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Ball Mill For Copper Ore

The refining techniques employed by copper producers depend on the ore type, as well as other economic and environmental factors. Currently, about 80 of global copper production is extracted from sulfide sources.

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    Regardless of the ore type, mined copper ore must first be concentrated to remove gangue or unwanted materials embedded in the ore. The first step in this process is crushing and powdering ore in a ball or rod mill.

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    Virtually all sulfide-type copper ores, including chalcocite Cu2S, chalcopyrite CuFeS2 and covellite CuS, are treated by smelting. After crushing the ore to a fine powder, it is concentrated by froth flotation, which requires mixing the powdered ore with reagents that combine with the copper to make it hydrophobic. The mixture is then bathed in water along with a foaming agent, which encourages frothing.

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    Jets of air are shot up through the water forming bubbles that float the water repellent copper particles to the surface. The froth, which contains about 30 copper, 27 iron and 33 sulfur, is skimmed off and taken for roasting.

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    If economical, lesser impurities that may be present in the ore, such as molybdenum, lead, gold, and silver, can also be processed and removed at this time through selective flotation. At temperatures between 932-1292F 500-700C, much of the sulfur content remaining is burned off as sulfide gas, resulting in a calcine mix of copper oxides and sulfides.

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    Fluxes are added to the calcine copper, which is now about 60 pure before it is heated again, this time to 2192F 1200CC. At this temperature, the silica and limestone fluxes combine with unwanted compounds, such as ferrous oxide, and bring them to the surface to be removed as slag. The remaining mixture is a molten copper sulfide referred to as matte.

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    As a current is introduced, copper ions begin to migrate to the cathode, or starter sheet, forming 99.9-99.99 pure copper cathodes.

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    Copper processing is a complex process that involves many steps as the manufacturer processes the ore from its raw, mined state into a purified form for use in many industries. Copper is typically extracted from oxide and sulfide ores that contain between 0.5 and 2.0 copper.

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    Most ball mills operate most efficiently between 65 and 75 of their critical speed. Photo of a 10 Ft diameter by 32 Ft long ball mill in a Cement Plant. Photo of a series of ball mills in a Copper Plant, grinding the ore for flotation. Image of cut away ball mill, showing material flow through typical ball mill.

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    Copper is mined either at open pit copper ore mines or underground copper ore mines. First the copper ore is blasted, loaded and transported to the primary crushers. Then the ore is crushed and screened, with the fine sulfide ore -0.5 mm going to froth flotation cells for recovery of copper.In the primary crusher, the ore is broken into smaller pieces of less than 25 centimetres in diameter.Our copper ore beneficiation plant have lots of advantages.

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