Usually metal ore processing plant normally uses two stages or three crushing and screening process. Individual large-scale concentrating plants use a four-stage crushing process when the original ore mass is processed. In recent years, the crushing and screening process has been simplified due to the increasing development of new self-grinding processes.

a broken process

When the self-grinding machine is used as the grinding equipment , the crushing process can be greatly simplified. Usually, after the crude ore is crushed (granularity of 350~0 mm), the raw ore enters the self-grinding mill for grinding. As shown in Figure 1. For some non-metallic minerals such as asbestos, limestone or the hardness is small, more developed joint metal ores, when using crusher or a hammer mill, a broken process may also be employed.

Two-stage crushing process

Including two sections of road breaking as shown in Figure 2 (b) or two sections and a closed circuit as shown in Figure 2 (a). The latter is the most common. That is to say, the second-stage crusher and the inspection sieve constitute a closed circuit, so that the particle size of the crushed product can be ensured. Create favorable conditions for the next stage of grinding operations. The two-stage crushing process is only applicable to small mines in the underground mining method. The original ore block is 200~400 mm, the product is 12~30 mm, the total crushing ratio is not large, and the broken ore is not large. 3 is a two closed-circuit of a lead-zinc ore concentrator used crushing process. The ore size sent to the plant is 200~0 mm. After screening through a sieve with a mesh size of 50 mm, the product on the sieve enters the first stage crusher (400 x 600 mm jaw crusher ). The first stage of crushed product and the sieved sieve product enter the vibrating screen with a sieve opening of 12 mm, and the second stage of the crushing is pre-screened. The product on the sieve enters a medium-sized cone crusher with a specification of ψ1200 mm, and the ore is discharged. Return to the vibrating screen for inspection and screening, and sieve the product (12~0 mm) to the grinding section.

When the production scale of the selected plant is not large, and the production capacity of the first-stage crusher is greatly surplus, the first-stage two-stage closed-circuit crushing process without pre-screening can be adopted.

The two-stage open-circuit crushing process is only used when some of the re-election plants send the crushed product directly to the rod grinding.

Three-stage crushing process

The three-stage crushing process is the most commonly used. Can be divided into two types:

(1) Three-stage open circuit Figure 4 (a) shows the three-stage open-circuit crushing process with all pre-screening. In some cases, the first and second segments may not be pre-screened. Due to the last paragraph of the process, this kind of process cannot guarantee the product granularity. It is only used when the grinding mill does not require strict grain size.

(2) Three sections and one closed circuit Figure 4 (b) shows the three-stage one closed circuit crushing process with full pre-screening. It is the most widely used non-ferrous metal concentrator in China. Can be used in large, medium and small concentrators. When the material is transported, the second stage crushed product and the third stage cyclic load are often combined and sent to the third stage for screening.

Figure 5 (a) is the first three-stage closed-circuit crushing process without a pre-screening common in a large black metal concentrator in China. Since magnetic iron ore quartzite, hardness, and blocks of ore is large (~ 1000 0 mm), commonly used in large tub (each about 60 tons of ore truck-mounted) directly to the ore into large size 1200 mm gyratory crusher Machine, so it is more difficult to use pre-screening before the first stage of crushing.

Fig. 5(b) shows an example of a three-stage closed-circuit crushing process in which the first stage and the second stage of the lead-zinc-bismuth are not pre-screened.

Four-stage crushing process

In order to obtain a finer crushed product and increase the total crushing ratio, a four-stage open crushing process or a four-stage one closed-circuit crushing process may be employed. The last section of the four-stage open-circuit crushing process is often replaced by a rod mill. This process can break the ore to 1.5~3 mm. The rod mill is both a fine crusher and a grinding machine here. This process has the transitional nature of the crushing process and the grinding process.

In summary, in the metal ore dressing plant, the most common is the three-stage one closed circuit crushing process. The crushing process adopted for a specific plant depends on the production scale of the plant and the required total crushing ratio. It is necessary to determine the technical and economic comparison of several options.

In the first stage of the above process, the jaw crusher or the gyratory crusher can be generally used. The second section of the three-stage crushing process uses a standard cone crusher ; the third section often uses a short-head cone crusher. For the concentrator with a small handling capacity, the third section can be used with a roller machine. In the two-stage closed-circuit crushing process, the medium-sized cone crusher is used in the last section, and the impact crusher or hammer crusher can be used in small-scale selection or crushing of brittle materials.

Before the coarse and medium crushing, the fixed strip screen or the cantilever strip screen is used for pre-screening; and before the fine crushing, the vibrating screen is used for pre-screening and checking the screening equipment .

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