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Jiaozuo Zhongxin Heavy Industrial Machinery Co.,Ltd.
Review turnkey mineral processing and gold recovery plant installations engineered by Zhongxin Heavy. Detailed case studies cover gold CIP/CIL cyanidation lines, copper ore flotation circuits, iron ore magnetic separation, and gravity concentration systems—complete with process flowsheets, equipment configurations, and verified mineral recovery rates.
Streamline your copper mining project with our turnkey 200 TPD Copper Ore Beneficiation Line in Peru. Designed and manufactured by Zhongxin Heavy Industrial, this complete EPC flotation plant integrates four-stage processing—crushing, wet ball grinding, differential froth flotation, and concentrate dewatering—engineered for high copper recovery (≥92%) and low operating costs.
To address the specific characteristics of Peru's copper mineral resources—predominantly porphyry and skarn-type copper deposits (such as chalcopyrite and bornite) with run-of-mine (ROM) grades of 0.4% - 2.0% Cu and associated gold, silver, or molybdenum—Zhongxin Heavy Industrial designed and delivered a complete copper flotation processing line with a daily throughput of 200 TPD.
The plant encompasses four core process stages: primary crushing, closed-circuit wet ball milling, differential flotation, and concentrate dewatering. Executed under an EPC (Engineering, Procurement, and Construction) turnkey model, Zhongxin provided a full-lifecycle service package ranging from preliminary ore beneficiation testing to equipment manufacturing, field installation, commissioning, and local operator training.
TECHNICAL PARAMETERS & METALLURGICAL BENCHMARKS
| Parameter | Value / Metric | Operational Remarks & Technical Standards |
| Daily Processing Capacity | 200 TPD | Based on run-of-mine (ROM) ore; 24h grinding + 10h crushing operation |
| Target Ore Type | Porphyry / Skarn Sulfide Copper Ore | Chalcopyrite & bornite (typical of Peruvian copper belts) |
| ROM Ore Grade | 0.4% - 2.0% Cu | Associated with Au / Ag / Mo |
| Feed Particle Size | 210 mm | Maximum feed size for primary jaw crusher |
| Grinding Fineness | -200 mesh (0.074mm) | Spiral classifier overflow fineness |
| Flotation Circuit Configuration | 1 Roughing, 2 Scavenging, 2 Cleaning | Middlings returned in a closed circuit |
| Flotation Recovery Rate | ≥92% (Sulfide Ore) / ≥ 85%(Oxide) | Optimized via targeted reagent regimes |
| Finished Concentrate Grade | 18% - 28% Cu | Meets international copper concentrate delivery standards |
| Concentrate Moisture Content | ≤ 12% | Final filter cake after disc vacuum filtration |
| Process Water Recovery Rate | ≥85% | Closed-loop circulation of thickener overflow and filtrate |
| Total Installed Power | 350kW | Includes all main, auxiliary, and pumping units |
| Plant Footprint | 1,200 m2 | Excluding ROM stockpile and tailings storage facility |
Four-Stage Process Flow Diagram
ROM Ore (≤210mm) ➔ Trough Feeder ➔ Primary Jaw Crusher ➔ Secondary Fine Jaw Crusher
➔ Vibrating Screen (20mm) ➔ Intermediate Bin ➔ Electromagnetic Feeder
➔ Wet Ball Mill ➔ Spiral Classifier (Overflow -200 mesh)
➔ Agitation Tank ➔ Flotation Circuit (1 Rougher, 2 Scavengers, 2 Cleaners)
➔ Center-Drive Thickener ➔ Disc Vacuum Filter ➔ Copper Concentrate Cake (≤12% Moisture)
1. Crushing & Screening Circuit
Process Flow: ROM Ore (≤210mm) ➔ Raw Ore Bin ➔ Trough Feeder ➔ Primary Jaw Crusher ➔ Fine Jaw Crusher ➔ Vibrating Screen (20mm) ➔ Intermediate Transfer Bin.
Operating Conditions: Operates 10 hours/day with a crushing throughput of 16 - 20 { t/h}. Oversize material (>20mm) is returned in a closed circuit to the fine jaw crusher. The crushing section operates independently, providing a buffer of qualified 0 - 20 mm}$ material for the grinding circuit.
2. Grinding & Classification Circuit
Process Flow: Intermediate Bin ➔ Vibrating Feeder ➔ Belt Conveyor ➔ Wet Ball Mill ➔ Spiral Classifier.
