Ore Crushing and Mill-Feed Preparation Line

This line crushes and screens ore to a controlled size suitable for the downstream mill or beneficiation stage. The circuit is selected from ore hardness, abrasiveness, feed grading and the required mill-feed size.

Project parameters

• Capacity: 50–300 t/h

• Duty: crushing, screening and stable mill-feed preparation

• Circuit: two or three stages, normally closed circuit

• Downstream process: grinding or beneficiation under a separate process design

About the solution

Ore preparation is not simply a size-reduction task. The line must provide controlled grading for stable mill operation, recirculate oversize and equalize the material flow. The final crushed size is determined by the ore's breakage characteristics and the requirements of the downstream process.

Hard ore commonly uses a primary jaw crusher and a secondary cone crusher. A third cone stage or additional screen can be added where necessary. Tramp-metal removal, metal detection, dust suppression and surge bins are selected according to the process risk and operating conditions.

Process flow

1. Run-of-mine ore enters a receiving hopper and grizzly feeder.

2. A jaw crusher performs primary reduction.

3. An intermediate screen or surge bin stabilizes the downstream flow.

4. A cone crusher performs secondary and, when required, tertiary crushing.

5. A vibrating screen controls the top size and returns oversize to the crusher.

6. Crushed ore transfers to a stockpile, bin or mill-feeding system.

Important project limits

• Gold, copper, iron or another metal name does not define one universal flowsheet

• Metal recovery must not be promised without mineralogical and laboratory testing

• Wet, sticky or clay-rich ore may require a dedicated feeding and screening approach

• Wear materials depend on ore abrasiveness and operating duty

• Final crushed size must be coordinated with the downstream mill

Applications

• Crushing stage for gold and silver ores

• Mill-feed preparation for copper and molybdenum ores

• Iron ore and other hard minerals

• Other ores supported by appropriate testwork

Information required for final engineering

Provide mineralogy, density, hardness and abrasiveness, moisture and clay content, feed grading and maximum lump size, required capacity and mill-feed size, downstream mill type and site plan. Qualified laboratory testwork is recommended.