NEWS

LATEST Copper Ore Crushing & Beneficiation: Complete Process, Equipment Selection and Performance Optimization

Copper ore is one of the most valuable and widely used metal mineral resources in the world. From electrical engineering and new energy storage to mechanical manufacturing and infrastructure, copper is essential due to its excellent electrical conductivity, thermal conductivity and mechanical properties. However, behind high-performance copper products lies a rigorous beneficiation process, in which crushing and grinding account for the highest energy consumption and determine the final recovery rate of copper concentrate.

This article provides a professional and SEO-friendly overview of copper ore crushing technology, including ore characteristics, process design, equipment selection and key optimization strategies for efficient plant operation.


1. Understanding Copper Ore: The Foundation of Crushing Design

Different types of copper ore show huge variations in hardness, abrasiveness and liberation size. Understanding ore properties is the starting point for selecting suitable crushing equipment.

Common copper ore types:

  • Porphyry copper ore – medium hardness, stable structure, high processing capacity required.

  • Sandstone copper ore – brittle, easier to crush, suitable for simplified circuits.

  • Sulfide copper ore (chalcopyrite, bornite, chalcocite) – high hardness and abrasiveness, requiring wear-resistant liners.

  • Oxide copper ore – softer, less abrasive, but requires precise particle size control to improve leaching or flotation efficiency.

Liberation size (0.074–0.2 mm) is a key parameter determining how fine the ore needs to be crushed before grinding.


2. Typical Crushing Process for Copper Ore

To achieve an optimal feed size for the grinding mill (usually ≤10–12 mm), a multi-stage crushing system is typically used.

(1) Three-stage closed-circuit crushing (used in medium & large copper mines)

Jaw Crusher → Cone Crusher (Secondary) → Cone Crusher (Fine) + Vibrating Screen

Advantages:
✔ Stable particle size
✔ Low over-crushing ratio
✔ High production capacity
✔ Lower energy cost for grinding

This is the mainstream solution for porphyry copper deposits in countries like Chile, Peru and Indonesia.

(2) Two-stage crushing (for soft ore or small-scale mines)

Jaw Crusher → Cone Crusher + Screen

Advantages:
✔ Reduced investment
✔ Simple layout
✔ Fast construction period


3. Equipment Selection: Key Factors for Copper Ore Crushing

❶ Jaw Crusher (Primary Crushing)

  • Designed for large feed sizes (≤900 mm)

  • High crushing ratio

  • Strong resistance to impact load

  • Options for heavy-duty frames and Mn18/Mn22 liners to resist abrasion

❷ Cone Crusher (Secondary & Fine Crushing)

Cone crushers are the core equipment for copper ore processing.

Types include:

  • Multi-cylinder hydraulic cone crusher – High capacity, laminated crushing, ideal for hard sulfide ore

  • Single-cylinder hydraulic cone crusher – Precise CSS control, best for stable fine crushing circuits

  • Gyratory crusher – Suitable for ultra-large processing lines

Key considerations:

  • Crushing cavity type (medium, fine, super-fine)

  • Liner material (Mn18Cr2 / Mn22Cr2)

  • Hydraulic protection & automatic control

  • Compatibility with closed-circuit screening

❸ Vibrating Screen & Feeder Systems

A high-efficiency screening system ensures stable particle size control and protects the grinding mill from overload.


4. Why Crushing Matters: Reducing Energy Consumption in Grinding

Crushing and grinding together account for 40–55% of the entire beneficiation energy consumption.
Among them, grinding consumes the most power.

Optimized crushing = lower cost per ton.

Benefits of achieving finer, uniform crushing:
✔ Reduced grinding load
✔ Lower kWh/t consumption
✔ Higher copper recovery due to improved liberation
✔ Increased plant throughput

This is especially critical for low-grade copper ore (<0.5% Cu).


