The Core Role of Crushing in Copper Ore Processing

17/10/2025

Copper ore, as a foundational material for electronics, renewable energy, and infrastructure, typically has a Mohs hardness of 6–7 and contains just 0.5–2% copper in its raw state. To extract valuable copper efficiently, the first critical step—crushing—must reduce large ore lumps (up to 1.5 meters in diameter) to uniform particles suitable for subsequent beneficiation. This process not only directly impacts grinding efficiency (accounting for 40–60% of total energy consumption) but also determines mineral liberation and final copper recovery rates.

Liming Heavy Industry, with three decades of expertise in mining equipment, has developed a mature three-stage closed-circuit crushing system tailored to copper ore's high hardness and abrasiveness. By integrating advanced 颚式，cone, and screening equipment, the company adheres to the "more crushing, less grinding" principle, which reduces energy consumption by 20–30% compared to traditional processes. This article focuses on Liming's core crushing equipment, process design, and on-site project outcomes, revealing its targeted solutions for copper ore processing challenges.

1. Three-Stage Closed-Circuit Crushing: The Optimal Process for Copper Ore

Copper ore's physical properties—high hardness, uneven composition, and tendency to produce fines—demand a systematic crushing approach. Liming's three-stage closed-circuit process (rough crushing → intermediate crushing → fine crushing + screening) ensures stable particle size distribution, minimizes over-crushing, and lays the groundwork for efficient downstream processing.

1.1 Process Flow and Design Logic

The process begins with rough crushing: Raw copper ore is fed into a jaw crusher via a vibrating feeder, reducing lumps from 1–1.5m to 100–200mm. This stage prioritizes handling capacity and equipment durability to withstand the impact of large ore blocks.

Next is intermediate crushing: Crushed material is screened, and oversize particles are sent to a single-cylinder hydraulic cone crusher, which further reduces the ore to 30–50mm. This step balances efficiency and particle shape, reducing wear on subsequent equipment.

The final fine crushing stage uses multi-cylinder hydraulic cone crushers to produce particles of 0–15mm (typically 0–12mm for grinding feed). A vibrating screen classifies the output; oversize material returns to the fine crusher, forming a closed circuit that guarantees consistent product granularity.

This design follows two core principles:

• Graded crushing: Matching equipment to ore size minimizes energy waste and equipment wear.

• Closed-circuit control: Real-time screening ensures no oversize material enters the grinding system, optimizing subsequent processing efficiency.

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2. Core Crushing Equipment for Copper Ore: Performance and Advantages

Liming's copper ore crushing equipment lineup is engineered for high hardness, continuous operation, and easy maintenance, with each model tailored to a specific crushing stage.

2.1 Rough Crushing: C6X Series Jaw Crusher – The "First Line of Defense"

The C6X series jaw crusher is Liming's flagship rough crushing equipment, designed to handle the largest and hardest copper ore lumps. Its key features include:

• Robust structural design: The detachable, weld-free frame uses high-strength steel, reducing transportation weight by 15% while improving structural rigidity. This design withstands the repeated impact of 1.2m-diameter ore blocks, ensuring 95%+ operational availability in harsh mining environments.

• Optimized crushing chamber: The deep, curved chamber adopts a "V-shaped" structure that increases the crushing ratio to 6:1–8:1, reducing the need for secondary crushing. In Xinjiang's copper mines, it consistently reduces 1m ore lumps to 150mm in one pass.

• Dual wedge adjustment system: Unlike traditional shim adjustment, this system allows quick discharge opening adjustments (from 10–100mm) without stopping production, adapting to varying ore hardness and downstream requirements.

• Integrated shock absorption: Elastic limit shock absorbers reduce vibration by 30%, protecting the foundation and extending equipment life by 20% compared to conventional jaw crushers.

Suitable for ores with compressive strength ≤300MPa, the C6X series is the primary choice for rough crushing in large-scale copper mines, with models ranging from C6X75 to C6X130, covering hourly capacities of 50–1,000 tons.

2.2 Intermediate Crushing: HST Single-Cylinder Hydraulic Cone Crusher – Efficiency Optimizer

For medium-hard to hard copper ore, the HST single-cylinder hydraulic cone crusher delivers high efficiency and easy maintenance, making it ideal for intermediate crushing. Its standout attributes include:

• Hydraulic integration technology: The integrated hydraulic system combines overload protection, discharge adjustment, and cavity clearing functions. If uncrushable debris (e.g., steel) enters the chamber, the system automatically lifts the mantle, 排出异物，and resumes operation—reducing downtime by 80% compared to spring cone crushers.

