How to Effectively Analyze Beneficiation Outputs?

Process flow testing is generally conducted before the preliminary design of a beneficiation plant or the modification of existing technology. These tests provide a reference for the design or technical renovation of the plant. Typically, laboratory tests are conducted first, followed by planning based on the results to determine if semi-industrial or industrial tests are necessary.

The testing process for beneficiation procedures is usually developed by a research unit, which also collects the necessary data. If conditions allow, the testing, design, and production departments can collaborate to finalize the test details.

I. General Content of Data Collection before Beneficiation

A. Understanding the Task and Client Requirements

1. Determine the scale and service life of the beneficiation plant.

2. Identify the main useful components and associated comprehensive utilization issues.

3. Outline the stages of testing and the required completion date.

4. Specify whether the plant will process ore from a single deposit or multiple deposits and types.

5. Note any special requirements for the chemical composition, grade, and particle size of the concentrate.

6. Analyze the supply and performance of water sources, beneficiation reagents, and roasting fuels in the plant area.

B. Geology-Related Information

1. Identify the type of deposit, geological reserves, orebody characteristics, ore types, grade features, mineralization patterns, and surrounding rock variations.

2. Perform a prospect evaluation and design a sampling strategy.

C. Mining Design Information

1. Outline mining development plans and methods.

2. Describe the co-mining or selective mining of different ore types.

3. Provide the rate of dilution and the grade of extracted ore.

4. Detail the ore type ratios and average grades for the designed mining area, and the planned ore type ratios and average grades for the next 5-10 years.

D. Beneficiation Information

1. Specify any special requirements for testing from the beneficiation design.

2. Review worldwide test research and production practices for similar ores.

3. Identify potential advanced technologies that could be applied.

II. Main Content of Beneficiation Process Flow Testing

A. Ore Properties Research

Understanding ore properties is crucial for selecting a beneficiation scheme and defining the plant design. This includes:

1. Spectroscopic qualitative and semi-quantitative analysis.

2. Comprehensive chemical analysis, mineral identification, phase analysis, size analysis, magnetic analysis, heavy liquid analysis, fire assay, grindability tests, and various physical properties (specific gravity, magnetic susceptibility, conductivity, moisture content, true and bulk densities, angle of repose, friction angle, hardness, viscosity, etc.).

B. Beneficiation Methods, Flow Structures, Indicators, and Process Conditions

These aspects directly influence the plant design and must be carefully considered to ensure reliable beneficiation indicators. For complex ores or those with limited beneficiation practice, exploratory tests should precede the testing program. The program should include schemes based on successful production practices and new technologies with proven potential for practical application. Multiple testing schemes should be considered for technical and economic comparisons, with detailed analysis of 1-2 key flow schemes.

Process conditions should be optimized by identifying their influencing factors and determining the best range for key operations. The flow structure should include the number of grinding and separation stages, roughing, cleaning, and scavenging operations, and mass flow diagrams. Slurry flow diagrams should be provided if necessary.

C. Analysis of Beneficiation Outputs

Various analyses (spectral, chemical, fire assay, phase, size, mineral identification) should be conducted on concentrate, middling, and tailings to address issues such as:

1. Low concentrate grade, low recovery rates, unmet chromite/manganese ratios.

2. Enrichment directions of certain co-occurring elements.

3. The performance of certain beneficiation operations and new technologies for different minerals.

Output properties like chemical composition, size characteristics, true and bulk densities, and sedimentation rates of concentrate and tailings are fundamental data for plant design.

D. Special Test Items

Special test items may be required based on user and design unit requests, such as flotation with recycled water, purification of beneficiation wastewater, filtration of flotation concentrate, utilization of off-spec ore, and supplementary tests after production trials.

III. Research on Beneficiation Methods and Process Testing

1. Research on Beneficiation Methods:

Due to advances in beneficiation technology, multiple methods may be available for treating a single ore type. Comparative testing of different methods should be conducted based on ore properties, product quality requirements, and construction conditions to select the most suitable method.

2. Separation Condition Testing:

Flotation: Tests should include grinding fineness, slurry concentration, temperature, pH, reagent regime, stirring, and flotation time. Additional tests may cover recycled water use, water quality, reagent removal, desliming, air pressure, and air volume.

Magnetic Separation: Tests should include magnetic induction intensity, material entry particle size, capacity, classification versus non-classification. For dry weak magnetic separation, additional tests on the impact of ore moisture and washing on separation indicators are needed. For wet strong magnetic separation, tests should cover slurry concentration, washing water pressure and volume, medium plate gap, rotation speed, and the aggregation of strongly magnetic minerals.

Gravity Separation: Tests should include feed quantity, particle size and range, slurry concentration (solid-liquid ratio), washing water pressure and volume, feed and discharge methods, and cut-off position. Specific equipment parameters should also be tested.

Comparison Tests of Major Raw Materials for Mineral Processing Reagents, Fuels, and Media: These tests should be conducted in conjunction with different mineral processing methods and equipment trials. They involve comparing the types, performance, specifications, consumption, and beneficiation effects of the main reagents, fuels, and media used. The goal is to select varieties that offer good beneficiation indicators, are cost-effective, have abundant sources, and cause minimal environmental pollution or are easy to manage.

Y&X Beijing Technology Co., Ltd. is a dedicated provider of beneficiation solutions for metal mines, specializing in efficient and environmentally friendly reagents. With extensive experience in copper, molybdenum, gold, silver, lead, zinc, nickel, magnesium, rare metals like cobalt and palladium, and non-metallic ores like bismuth, fluorite, and phosphate, we offer customized solutions tailored to the specific nature of your ore and production conditions. Our goal is to ensure maximum benefits for our customers through advanced beneficiation methods and high-efficiency reagents. Y&X is committed to providing one-stop beneficiation solutions and looks forward to a successful partnership with you.