Application Scheme of Decanter Centrifuges in Copper Ore Dewatering Process
This document systematically sorts out the application scheme of decanter centrifuges in the copper ore dewatering process, covering process positioning, core model selection, performance parameters, application advantages and on-site precautions. It is suitable for technical scheme compilation, customer communication and equipment model selection reference.
I. Process Positioning and Application Scenarios
Copper ore dewatering is a core link in hydrometallurgical plants/copper concentrators. Decanter centrifuges are mainly used for solid-liquid separation and filter cake dewatering of ore pulp, with the core application scenarios as follows:
Flotation Tailings Dewatering: Treating tailings pulp after flotation, separating the aqueous phase for recycling, and reducing the moisture content of the solid phase (filter cake) to meet the requirements for transportation and stockpiling.
Leaching Residue Dewatering: Handling slag after heap leaching/agitation leaching, recovering residual leachate from the slag, and reducing the cost of subsequent environmental treatment.
Concentrate Thickening and Dewatering: Performing deep dewatering on copper concentrate pulp to meet the moisture content standards for concentrate drying, transportation or smelting (the filter cake moisture content is generally required to be 10%–18%).
Wastewater Treatment Sludge Dewatering: Dealing with biochemical/physicochemical sludge from mineral processing wastewater/heavy metal-containing wastewater to achieve sludge reduction.
II. Core Working Principle
Through centrifugal force generated by high-speed rotation, decanter centrifuges make solid particles (copper minerals and gangue) in the ore pulp rapidly settle on the inner wall of the drum. The differential speed between the screw conveyor and the drum continuously pushes the solid phase to the conical end of the drum for discharge (forming a dewatered filter cake); the liquid phase is discharged through the overflow port at the large end of the drum, realizing solid-liquid separation and dewatering.
For copper ore pulp with high specific gravity and strong abrasiveness, decanter centrifuges with large length-diameter ratio and wear-resistant materials are usually adopted, equipped with a differential speed control system to precisely adjust the pushing speed, ensuring dewatering efficiency and equipment service life.
III. Key Selection Parameters and Recommended Configuration (Special for Copper Ore Dewatering)
| Parameter Item | Recommended Configuration | Remarks |
| Processing Capacity | Adjusted according to pulp concentration, usually 20–80 m³/h per unit; multiple units can be operated in parallel for large-scale copper mines (e.g., cluster configuration of 37 units) | Optimal processing capacity is achieved when pulp concentration is 30%–40% |
| Drum Length-Diameter Ratio | ≥4.0 (e.g., 4.2, 4.5) | The larger the length-diameter ratio, the longer the residence time and the better the dewatering effect |
| Material Selection | Drum/screw: Duplex stainless steel 2205/2507 or tungsten carbide wear-resistant coating; Shell: SS316L; Seals: Pulp-resistant and acid-resistant materials (e.g., nitrile rubber, fluororubber) | Copper ore pulp contains abrasive particles and acidic media, so wear resistance and corrosion resistance must be enhanced |
| Differential Speed Control System | Variable frequency speed-regulating differential (e.g., planetary gear differential), with adjustable differential speed range of 0–30 rpm | Adapt to different pulp concentrations and particle size distributions, ensuring uniform discharge of filter cake |
| Dewatering Index | Filter cake moisture content: 12%–18% (concentrate), 18%–25% (tailings); Liquid clarity: SS ≤ 100 mg/L | Can be optimized by adjusting rotating speed, differential speed and feed concentration |
| Explosion-Proof/Protection Grade | ATEX/IECEx Zone 2 (if flammable and explosive media are involved), IP54/IP55 protection | Dust and rain protection are required for outdoor concentrators |
IV. Application Advantages
Continuous Operation with Large Processing Capacity: 24/7 uninterrupted operation, with a single-unit processing capacity far exceeding that of plate-and-frame filter presses and belt filter presses, suitable for large-scale production in large copper mines.
High Degree of Automation: Realizing full automatic control of feeding, rotating speed, differential speed and slag discharge, reducing manual intervention and operation costs.
Excellent Dewatering Effect with Recyclable Filtrate: Low moisture content of filter cake, facilitating transportation and stockpiling; high clarity of filtrate, which can be directly reused in the mineral processing process to realize water resource recycling.
Small Floor Area: Compared with traditional filter press equipment, it occupies a smaller floor area under the same processing capacity, suitable for site optimization of concentrators.
Wide Adaptability: Capable of handling copper ore pulp with different concentrations (10%–45%) and particle sizes (0.01–1 mm), with strong adaptability to pulp fluctuations.
V. On-Site Application Precautions
Pulp Pretreatment:
Before feeding, large-particle impurities (e.g., stones larger than 5 mm) should be removed through grids/ hydrocyclones to avoid damaging the screw conveyor and drum.
If the pulp has high viscosity (e.g., containing clay minerals), a small amount of flocculant (e.g., polyacrylamide PAM) can be added to improve sedimentation efficiency and dewatering effect.
Equipment Operation and Maintenance:
Regularly inspect the wear condition of wear-resistant coatings/liners and replace them in a timely manner.
Regularly replace lubricating oil and seals to avoid liquid leakage and equipment failure.
Establish an equipment operation record, recording parameters such as feed concentration, rotating speed, differential speed and filter cake moisture content to facilitate process optimization.
Environmental Protection and Safety:
The filtrate must be tested to meet the standard before reuse or discharge to avoid heavy metal pollution.
Noise reduction and vibration prevention measures should be taken during equipment operation, and operators must wear protective equipment.
If toxic media such as cyanide are treated, corresponding safety protection and emergency treatment facilities must be equipped.
VI. Typical Case Reference
A copper ore enterprise in the Netherlands adopted 37 large length-diameter ratio decanter centrifuges (made of duplex stainless steel, with a processing capacity of 50 m³/h per unit) for flotation tailings dewatering. The moisture content of the filter cake was stably maintained at 16%–18%, and the filtrate reuse rate reached 95%, which significantly reduced water resource consumption and tailings transportation costs.
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