• High-capacity design: The large-diameter eccentric shaft and optimized stroke (16–30mm) increase throughput by 20–30% over similar models. In Guangdong's 8,000-ton-per-day (TPD) copper processing line, the HST160 model achieves 180–220t/h with stable discharge of 30–50mm.

• Intelligent control: Equipped with a PLC control system, it monitors load, temperature, and oil pressure in real-time. Operators can adjust parameters remotely, ensuring consistent output even as ore hardness fluctuates.

• Low maintenance cost: The integral frame and centralized lubrication system reduce maintenance time by 40%. Wear parts (concave and mantle) use high-chromium alloy, extending service life to 3–6 months in copper ore applications.

The HST series covers capacities of 50–600t/h, with discharge sizes adjustable from 10–60mm, making it versatile for both intermediate crushing and fine crushing in small-to-medium mines.

2.3 Fine Crushing: HPT Multi-Cylinder Hydraulic Cone Crusher – Particle Shape Specialist

Fine crushing directly determines the quality of grinding feed, and the HPT multi-cylinder hydraulic cone crusher excels at producing cubical particles with minimal fines. Its key advantages include:

• Layered crushing technology: The unique crushing chamber curve enables "layer-by-layer compression" of ore, reducing fines content by 15% and improving particle shape (cubicity ≥90%). This enhances mineral liberation in subsequent grinding, boosting copper recovery rates by 3–5%.

• Multi-cylinder hydraulic system: Six symmetrically arranged hydraulic cylinders provide uniform crushing force, increasing capacity by 10–20% compared to single-cylinder models. In Xinjiang's copper project, two HPT300F units achieve a combined capacity of 200–250t/h with discharge size ≤15mm.

• Intelligent load adaptation: The automatic control system adjusts the crushing force based on ore feed rate, maintaining optimal load (80–90% of rated capacity) and reducing energy consumption by 25% per ton of ore.

• Wear-resistant optimization: The concave and mantle use gradient wear-resistant materials, with the upper section (high impact) using high-tungsten alloy and the lower section (high abrasion) using high-chromium alloy—extending overall service life by 25%.

The HPT series offers models from HPT200 to HPT800, with capacities of 100–2,000t/h, catering to large-scale copper mines requiring high-quality, fine-grained feed.

2.4 Supporting Equipment: YZS Series Vibrating Screen – Quality Control Core

Vibrating screens are critical to closed-circuit crushing, and Liming's YZS series ensures precise classification with:

• High-frequency vibration system: The 1,600rpm vibration motor achieves classification efficiency ≥90%, accurately separating oversize material (returned to crushers) from qualified particles. In the Xinjiang project, two YZS2160 screens handle 250t/h of material with a screening accuracy of ±2mm.

• Adjustable amplitude: The eccentric block design allows amplitude adjustment (4–8mm) to adapt to different ore moisture contents (up to 10%), preventing screen blockage.

• Durable structure: The polyurethane screen mesh has 3–5 times longer service life than steel mesh, while the sealed frame reduces dust leakage, meeting environmental standards.

3. Project Case Studies: Liming's Crushing Solutions in Action

Liming's copper ore crushing systems have been validated in projects across China, demonstrating adaptability to diverse geological conditions and production scales.

3.1 Xinjiang Hami High-Hardness Copper Ore Project

Project Background

A mining enterprise in Xinjiang Hami developed a porphyry copper deposit with high hardness (Mohs 7) and abrasive gangue. The client required a crushing line with:

• 200–250t/h throughput

• Discharge size ≤15mm (for subsequent grinding)

• 95%+ operational availability in desert conditions

Equipment Configuration

Liming's engineering team designed a three-stage closed-circuit system:

• Rough crushing: PE750×1060 jaw crusher (upgraded predecessor of C6X series)

• Intermediate crushing: HPT300C multi-cylinder hydraulic cone crusher

• Fine crushing: 2×HPT300F multi-cylinder hydraulic cone crushers

• Screening: 2×YZS2160 vibrating screens

Project Outcomes

Since commissioning in 2024, the line has achieved:

• Stable daily output of 5,000 tons, meeting the client's annual target of 1.5 million tons

• Discharge size with 90% passing 12mm, reducing grinding energy consumption by 22%

• 96% equipment availability over six months of continuous operation

• Wear part replacement cycle of 4 months, 30% longer than the client's previous equipment

"The equipment handles our hard ore effortlessly, and the closed-circuit design ensures consistent feed for grinding," noted the mine's operations director. "Liming's after-sales team also provided on-site training, helping our staff master maintenance skills quickly."

