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Given the continuous decline in mineral resource grades and the persistent rise in energy costs, concentrator plants urgently need to adopt refined cost management strategies to enhance market competitiveness. This paper synthesizes empirical case studies and technical standards from both domestic and international sources to systematically analyze the scientific principles and implementation pathways of three core strategies: stage-wise reagent dosing in flotation, equipment energy efficiency monitoring, and tailings recycling. The study aims to provide practical guidance for establishing a comprehensive, high-efficiency, and full-process cost control system.
Staged dosing is based on the interaction mechanism between reagent properties and flotation processes:
Low-solubility reagents (e.g., kerosene, diesel) are prone to entrainment in froth, requiring batch replenishment during roughing and scavenging stages to maintain effective pulp concentration.
Oxidation/degradation-sensitive reagents (e.g., sodium sulfide, xanthate) require multi-point dosing to avoid deactivation due to pulp oxidation.
Case Study: A coal preparation plant in Huaibei allocated 70% of the collector to the pulp pre-conditioner and 30% as gradient dosing across flotation cells, achieving:
0.2 kg/t reduction in oil consumption,
0.8% decrease in clean coal ash content,
Annual reagent cost savings exceeding ¥2 million.
The control core combines PLC with AI algorithms to dynamically adjust dosing (error ±1.5%) using real-time feedback on pulp pH, density, and flow rate.
Application: For fine-grained minerals (e.g., -20μm hematite), reagent utilization increased by 15–20%, with concentrate grade fluctuations reduced by 30%.
Typical Configuration:
Sensor Type | Control Parameter | Actuator |
Ultrasonic Flow Meter | Slurry Flow Rate | Variable Frequency Dosing Pump |
Online pH Meter | Slurry pH | Pneumatic Control Valve |
Froth Image Analyzer | Froth Layer Thickness/Stability | Reagent Spray Density |
Dosing Method | Reagent Cost per Ton (RMB) | Recovery Rate Increase (%) | Applicable Scenarios |
Bulk Dosing | 18–22 | 82–85 | Soluble/Stable Reagents (e.g., No. 2 Oil) |
Staged Dosing | 15–18 | 86–89 | Low-Solubility/Oxidation-Prone Reagents |
The monitoring framework complies with *GB/T 31960.1-2015 Technical Specifications for Electric Energy Efficiency Monitoring Systems*, establishing a multi-dimensional network covering:
Electricity (±0.5% accuracy),
Water consumption (±1.5%),
Thermal energy (±1°C).
Hidden Loss Identification: A copper concentrator identified excessive bearing friction in a ball mill via infrared thermography. No-load energy consumption accounted for 12% of total system usage, leading to annual electricity savings of 1.5 million kWh.
Equipment-Level: Replacing induction motors with permanent magnet synchronous motors reduced grinding system power consumption by 18%.
Process-Level: High-intensity magnetic pre-discarding increased waste rejection to 14.28%, saving 20 million kWh/year (listed in the National Industrial Energy-Saving Technology Catalog).
Management-Level: Linking “energy consumption per ton of ore” to team performance metrics cut energy costs by 20% over three years.
Perception Layer: Current sensors, ultrasonic flow meters, vibration monitors.
Transmission Layer: Real-time data upload via Industrial IoT (5G/OPC UA protocol).
Analytics Layer: AI algorithms establish equipment efficiency baselines for precise anomaly detection.
Application Layer: Generates efficiency reports and optimization recommendations integrated with production management systems.
Utilization Approach | Key Technology | Payback Period (Years) | Case Study Benefits |
Valuable Component Recovery | Combined Flotation Column + Gravity Separation | 2–4 | Yunnan lead-zinc tailings project recovers 2,200 t/y zinc concentrate (IRR 18%) |
Construction Material Production | Autoclaved Tailings Bricks (≥60% tailings content) | 3–5 | Anshan-Benxi iron mine produces 120 million bricks/year, saving 300,000 t clay |
Ecological Restoration | Substrate Improvement (pH adjustment + organic matter) | 5–8 | Dexing Copper Mine increased vegetation coverage from 15% to 75% |
Fine Particle Separation: Nanobubble flotation (bubble size <100 nm) improved recovery of -20μm minerals from 45% to 68% (Central South University data).
Construction Material Strength: Adding 3% silane coupling agent enhanced tailings concrete’s compressive strength to 35 MPa (Silicate Bulletin 2023).
Economic Viability: Applying the “Gold Reserve Model” to calculate marginal costs ensures project IRR ≥12% (may require government subsidies or carbon trading revenue).
Case Study: Comprehensive Process Transformation at a Luoyang Mining Operation
Intelligent Control: Digital twin technology achieved:
15% increase in ball mill throughput efficiency,
8% reduction in reagent consumption per unit.
Unmanned Transport: AGVs combined with rail-based ore bins reduced operational staff by 40%, saving ¥12 million annually in labor costs.
Quality Control: Online XRF analyzers maintained concentrate grade fluctuations within ±0.8 g/t, meeting premium smelting standards.
The integration of staged reagent dosing, energy efficiency monitoring, and tailings reutilization forms a robust framework for cost control in mineral processing plants. With the continued advancement of digital twins and AI decision systems, the industry is moving toward an intelligent era of “predict-optimize-self-heal” operations. This transformation not only enhances economic efficiency but also promotes sustainable, green, and low-carbon development in mineral processing.
Keywords: Cost Control, Mineral Processing, Staged Reagent Dosing, Energy Efficiency, Tailings Recycling, Digital Transformation
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