This article narrates the story of a copper-gold ore dressing plant in Kyrgyzstan that, when faced with low production efficiency, managed to significantly enhance its production capacity and metal recovery rates through technological transformation and process optimization. The main improvements included optimizing the process structure, replacing the flotation machine stator and impeller with new models, and adopting a new type of collector. These modifications led to a substantial increase in both copper and gold grades and recovery rates, bringing significant economic and social benefits to the mining plant.
The copper-gold ore dressing plant located in Kyrgyzstan failed to meet the expected production standards after its completion and commissioning. Issues such as poor process flow and insufficient equipment capacity in the crushing, grinding, and dewatering systems led to low production efficiency.
Through systematic technical diagnosis, the root causes affecting production were identified. Subsequently, a series of process optimization and transformation measures were implemented, including:
1.Process Structure Optimization
The original one-stage closed-circuit grinding process was improved to a two-stage closed-circuit grinding process, effectively solving the over-grinding issue and enhancing grinding efficiency.
The flotation process was adjusted from the original two rough selections, two fine selections, and two scavenging selections to one rough selection, three fine selections, and three scavenging selections, reducing the workload and improving metal recovery rates.
2.Improvement of Flotation Machine Structure
The plant replaced its components with self-developed flotation machine stators and impellers made of high wear-resistant materials, which can improve air dispersion and enhance the contact between pulp and air, thereby improving flotation effects.
3.Addition of Diversion Trench
A horizontal diversion trench was added inside the flotation machine to help foam discharge more quickly, preventing untimely discharged foam from affecting the recovery rate of concentrate.
4.Automatic Level Control System
An automatic control device was introduced to maintain the stability of the pulp level, ensuring the continuity and stability of the ore dressing process.
5.Optimization of Foam Flushing Water Position
The foam flushing water setting was moved from the bottom of the foam trough to the top of the foam, spraying directly onto the foam surface, accelerating foam rupture and flow, and improving flotation efficiency.
6.Application of New Collector
The new OT-Y10 collector replaced the traditional butyl xanthate, significantly enhancing the flotation effect of minerals, especially when processing oxidized ores.
7.Adjustment of Reagent System
Based on changes in the properties of the ore, the dosage and addition points of collectors, frothing agents, and activators were adjusted to optimize the efficiency of reagent use.
8.Replacement of Metering Pumps
The on-site reagent metering pumps were replaced to improve the accuracy of reagent addition and ensure the stability and reliability of the flotation process.
Through this series of technical optimizations and transformation measures, the grinding and flotation systems of the mine have been significantly improved, not only enhancing the grade and recovery rate of concentrate but also reducing production costs and strengthening the company's market competitiveness.
Copper grade increased from 21.2% to 24.0%.
Copper recovery rate increased from 72.4% to 90.0%.
Gold grade increased from 38.8 grams/ton to 42.4 grams/ton.
Gold recovery rate increased from 69.4% to 82.0%.
The transformation not only improved the economic benefits of the mining plant but also created job opportunities for the local community and promoted the development of the regional economy, becoming a model of international cooperation under the "Belt and Road" initiative.
The future of mining lies in innovation and continuous improvement. The transformation case of the copper-gold mine in Kyrgyzstan provides valuable experience for the global mining industry, demonstrating the great potential of technological innovation in improving production efficiency and economic benefits.
Want to learn more about mining technology transformation cases or explore how to apply these innovations to your mine? Contact Xinhai immediately, let's embark on a journey of mining technology innovation together!