5. Common Processing Challenges & Solutions

① Excessive liner wear

Solution:

  • Use high-Mn alloy liners

  • Adopt laminated crushing cone design

  • Pre-screening to remove fines

② Over-crushing creating excess fines

Solution:

  • Real-time CSS adjustment

  • Replace coarse cavity with fine cavity

  • Optimize feed distribution

③ Wet sticky ore causing blockages

Solution:

  • Use bar-type vibrating feeder

  • Increase pre-screening efficiency

  • Apply anti-clogging chute design


6. Intelligent Control in Modern Copper Mines

Digitalization and automation are the main trends in copper beneficiation plants.

Smart features include:

  • Real-time monitoring of pressure, power and chamber load

  • Automatic CSS control for stable product size

  • AI-driven optimization for crushing–grinding integration

  • Predictive maintenance for liners and bearings

This helps achieve higher uptime (≥95%) and lower operational cost.


Copper ore beneficiation is a highly technical process, and crushing plays a decisive role in energy consumption, product size, and final recovery rate. Through proper process design, equipment selection and intelligent optimization, mining enterprises can achieve:

  • Higher ore processing capacity

  • Lower unit energy cost

  • Better grinding efficiency

  • Higher copper concentrate recovery

  • Safer and more stable production


Previous News

15/5/2024

15/5/2024

Differences Between CIL and CIP Gold Extraction

Carbon In Leach (CIL) and Carbon In Pulp (CIP) are two commonly used methods in the gold extraction process. Although both methods involve the use of activated carbon to adsorb gold, there are significant differences in their operation processes, equipment layout, and application conditions. This article will explore the differences between CIL and CIP, highlighting their respective advantages, disadvantages.

240515.jpg

1. Basic Principles

1.1 Carbon In Leach (CIL)

The Carbon In Leach (CIL) process involves adding activated carbon directly into the leaching tanks where both leaching and adsorption occur simultaneously. The CIL process includes the following steps:

  • Crushing and grinding the gold ore into a pulp.

  • Mixing the pulp with sodium cyanide solution to dissolve the gold into a cyanide complex.

  • Adding activated carbon to the pulp during the leaching process, where the activated carbon adsorbs the dissolved gold.

  • After leaching and adsorption, the pulp undergoes solid-liquid separation to recover the gold-laden activated carbon.

  • The gold-laden activated carbon undergoes desorption and electrolysis to recover the gold.

1.2 Carbon In Pulp (CIP)

  • The Carbon In Pulp (CIP) process differs primarily in the timing of adding activated carbon. The CIP process includes:

  • Crushing and grinding the gold ore into a pulp.

  • Mixing the pulp with sodium cyanide solution to dissolve the gold into a cyanide complex.

  • After leaching, transferring the pulp to a series of adsorption tanks where activated carbon is sequentially added to adsorb the dissolved gold.

  • After adsorption, the pulp undergoes solid-liquid separation to recover the gold-laden activated carbon.

  • The gold-laden activated carbon undergoes desorption and electrolysis to recover the gold.

2. Main Differences

2.1 Process Differences

Simultaneous Leaching and Adsorption: In CIL, leaching and adsorption occur simultaneously in the same step, whereas in CIP, leaching occurs first, followed by adsorption.

Process Complexity: CIP has a relatively simpler process because leaching and adsorption are separate steps. CIL requires more precise control of process parameters as leaching and adsorption occur concurrently, making it more complex to operate.

2.2 Equipment Configuration

CIL: Since leaching and adsorption occur in the same tank, CIL requires fewer tanks, but each tank is larger and more complex in design.

CIP: CIP requires separate leaching and adsorption tanks. Although there are more tanks, each tank is simpler in design and offers greater operational flexibility.

2.3 Gold Ore Characteristics

Ore Type Suitability: CIL is more suitable for low-grade, high-clay-content ores as these ores can clog the leaching tanks during processing. CIL’s design can better handle this issue. CIP is more suitable for high-grade, uniformly sized ores.

Pulp Handling Capacity: CIL requires stricter control over pulp concentration and particle size, while CIP is relatively more forgiving.