3.2 Guangdong Jiangmen 8,000 TPD Copper Processing Line

Project Background

A smelter in Guangdong needed to expand its crushing capacity to support an 8,000 TPD copper ore processing system, with requirements for:

• Energy efficiency (complying with China's "double carbon" standards)

• Fast equipment adjustment to handle varying ore grades

• Low dust emissions (<15mg/m³)

Equipment Configuration

Liming deployed a high-efficiency crushing line:

• Rough crushing: C6X110 jaw crusher

• Intermediate crushing: HST250 single-cylinder hydraulic cone crusher

• Fine crushing: 3×HPT500 multi-cylinder hydraulic cone crushers

• Screening: 3×YZS2470 vibrating screens + pulse dust collectors

Project Outcomes

• Throughput reached 8,200 TPD, exceeding the client's target

• Energy consumption per ton of ore reduced by 25% compared to the old line

• Dust emissions controlled at 12mg/m³, meeting national environmental standards

• The HST and HPT crushers' hydraulic adjustment system allowed parameter changes in 10 minutes, adapting to ore grade fluctuations

3.3 Inner Mongolia Low-Grade Copper Ore Project

Project Background

A mine in Inner Mongolia processed low-grade copper ore (0.5–0.8% copper) requiring strict particle size control to maximize recovery. The key demands were:

• Fine discharge size (0–10mm)

• Minimal fines generation (to avoid copper loss)

• Low operational costs

Equipment Configuration

• Rough crushing: C6X90 jaw crusher

• Intermediate crushing: HST160 single-cylinder hydraulic cone crusher

• Fine crushing: 2×HPT300F multi-cylinder hydraulic cone crushers (with fine crushing chambers)

• Screening: 2×YZS2160 vibrating screens (double-layer, for precise classification)

Project Outcomes

• 85% of output achieved 0–10mm, with fines content <8%

• Subsequent flotation recovery rate increased by 4% due to improved mineral liberation

• Annual operational costs reduced by 18% via energy savings and long-wearing parts

4. Technological Advantages of Liming's Crushing Solutions

Beyond individual equipment performance, Liming's crushing systems stand out for integrated advantages that solve core industry pain points.

4.1 Adherence to "More Crushing, Less Grinding"

By optimizing the three-stage process and equipment matching, Liming reduces the average particle size of grinding feed from 20mm (traditional) to 10–12mm. This decreases grinding time by 20–30% and lowers energy consumption by 15–25kWh per ton of ore—critical for mines facing rising energy costs.

4.2 Intelligent and Adaptive Operation

All core crushers integrate PLC control systems with the following capabilities:

• Real-time monitoring of load, temperature, and vibration

• Predictive maintenance alerts (e.g., bearing wear, oil contamination)

• Automatic adjustment of discharge size and crushing force based on ore properties

In large mines, these systems connect to a central control room, enabling remote operation and data analysis—reducing on-site labor by 30%.

4.3 Environmental and Economic Balance

Liming's crushing solutions address environmental compliance without sacrificing efficiency:

• Sealed equipment covers + pulse dust collectors reduce emissions to <15mg/m³

• Hydraulic systems eliminate spring fatigue and oil leakage, reducing waste

• Wear parts use recyclable alloys, lowering disposal costs

The total cost of ownership (TCO) is 15–20% lower than imported equipment, with faster delivery (3–6 months) and local after-sales support (spare parts delivered within 72 hours in China).

4.4 Customization for Diverse Conditions

Liming's engineering team conducts on-site geological surveys to tailor solutions:

• For high-altitude mines (e.g., Tibet): Equipment modified for low oxygen and extreme temperatures

• For remote mines (e.g., western China): Mobile crushing stations (integrating C6X jaw crusher + HST cone crusher) for flexible deployment

• For small mines: Compact lines with fewer equipment units to reduce initial investment

5. Conclusion

In copper ore processing, crushing is the foundation of efficiency, and Liming Heavy Industry has established itself as a leader through its three-stage closed-circuit system and specialized equipment. The C6X jaw crusher, HST single-cylinder cone crusher, and HPT multi-cylinder cone crusher form a synergistic lineup that handles high hardness, ensures particle quality, and reduces energy consumption.

From Xinjiang's desert mines to Guangdong's industrial hubs, Liming's projects demonstrate that its solutions are not just equipment combinations but integrated systems tailored to specific needs. By adhering to "more crushing, less grinding," integrating intelligence, and balancing environmental performance with cost-effectiveness, Liming provides mining enterprises with reliable tools to improve productivity and profitability.

As copper demand grows and ore grades decline, Liming's focus on crushing technology innovation will remain pivotal in driving the industry toward more efficient, sustainable processing.

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