500 to 850 TPD Cu-Pb-Zn Polymetallic Ore Processing Plant Capacity Expansion Without Production Stoppage

Process Audit & Simulation

Conduct a full-process calibration and computer simulation of the existing 500 TPD line to precisely identify bottlenecks in crushing, grinding, flotation, and dewatering sections.

Grinding Circuit Upgrade

Install a higher-power or more efficient vertical mill/ball mill as a secondary grinding stage in the compact space next to the existing ball mill, forming a new closed circuit. Use precise piping cut-over plans to online transfer and balance the load between old and new systems, increasing capacity to ~650 TPD.

High-Efficiency Dewatering Equipment Replacement

Gradually replace original thickeners and filters with high-capacity, small-footpaste high-rate thickeners and high-pressure filter presses. Utilize short parallel operation windows for cut-over, ensuring final product handling meets 850 TPD requirements.

Construct Parallel Pre-treatment Module

First, construct a compact, modular “Fine Crushing-Screening-Buffering” unit in available space. This unit operates independently, processes part of the incremental feed, reduces load on the original primary-secondary crushing circuit, and paves the way for grinding capacity expansion.

Flotation Circuit Optimization

Replace existing flotation machine rotors & stators with high-efficiency models, and “embed” or “series-connect” new compact flotation columns or cells within the existing bank layout, significantly improving efficiency and volumetric capacity without a substantial footprint increase.

Plant-wide Automation & Slurry Flow Control

Install an integrated PLC/DCS control system with online analyzers. Use intelligent algorithms to optimize feed rates, slurry density, reagent dosage, and pump speeds in real-time, ensuring stable and balanced slurry flow throughout the expanded circuit for maximum and stable output.