3. Advantages and Disadvantages

3.1 CIL Advantages and Disadvantages

Advantages:

Simultaneous leaching and adsorption result in a shorter process with faster reaction times.

Better suited for high-clay-content ores.

Disadvantages:

Requires precise control of leaching and adsorption process parameters, making it complex to operate.

Higher initial investment due to more demanding equipment and process design.

3.2 CIP Advantages and Disadvantages

Advantages:

Simple process with high operational flexibility.

Adsorption tanks can be used in series, improving adsorption efficiency.

Suitable for high-grade gold ores with simpler process control.

Disadvantages:

Requires separate leaching and adsorption tanks, occupying more space.

Less effective for high-clay-content ores.


The determination of the gold ore extraction process requires strict extraction tests and is determined by professionals. If you have any gold ore extraction needs, please leave a message below, one engineer from our team will contact you shortly.




2/5/2024

2/5/2024

New C6X series jaw crusher machine for sale in South Africa

Hot C6X series jaw crusher coming!We have a big discount in south aferica. Check the machine data below.


Features:

 Detachable and non-welded structure rack: The rack adopts separate design of side walls, front and rear walls, and is bolted and fixed.

 Replace the welding frame to avoid welding defects;

 Integrated motor base: saves about 15% of installation space; separate design

 Optimize the crushing chamber structure: the actual feed size increases and the crushing efficiency improves;

 Elastic limit shock absorbing device.

 image.png

Single unit output:

 The production capacity of a single machine varies depending on the machine model, with a minimum output of 80-290 t/h and a maximum output of 610-1510 t/h.

 500tph river stone EPC crushing project in Lhasa, China

 

Application: commercial concrete mixing station

Processed material: river stone            Capacity: 500T/H

Output size: 0-5mm, 5-13mm, 13-25mm, 25-31.5mm

Equipment: F5X1860 vibrating feeder, C6X145 jaw crusher, 2 sets of HST315 cone crusher, 2YK3X3075 vibrating screen, S5X2760-2 vibrating screen, 3 sets of S5X2760-3 vibrating screen, VSI6X1263 sand making machine, 2 sets of TX-36-45 fine sand recovery device, sewage system, 2 sets of dust collector


Get the favourable prices by leaving your requirements at the bottom of the site or online Chat.


25/4/2024

25/4/2024

The difference between NK and MK series portable crushing plant

The mobile crusher can be put into production in a short time, and the production line is more integrated when the space is limited. You can also flexibly change production sites.

The followings are two types of mobile crushers that we supply.

image.pngimage.png
NK Mobile CrusherMK Mobile Crusher

1. The frames are different.

2. The electrical control cabinet is different.

3. The configuration plans are different. NK focuses on small and medium-sized production lines (100-500 t/h), while MK focuses on medium and large-sized production lines (up to 800 t/h).

4. The finished belt configurations are different.


Leave your message below for the technical data and quotes!

24/4/2024

24/4/2024

Liming Showcase Innovations at MiningWorld Russia 2024

MiningWorld Russia is an internationally recognized exhibition dedicated to the mining and extractive industries. As a business platform, the exhibition brings together equipment and technology manufacturers with buyers from Russian mining companies, mineral processors and wholesalers interested in purchasing the latest solutions for the mining industry.

 01.jpg

Liming will take part in the MiningWorld Russia 2024 exhibition with our newest stone crushers and mills. Welcome to our booth to find out more details!


Date: April 23-25, 2024

Booth No.: C1009

Venue: Crocus Expo IEC, Pavilion 1, Hall 3, Moscow


12/3/2024

12/3/2024

With New Investment, Iron Ore Processing Project Marks a Breakthrough

Recently, it has been reported that Guinea's Simandou iron ore project has successfully secured a $15 billion financing, sparking widespread attention in the global mining industry. As manufacturers of iron ore processing equipment, we are filled with confidence and see tremendous development opportunities in this.

The Simandou iron ore project has long been under the spotlight due to its abundant resource reserves and potential development value. The successful financing of this project will inject new momentum into the mining industry in Guinea and the entire region. As suppliers of processing equipment, we will actively participate, providing high-quality processing equipment and comprehensive technical support to the project.

