platform should be able to withstand the dismantling The weight of the old parts and the new parts to be installed, the protective railings must be placed around the operating platform, and the lifting holes of the lifting equipment, parts and other materials should be left on the floors of the multi-storey building; A safety cover is provided for the exposed transmission parts (such as triangular tape, couplings, etc.). For crushing, sieving, drying and dust-prone work, it is generally necessary to design ventilation and dust collection so that the indoor dust concentration reaches the national standard; for factories that produce more harmful gases, such as pharmaceutical preparation rooms, drug delivery rooms, and laboratory, It is necessary to strengthen the ventilation and ventilation system (see metallurgical plant mine ventilation design and metallurgical mine dust removal design).
The open pit should be placed in the downwind direction of the maximum wind frequency, and maintain a certain distance from the main production plant. When the conditions are not available, it is necessary to strengthen the dustproof measures and adopt full-closed or timely spraying of the surface curing agent. The ore dressing process should adopt a non-toxic process as much as possible. Measures should be taken for the beneficiation wastewater, recycled to the production, and the tailings facilities should be improved. The operation consoles of all floors in the plant shall be equipped with flushing conditions, and the sewage on the platform shall flow into the sewage discharge system; the sewage in the plant and the environmentally harmful wastewater (including toxic and heavy metal ion wastewater) shall not be directly discharged to the outside, and shall be naturally purified by the tailings pond. If the emission standards are not met, further purification is required.

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