Operating Conditions: Operates 24 hours/day with a ball mill feed rate of 8 - 9 t/h. Classifier overflow particle size is controlled to -200 mesh (≤0.074mm). Coarse underflow returns to the ball mill for regrinding in a closed-circuit loop. Qualified slurry flows by gravity into the agitation tank.
3.Differential Flotation Circuit
Process Flow: -200 mesh Slurry ➔ Agitation Tank (Reagent Conditioning) ➔ Rougher Flotation ➔ Scavenger Flotation ➔ Cleaner Flotation.
Operating Conditions: Employs a standard flotation circuit comprising 1 roughing stage, 2 scavenging stages, and 2 cleaning stages. Collectors, frothers, and modifiers are added quantitatively from reagent tanks. Middlings (scavenger froth) are returned to the roughing stage in a closed circuit to ensure an overall copper recovery rate of ≥ 92%.
4.Concentrate Dewatering Circuit
Process Flow: Cleaner Copper Concentrate Froth ➔ Slurry Pump ➔ Thickener (Primary Thickening) ➔ Disc Vacuum Filter (Secondary Dewatering).
Operating Conditions: Produces a copper concentrate filter cake with a moisture content of ≤ 12%, suitable for direct packaging and transport. Thickener overflow and filter filtrate are recovered into the process water recycling tank, achieving a closed-loop water cycle complying with local environmental discharge standards in Peru.
Complete Equipment Configuration List
| Process Section | Equipment Name | Model / Specification | Qty | Core Technical Features |
| Crushing | Trough Feeder | Chute Feeder (≤210 mm) | 1 set | Evenly feeds raw ore into primary jaw crusher |
| Primary Jaw Crusher | PE Series (Feed≤ 210 mm, Output 30-60 mm) | 1 set | Primary coarse reduction for hard ROM ore | |
| Fine Jaw Crusher | PEX Series (Output ≤ 20mm) | 1 set | Secondary fine crushing to prepare ball mill feed | |
| Vibrating Screen | Single-Deck 20mm Mesh | 1 set | Screen classification;> 20 mm returned in closed circuit | |
| Grinding | Vibrating Feeder | Electromagnetic Type | 1 set | Quantitative feeding from intermediate bin |
| Wet Ball Mill | High-Capacity Wet Overflow Mill (8-9 t/h}) | 1 set | Wet grinding to -200 mesh (≤ 0.074mm) | |
| Spiral Classifier | Spiral Classifier (Overflow -200 mesh) | 1 set | Closed-circuit classification producing qualified slurry | |
| Flotation | Agitation Tank | Chemical Pulping / Mixing Tank | 2 sets | Thoroughly mixes slurry with flotation reagents |
| Flotation Machine | Rougher, Scavenger, & Cleaner Banks | 1 set | Selectively separates copper minerals from gangue | |
| Reagent Tank | Chemical Dosing Tank Skid | 1 set | Precise metering of collectors, frothers, and modifiers | |
| Slurry Pump | Heavy-Duty Slurry Pump | 2 sets | Efficient transport of slurry and concentrate froth | |
| Dewatering | Thickener | Center-Drive Thickener | 1 set | Single-stage thickening to increase slurry density |
| Disc Vacuum Filter | Disc Vacuum Filter Unit | 1 set |
Optimize your mineral beneficiation circuit with our high-recovery mineral processing equipment. We manufacture heavy-duty grinding ball mills, spiral classifiers, hydrocyclones, froth flotation machines, and magnetic separators designed for processing gold, copper, iron, and manganese ores. Engineered for continuous duty and maximum mineral extraction efficiency, our machinery ensures reduced wear, lower power consumption, and improved concentrate grades across all hard-rock mining operations.
Discover custom-engineered mineral processing lines and complete aggregate production plant solutions tailored to your capacity and ore characteristics. From turnkey gold ore processing plants (CIP/CIL & flotation) and copper extraction lines to high-capacity sand-making and aggregate crushing circuits, we provide end-to-end flowsheets—integrating crushing, wet grinding, classification, and slurry dewatering. Partner with us for optimized plant layout design, factory-direct equipment supply, and maximum ROI.
This section is designed to address the most pressing inquiries customers may have regarding the daily operation, maintenance, product advantages, and after-sales service of our cone crushers. Our aim is to help you gain a comprehensive understanding of our overall capabilities and enable you to make informed decisions for your projects.
Choosing Zhongxin genuine wear parts reduces downtime and significantly boosts your mining operation's ROI.
We help clients develop maintenance plans to solve issues before wear affects production.
We offer customized parts for materials like granite or gold ore, increasing wear resistance by 30%.
Leveraging our optimized supply chain, we promise the fastest delivery of parts to global sites.
