Complete Mineral Processing Solution

Summary：SBM delivers complete mineral processing solutions from ore testing to plant operation. Our integrated approach ensures maximum mineral recovery, efficiency, and profitability for mining projects worldwide.

In the mining and mineral processing industry, the efficient extraction and purification of valuable minerals from raw ore stand as critical imperatives that directly impact the economic viability and sustainability of operations worldwide. This complex transformation of raw, heterogeneous ore into high-purity, marketable concentrates demands more than just advanced machinery; it requires a seamlessly integrated, scientifically-grounded process where each stage is meticulously engineered to work in synergy with the next.

SBM, with decades of dedicated expertise and relentless innovation, has firmly established itself as a preeminent global provider of complete mineral processing solutions. This article delves into the comprehensive process and the integral role each stage plays, to achieve unparalleled levels of mineral recovery and superior product quality, meeting the exacting demands of modern mining enterprises.

1. The Complete Mineral Processing Flowchart

SBM's complete mineral processing solution encompasses a series of interconnected stages, each designed to transform raw ore into high - grade mineral concentrates. The process, as depicted, includes dressing test, technical design, equipment supply, installation & commissioning, plant operation, and spare parts supply.

1.1 Dressing Test

Before any large - scale mineral processing plant is constructed, a dressing test is essential. This stage involves laboratory - scale experiments to analyze the raw ore's properties, such as mineral composition, particle size distribution, and the degree of liberation of valuable minerals from gangue. By conducting these tests, SBM's engineers can determine the most suitable processing methods and parameters. For example, if the ore contains sulfide minerals, flotation might be identified as the preferred separation technique, and the optimal reagent dosages and pH levels for efficient flotation can be established. This test serves as the foundation for the subsequent technical design, ensuring that the solution is tailored to the specific ore characteristics.

1.2 Technical Design

Based on the results of the dressing test, SBM's team proceeds with technical design. This phase involves creating detailed blueprints for the entire mineral processing plant, including the layout of equipment, the configuration of processing circuits (such as crushing, grinding, classification, and separation circuits), and the integration of auxiliary systems like power supply and water management. The design must strike a balance between process efficiency, space utilization, and future expandability. For instance, in a plant processing hard rock ores, the design would incorporate robust crushing equipment and efficient grinding systems to ensure adequate liberation of minerals, while also optimizing the flow of materials between different processing units to minimize bottlenecks.

1.3 Equipment Supply

SBM boasts a wide range of high - performance mineral processing equipment, each meticulously engineered to meet the demands of different stages.

• Crushing Equipment: Primary crushers (e.g., jaw crushers) reduce the raw ore to a manageable size, followed by secondary and tertiary crushers (such as cone crushers) to further refine the particle size. This gradual size reduction is crucial for preparing the ore for subsequent grinding.
• Grinding Equipment: Ball mills or rod mills are employed to grind the crushed ore into fine particles, facilitating the liberation of valuable minerals from the gangue matrix. The selection of grinding equipment depends on factors like ore hardness and the desired fineness of the product.
• Classification Equipment: Hydrocyclones or vibrating screens classify the ground ore into different size fractions. Oversized particles are returned to the grinding circuit for reprocessing, while appropriately sized particles move on to the separation stage.
• Separation Equipment: Depending on the ore type, various separation technologies are utilized. Magnetic separators are effective for separating magnetic minerals like magnetite, while flotation cells are used for sulfide or oxide minerals that can be selectively floated using reagents. Gravity separation equipment, such as jigs or shaking tables, is employed for minerals with significant density differences from gangue.

1.4 Installation & Commissioning

Once the equipment is supplied, SBM's technical team oversees the installation and commissioning process. Installation involves the precise placement and assembly of all equipment according to the technical design. Commissioning is a critical phase where each unit is tested individually and then as part of the entire system. During commissioning, operational parameters are fine - tuned to ensure that the plant operates at peak efficiency. For example, the speed of the ball mill, the flow rate in hydrocyclones, and the reagent addition rates in flotation cells are adjusted to achieve the desired product quality and throughput. Any issues identified during this stage are promptly addressed to ensure a smooth transition to full - scale plant operation.

1.5 Plant Operation

After successful commissioning, the mineral processing plant enters the operation phase. SBM provides comprehensive support to ensure the plant runs smoothly and efficiently. This includes training plant operators on equipment operation and maintenance, as well as offering remote monitoring and control systems. These systems allow for real - time tracking of key performance indicators (KPIs) such as throughput, concentrate grade, and recovery rate. Operators can adjust parameters as needed to respond to changes in ore feed or market demands, maximizing the plant's productivity and profitability.

1.6 Spare Parts Supply

To minimize downtime and maintain continuous operation, SBM offers a reliable spare parts supply service. Critical components, such as crusher wear parts, mill liners, and flotation cell impellers, are stocked and readily available. This ensures that any worn - out or damaged parts can be quickly replaced, reducing the impact of equipment failures on production schedules.

2. Core Equipment for Mineral Processing

SBM provides a comprehensive suite of advanced mineral processing equipment, each meticulously engineered to excel in specific stages of the mineral processing workflow. Our equipment portfolio combines robust construction with intelligent design to deliver optimal performance, reliability, and efficiency across diverse mining applications.

2.1 Gyratory Crusher

SBM's Gyratory Crusher stands as the cornerstone of primary crushing solutions for large-scale mining operations. This robust machine is specifically engineered to handle the most challenging ore reduction tasks, efficiently processing raw ore blocks with feed sizes up to 1,500 mm and reducing them to manageable 200-250 mm outputs.

