A copper ore crushing and screening plant is a large-scale industrial facility that processes raw copper ore extracted from nature to make it suitable for metal production. Copper ore is naturally found in large, irregular rock formations containing impurities such as soil and unwanted minerals. For efficient processing and refining, the ore must go through several stages to reach the required size and purity levels.

Copper ore crushing and screening plants mechanically crush and screen the ore into specific particle sizes. Additionally, various separation methods such as magnetic separation and flotation are used to remove impurities. The final result is high-quality copper concentrate, which is used in metallurgical plants.

Working Principle of a Copper Ore Crushing and Screening Plant

1. Raw Material Feeding
  • Copper ore is transported from mining sites to the facility using large trucks or conveyor belts.
  • It is fed into a bunker, where vibrating feeders regulate the flow into crushers.
2. Pre-Screening and Impurity Removal
  • Vibrating screens separate large stones, soil, and unwanted minerals.
  • Magnetic separators remove low-metal content materials and non-magnetic impurities.
3. Primary Crushing
  • Large copper ore pieces are broken down using jaw crushers or impact crushers into smaller fragments.
4. Secondary and Tertiary Crushing
  • Further crushing is done using cone crushers to achieve the desired particle size.
5. Screening and Sizing
  • Vibrating screens classify crushed copper ore into different size fractions such as 0-10 mm, 10-30 mm, and 30-60 mm.
6. Ore Enrichment (Flotation and Magnetic Separation)
  • In flotation tanks, copper minerals are extracted using chemicals, separating them from unwanted materials.
7. Storage and Transportation
  • Processed copper ore is stored and transported to steel plants or refineries via trains, trucks, or ships.