Kazakhstan's Zizutsk mining company polymetallic ore concentrator

Kazakhstan gold hot hereby Bratsk beneficiation plant designed by the former Soviet Union Michalis Noble Mineral Processing Research and Design Institute, commissioned in 1989, the annual ore processing capacity of 1.5 million t. Copper-containing metallic deposit Орловск to provide the base ore concentrator. The ore is a dense lump ore and disseminated copper ore, copper- zinc ore and polymetallic ore. During the mining process, the copper- lead -zinc polymetallic ore with varying composition of the material was designed. The ore copper and zinc grades ranged from 3.0% to 5.0%.

The treated ore, the primary metal minerals pyrite, chalcopyrite, sphalerite, covellite, chalcocite, bornite, tetrahedrite, and magnetite. Non-metallic minerals accounted for 20%, mainly quartzite, chlorite and sericite. Small amounts of gold and silver are also present in the ore, which are closely associated with sulfide minerals.

The ore is characterized by a fine-grained structure, unevenly embedded copper minerals, and pyrite and sphalerite are closely symbiotic, so it is difficult to obtain a qualified quality zinc concentrate.

The concentrator that processes the Орловск polymetallic ore has long adopted the cyanide process recommended by the Russian Institute of Nonferrous Metals Mining and Metallurgy. The ore processing capacity of the ore dressing plant is low and fails to meet the design processing capacity. The preferred flotation process is qualified for copper-lead concentrate, with a copper recovery of 86%, a zinc product with a zinc grade of 38% and a zinc recovery of 48%.

After the merger of the company Казахмыс (Kazakhstan Copper Company) in 1997, the company has developed a comprehensive plan for the company's development and improvement of beneficiation efficiency. According to this plan, the mine's ore mining capacity has increased to 1.6 times, making the processing capacity of the concentrator reach the design capacity. Therefore, it is verified by experiments that the first stage of grinding is self-grinding, and the correctness of the second and third stage broken ore preparation process is removed. At the same time, the designed and improved new beneficiation process was studied in the concentrator laboratory.

According to the test results, the copper concentrate de-coppering and de-ironing operations were added to the original design process. The process can increase the copper recovery rate of copper-lead concentrate to 88% and lead recovery rate to 80% (lead contained in copper-lead concentrate can be recovered in the smelter of the company), zinc grade of zinc concentrate Reached 45%. The separation agent system using lime, zinc sulfate and sodium sulfide can strengthen the flotation of copper sulfide minerals in copper-lead flotation operation, which can stabilize the flotation recovery rate of copper at 90% and reduce the amount of cyanide by half. (from 300g/t to 150g/t). By improving the cocoon of coarse copper minerals, the concentration and filtration plant can be stabilized, and the copper concentrate water is reduced from 14% to 10%.

The improvement of the beneficiation process index is largely attributed to the application of the selective foaming agent, methyl isobutylmethanol (MIBC), which is used in the concentrating plant under the condition of returning water. 1/5 of the foaming agent T-80 is 5 to 10 g/t. In the bubbling flotation with MIBC, the flotation foam formed is not only brittle but also small in amount, and the foam product is easy to be transported by the slurry pump, reducing the overflow metal loss of the thickener.

After the concentrator reached the design processing capacity and obtained the planned copper beneficiation index, the annual output of the copper concentrate of the concentrator reached 60,000 tons.

In order to improve the zinc recovery rate of flotation zinc concentrate from polymetallic ore, the cyanide-free beneficiation process was successfully applied in 2003. The process is based on the following stages: stage dissociation of sulfide minerals, application of mineral natural Floatability, the use of unconventional selection methods for copper-lead concentrates and adjustment of the slurry ion composition of the separation process.

A preferential flotation of the ore is initiated to separate the fast flotation zinc concentrate from the copper-lead mixed flotation tailings, followed by copper removal and de-ironing of the zinc concentrate. This method can reduce the amount of cyanide by half when the zinc recovery rate is increased to 52%. Recently, through the transformation of the concentrator, the three-stage grinding and one-stage separation flotation process were applied, and the zinc recovery rate of the zinc concentrate was increased to 64%. During this period, the de-mining cost of the zinc concentrate was reduced by 1/3, from 7.5 yuan/t to 5.0 yuan/t. By 2004, the concentrator adopted a copper-lead crude concentrate cyclone-flotation separation separation process that was not used in the world's polymetallic ore dressing practice (Fig. 1). The copper grade in the copper-lead concentrate was from 17.5. While the % increased to 1.90%, the zinc recovery of zinc concentrate increased to 67% (Table 1).

Further improve the cyanide-free process (using fine screening in copper-lead concentrate selection, re-grinding of zinc coarse concentrate and automatic analyzer for installing ore metal content) and stabilizing the composition of ore. It is expected that the copper grade of copper-lead concentrate Can be increased to 20%, zinc concentrate zinc recovery rate can reach 72% to 75%. This will complete the company's proposed annual production of zinc to 45,000 tons without reducing copper production.

Figure 1 Multi-metal beneficiation process of the Zützinksk concentrator

Table 1 Multi-metal beneficiation process indicators of the Zützinksk concentrator

Note: The lead grade of copper-lead concentrate is 3% to 4%.

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