1-230GG6092Y06.jpg

The arrival of this investment signifies a new round of development opportunities for the iron ore processing industry. We will increase research and development investment, continuously improve the intelligence and automation level of equipment to meet the project's demand for efficient production and energy conservation. Additionally, we will enhance cooperation with the project stakeholders, offering customized solutions to tailor the most suitable production line, maximizing the value of resources.

The vigorous development of the iron ore processing project will drive the prosperity of the entire industry chain. Besides equipment provision, we will also actively engage in technical training and after-sales services, assisting the project stakeholders in enhancing production efficiency, reducing operating costs, and achieving sustainable development.

As manufacturers of iron ore processing equipment, we will continue to keep pace with the project's development, innovate continuously, and provide customers with higher-quality products and services, jointly creating a bright future for the iron ore processing industry.

ore-b-2.jpg




29/3/2023

29/3/2023

Heap leaching gold extraction process

[Process introduction] : Gold heap leaching process is to break low-grade gold ore to a certain particle size (or granulation), pile it on a leakproof bottom mat made of asphalt, concrete or plastic materials, spray with low-concentration cyanide, alkaline solution, non-toxic solvent or dilute sulfuric acid and other solutions on the mine heap to dissolve gold, and the gold-containing solution percolates out from the mine heap. Then the gold is recovered by activated carbon adsorption or zinc powder replacement precipitation.

1-230GG60T4X9.jpg

[Application field] : Gold heap leaching is often used to develop small ore bodies or low-grade gold deposits, or both, and cannot be exploited by conventional methods.

ore-b-l.jpg


18/3/2024

18/3/2024

Explore crushing and milling Opportunities at Our Booth - Spring Canton Fair Invitation

Dear customers,


We are thrilled to extend a cordial invitation to you and your esteemed team to visit our booth at the upcoming Spring Canton Fair, scheduled to commence in mid-April.

As one of the premier events in the realm of international trade, the Spring Canton Fair provides a dynamic platform for businesses to showcase their products, foster connections, and explore new opportunities. We are excited to be part of this prestigious event, and we would be honored to have you join us.

We will bring our new crushing and grinding machine with us there. Our team of experts will be on hand to provide insights, answer queries, and discuss potential collaborations. Whether you are interested in exploring new business opportunities, learning about our latest offerings, or simply networking with industry peers, we guarantee a valuable and enriching experience.

Here are the details of our booth:

Booth Number: Processing machinery and equipment exhibition area, exhibition hall 20.1, booth number K07

Location:  No. 382, Yuejiang Middle Road, Haizhu District, Guangzhou, China

Time :April 15-19, 2024

20240320145809.png

To ensure that we can provie you with personalized attention during your visit, we encourage you to schedule a meeting with us in advance. Please feel free to contact online help to arrange a convenient time.


We genuinely look forward to welcoming you to our booth and engaging in meaningful discussions that can pave the way for mutually beneficial partnerships and collaborations.We eagerly anticipate the opportunity to connect with you at the Spring Canton Fair.


Warm regards,

Liming Team

7/3/2024

7/3/2024

1200 tons of Henan's new green building materials production line

The project covers an area of 840 acres, has an ore reserve of more than 50 million tons, and a designed annual output of 5 million tons.

image.png

Processing materials: granite

Production capacity: 1200T/H

Finished product particle size: 0-5mm, 5-10mm

                 10-16mm, 16-33mm

Equipment configuration: 2 C6X jaw crushers

                 2 HST single-cylinder hydraulic cone crushers

                 4 HPT hydraulic cone crushers

                 12 sets of S5X series circular vibrating screens

The EPC project team is deeply involved in the management of the project construction process throughout the entire process, and strictly implements scientific measures of mining and greening at the same time. The entire production line meets the requirements for modular, industrialized, park-based, intelligent, and green production.


  • Home
  • Prev
  • ···678910···
  • Last
Clicky