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In order to improve the comprehensive utilization rate of associated valuable elements and resources, a lot of research and improvement have been carried out on the flotation separation process of chalcopyrite and pyrite. These improvements are aimed at adapting to the changes in mineral flotation characteristics and ore properties, and optimizing resource recovery and processing efficiency. At present, there are five commonly used flotation separation process flows: direct flotation separation process, preferential flotation process, mixed-preferential flotation process, mud and sand separation process, and combined beneficiation and smelting process. Each process has its specific applicable conditions and operating characteristics, and can effectively cope with different ore types and processing requirements. This article will introduce the status of these five flotation separation process flows in detail, and explore their respective scope of application, process flow and their advantages and disadvantages.
Use the table of contents below to navigate through the guide:
The direct flotation separation process is mainly used to process massive copper-bearing pyrite with high sulfur content in the raw ore. First, the ore is finely ground to ensure the appropriate particle size. Then, during the flotation process, inhibitors are used to suppress the flotation of pyrite, thereby effectively separating the copper minerals. Finally, the flotation tailings are sulfur concentrates. This process is simple to operate and efficient, and can quickly obtain sulfur concentrates, especially suitable for processing ores with high sulfur content. However, for ores with very high sulfur content, it may be necessary to adjust the dosage of inhibitors and operating conditions to ensure effective separation of copper minerals.
When the ore is a massive copper-bearing pyrite and the direct flotation separation process cannot obtain qualified sulfur concentrate, the priority flotation separation process is the most appropriate. The first thing to get by flotation is the copper concentrate, and then the copper tailings are subjected to sulfur flotation to obtain the sulfur concentrate. This process can also be used to treat impregnated copper-sulfur ores. It is worth noting that when flotating copper concentrate, it is necessary to pay attention to the control of the amount of inhibitor, in order to save the amount of activator required for the subsequent flotation of pyrite. In addition, it is also necessary to re-grind the coarse concentrate or the medium ore according to the particle size characteristics of the ore to further improve the flotation index of copper.
When the original ore is a disseminated copper-sulfur ore, the concentrator generally adopts a mixed-preferential flotation separation process. First, under the conditions of coarse grinding particle size and low pulp alkalinity, the copper-sulfur mixed concentrate is floated out, and then lime and other inhibitors are added to the pulp to re-grind the mixed concentrate, inhibiting the floating of pyrite in the high-alkalinity pulp, and flotation to obtain copper concentrate. This process can significantly improve the economic effect of the concentrator, but it has high requirements for the control accuracy of the operation.
The mud and sand sorting process is suitable for situations where the sulfur content in the ore part is high and the gangue minerals are mainly concentrated in fine mud. In this process, copper-sulfur ore is first coarsely ground. Next, through mud and sand sorting, the mud and ore are effectively separated, thereby reducing the negative impact of the mud on copper flotation. This can significantly improve the quality of copper concentrate and improve the production efficiency of sulfur concentrate. This process ensures higher copper mineral recovery and optimizes the grade of the sulfur concentrate by reducing fines interference in the flotation separation process. For ores with high fine mud content, the mud and sand separation process is particularly effective and can improve the stability and economy of the entire flotation system.
The combined dressing and smelting process is suitable for situations where copper-sulfur ore is severely oxidized and contains a large amount of copper sulfate. First, after the raw ore is crushed to appropriate particle size, the ore is washed and deslimed. After the solid-liquid separation of the ore slime, sponge iron can be used to replace the copper ions in the liquid phase, or ion exchange, extraction, electrowinning and other methods can be used to recover the copper ions in the liquid phase. The washed ore then enters the flotation operation for separation.
This process effectively divides the treatment of oxidized ores into two steps: first, remove the slime through washing and desliming to reduce the interference of fine mud on subsequent flotation; then, recover the copper ions in the liquid phase through a combined selection and smelting method , further improving the copper recovery rate. The combined dressing and smelting process can not only process severely oxidized ores, but also significantly improve the recovery efficiency of copper minerals and optimize the overall treatment effect.
Through the above brief introduction to the five flotation separation methods of chalcopyrite and pyrite, we can understand that each process has its unique application conditions and operating requirements. These flotation separation processes are also constantly being improved and optimized, which can not only improve the efficiency of ore processing, but also improve the utilization efficiency of ore resources. In order to further improve the utilization rate and economic benefits of ore resources, understanding and mastering these process flows is of great significance to improving the efficiency of ore processing and resource utilization.