Working Principle:

The crusher operates through an optimized mechanical design where a crushing head gyrates within a fixed cone-shaped chamber. This unique crushing action compresses ore against the chamber walls, achieving efficient size reduction through a combination of impact and compression forces.

Key Features and Technical Advantages:

Applications: Primarily used for coarse crushing of hard rock ores such as copper, gold, iron, and other metallic and non-metallic minerals.

2.2 Multiple Cylinder Cone Crusher

The multiple cylinder cone crusher is designed for secondary or tertiary crushing, providing uniform and precise particle size reduction to optimize downstream grinding processes.

Working Principle:

The crusher operates through an innovative multi-cylinder hydraulic system that simultaneously adjusts both the crushing chamber geometry and discharge opening. The rotating mantle compresses ore against concave liners, achieving efficient size reduction through a combination of inter-particle crushing and controlled compression forces.

Key Features and Technical Advantages:

Applications: Ideal for medium to hard ores requiring fine crushing such as iron ore, copper ore, and other minerals.

2.3 Single Cylinder Hydraulic Cone Crusher

SBM's Single Cylinder Cone Crusher delivers outstanding versatility and performance for diverse crushing applications. Combining simplified engineering with advanced hydraulic technology, this crusher provides exceptional adaptability in meeting varying production requirements while maintaining optimal operational efficiency.

Working Principle:

The crusher utilizes an innovative single hydraulic cylinder system that precisely controls both the discharge setting and provides comprehensive overload protection. Through the cylinder's precise movement, the mantle position is adjusted to optimize the crushing chamber size, achieving efficient size reduction through a combination of compression and shear forces.

Key Features and Technical Advantages:

Applications:

Ideal for secondary and tertiary crushing applications where flexibility and efficiency are paramount:

• Medium to hard ore processing in metallic and non-metallic minerals
• Operations requiring frequent adjustment of product specifications
• Mobile crushing plants and space-constrained installations
• Aggregate production with strict particle shape requirements

2.4 Portable Crusher

Portable crushers provide on-site crushing capability with mobility, reducing transportation costs and improving operational flexibility, especially in remote or difficult-to-access mining areas.

Working Principle:

The portable crusher plant integrates a complete crushing system - including crusher, feeder, screens, and conveyors - on a single robust chassis. This integrated design enables the unit to function as a self-contained processing plant, with hydraulic systems allowing quick setup and configuration changes for different production requirements.

Key Features and Technical Advantages:

Applications: Ideal for small to medium mining operations, quarrying, and construction sites requiring flexible crushing solutions.

2.5 Ball Mill

The ball mill is a vital piece of equipment for fine grinding, where steel balls within a rotating cylinder grind the crushed ore into fine particles, liberating valuable minerals from the gangue.

Working Principle:

Steel balls tumble inside the rotating mill shell, exerting impact and attrition forces on the ore particles to reduce their size.

Key Features and Technical Advantages:

• High grinding efficiency adaptable to different ore hardness.
• Adjustable rotational speed and ball charge for precise control of product fineness.
• Supports both wet and dry grinding processes.
• Durable design with easy access for maintenance and ball replacement.

Applications: Widely used in mineral processing for grinding ores before flotation, leaching, or gravity separation.

3. Successful Global Mineral Processing Project

SBM's solutions have been successfully implemented in various global projects, showcasing their effectiveness:

• Tanzania Gold Ore Processing Plant: Utilizing SBM's crushing and grinding equipment, this plant efficiently processes gold ore, achieving high gold recovery and meeting local market demands.
• Sudan Gold Ore Processing Plant: The project leverages SBM's complete solution, from ore crushing to gold separation, ensuring stable and efficient gold production in a challenging operating environment.
• Philippines Gold Ore Processing Plant: With SBM's equipment and technical support, the plant optimizes gold extraction, contributing to the country's mineral industry growth.
• Mali Gold Ore Processing Plant: This project demonstrates SBM's capability to deliver reliable solutions for gold processing in African regions, supporting local economic development.
• Sichuan Gold Co., Ltd. Project: Catering to domestic mineral processing needs, SBM provides tailored solutions that enhance the efficiency of gold extraction for this Chinese enterprise.
• Zijin Mining Group: As a major mining company, Zijin Mining benefits from SBM's advanced equipment and technical expertise, improving mineral processing efficiency and productivity.

4. Advantages of SBM's Complete Mineral Processing Solution

4.1 Customization

By starting with a dressing test, SBM's solutions are highly customized to the specific ore and client requirements. This ensures that each plant is optimized for maximum mineral recovery and minimal waste generation.

4.2 Integration

The seamless integration of all stages, from design to operation, eliminates inefficiencies that can arise from disjointed processes. Each component of the solution is designed to work in harmony with the others, resulting in a highly efficient and cohesive system.

4.3 Technology Leadership

SBM incorporates advanced technologies into its equipment and processes. For example, intelligent control systems use sensors and automation to optimize equipment performance, while energy - efficient designs reduce operational costs and environmental impact.

4.4 Comprehensive Support

From the initial test to ongoing operation and maintenance, SBM provides end - to - end support. This allows clients to focus on their core business while relying on SBM's expertise to ensure the success of their mineral processing operations.

SBM's complete mineral processing solution represents a holistic approach to mineral extraction and purification. By combining scientific testing, innovative design, high - quality equipment, and comprehensive support, SBM enables clients in the mining industry to achieve efficient, sustainable, and profitable mineral processing operations. Whether processing precious metals, base metals, or non - metallic minerals, SBM's solution is tailored to meet the unique challenges and opportunities of each project, solidifying its position as a leader in the global mineral processing equipment and solution market.