Flow Diagram and Process Optimization of Copper Cone Crusher Systems
- Introduction to Copper Ore Comminution
Copper beneficiation requires precise size reduction to achieve optimal mineral liberation. Cone crushers serve as critical secondary/tertiary crushing units, processing 10–250mm feed into 5–20mm particles suitable for downstream grinding/flotation. This analysis details system architectures, component interactions, and efficiency benchmarks.
- Standard Flow Diagram Configurations
2.1 Three-Stage Crushing Circuit
Figure 1: Typical copper ore processing flow with cone crushers
ROM Ore → Grizzly Screen → Primary Jaw Crusher (150→200mm) → Secondary Cone Crusher (200→50mm) →
Tertiary Cone Crusher (50→10mm) → Vibrating Screen → Oversize Recirculation / Undersize to Ball Mills
Key Components:
Pre-Screening: Grizzly screens remove fines (<30mm) to reduce crusher load
Cone Crusher Types:
Secondary: Hydraulic models (e.g., Nordberg HP300) for coarse reduction
Tertiary: Multi-cylinder designs (e.g., Sandvik CH890) for precise shape control
Closed-Loop Control: PLC systems adjust crusher gaps based on real-time power draw
- Advanced System Designs
3.1 Hybrid HPGR-Cone Crusher Circuits
Modern plants integrate High-Pressure Grinding Rolls (HPGR) with cone crushers to:
Reduce energy consumption by 15–25%
Generate micro-cracks in ore for improved leaching efficiency
Flow Example:
HPGR → Wet Screening → Cone Crusher (Closed Side Setting: 12mm) → Cyclone Classification
3.2 Mobile Crushing Units
Modular cone crushers (e.g., Metso Lokotrack LT300HP) enable:
Rapid deployment in satellite deposits
Feed flexibility (50–300 tph capacity)
- Operational Parameters
StageFeed Size (mm)CSS (mm)Power (kW)Product P80 (mm)Secondary200–5025–40250–40030–50Tertiary50–208–15150–3005–15
Critical Settings:
Eccentric Throw: 30–50mm for coarse crushing
Crushing Chamber: Steep-head designs (e.g., Symons 7’) for finer outputs
- Case Study: Chilean Copper Plant
A Codelco operation achieved 23% throughput increase by:
Replacing tertiary screens with Derrick Stack Sizer for fines removal
Implementing AI-based gap control (RockSense system)
Switching to ceramic-lined mantles (wear life extended by 40%)
- Maintenance and Safety
Wear Monitoring: Laser profiling of mantles/concaves every 500h
Dust Control: Dry fog systems at transfer points (OSHA PEL compliance)
Emergency Protocols: Hydraulic tramp release activates at >10% overload
- Future Trends
Digital Twins: Real-time simulation of crusher performance
Bio-Lubricants: Soybean-based hydraulic fluids for sustainability
Ore-Sorting Integration: XRT sensors pre-concentrate feed to reduce crusher load