Research and Industrial Application of Lead-Zinc Ore Beneficiation Technology

Lead-zinc ore, as a crucial source of non-ferrous metals, plays a vital role in modern industries due to its extensive applications in batteries, alloys, and corrosion-resistant materials. However, the beneficiation of lead-zinc ores presents significant challenges, including mineralogical complexity, fine-grained dissemination, and environmental concerns. This paper systematically explores the characteristics of lead-zinc deposits, the latest advances in flotation reagents and processes, as well as the optimization of beneficiation equipment and industrial applications. By analyzing key technologies such as selective reagent schemes, advanced flotation circuits, and intelligent process control, this study aims to provide practical solutions for improving recovery rates, reducing energy consumption, and minimizing environmental impact in lead-zinc ore processing.

Characteristics of China’s Lead and Zinc Minerals

China is rich in lead and zinc ore resources. After more than 40 years of development and the gradual expansion of production bases, reserves now exceed 90 million tons, currently ranking first in the world. 90% of the minerals are primary sulfide ores. Lead’s physical properties make it crucial for industrial development and applications. It is widely used in lead-acid batteries and other applications, and also has specialized applications in the manufacture of radiation-related protective equipment. Zinc is also abundant, accounting for over 90% of China’s total plomb and zinc production. Zinc is a chemically active element that readily reacts with other substances. At room temperature, it reacts with air to form a thin, dense film of basic zinc carbonate on the surface, which inhibits the oxidation of the lead and zinc ore.

Discussion on Lead-zinc Ore Dressing Technology

With the continued development and utilization of mineral resources, lead and zinc ore, as a key nonferrous metal resource, is attracting increasing industry attention for its efficient and environmentally friendly beneficiation technologies. This article explores the current status and future trends of lead and zinc ore beneficiation technologies, focusing on key topics such as reagent application, beneficiation process optimization, flotation process characteristics, and equipment development, aiming to provide technical references for the industry.

Types and Applications of Reagents

The main controlling factor of lead-zinc ore beneficiation technology is the selection of reagents for the flotation of lead-zinc ore. The flotation reagents of lead-zinc ore include three categories, the main components of which are xanthate, black reagent, and sulfur-nitrogen reagent. Xanthate is a typical flotation reagent for lead-zinc sulfide ores and is mainly used for the flotation of galena and sphalerite. The commonly used black reagent is toluene-based black reagent, which is mainly used for lead-zinc sulfide ores containing pyrite. Compared with xanthate, black reagent has relatively weaker collection ability, but better selectivity and foaming effect. For example, when it is used in the flotation of sulfide ores that need to suppress the flotation of lead and copper from pyrite, the application of black reagent can effectively reduce the amount of pyrite inhibitor and improve the concentrate grade.

Ore Dressing and Problem-solving Methods

The floatability of lead-zinc ores is not much different, and the difference in mineral specific gravity and magnetic properties is not obvious, which makes its ore dressing method relatively simple. The main lead-zinc mines in my country mainly adopt the flotation enrichment and recovery of lead and zinc valuable minerals. The main problem in the flotation process of lead-zinc ore is the serious phenomenon of mineral over-grinding and sliming. In practical production, our ore dressing plant also faces the change of deep mineral properties, such as the emergence of carbonaceous lead-zinc ore and other unfavorable flotation phenomena. The appearance of ore slime and carbonaceous minerals seriously affects the smooth application and development of lead-zinc ore dressing technology and causes a change in the flotation sulfiding agent. The concentration of sulfiding agent will decrease during the flotation process. Under the influence of these comprehensive factors, the solubility of the ore pulp gradually increases, and the amount of mineralizer will also gradually increase. Professional technicians can use hydrocyclones, spiral classifiers, ore washing equipment, etc., to separate the desliming, and on this basis, treat the lead-zinc ore.

Flotation Process and Its Characteristics

China’s lead-zinc ore resources are mostly sulfide lead-zinc ores and a few oxidized lead-zinc ores. There are many poor ores and few rich ores. In the flotation process, the treatment method of oxidized lead-zinc ore is usually to sulfide and then treat it by sulfidation. In the application process, the treatment method of lead first and then zinc is often adopted. The flotation process also maintains the order of sulfur first, then oxygen. The direct priority flotation process has the advantages of a simple principle, convenient operation, and low cost, making it suitable for production in small industrial plants. The mixed flotation process is suitable for ores with dense mineral clusters. It has requirements for subsequent process work and requires a certain investment. The iso-flotation process was developed based on the above two flotation processes. This method avoids the influence of physical and chemical phenomena and has the following advantages. First, in the iso-floatable area where lead is mainly selected, the floating amount of zinc reaches approximately 30%, and the floating amount of sulfur reaches approximately 55%. The iso-flotation process does not require corresponding additives and has a certain degree of suppression ability. Therefore, the lead content in the lead concentrate can reach over 70%, zinc reaches 3%, and sulfur reaches 16%, and the other contents are also very stable.

Current Status and Development of Lead-Zinc Ore Dressing Technology and Equipment

As an important component of lead-zinc ore dressing technology, équipement de traitement des minerais is of great significance to the acquisition of mineral processing indicators and the development of mineral processing technology. In the context of rapid social development, when reforming and developing, established mineral mining, flotation and processing enterprises need to improve and optimize their equipment and facilities based on the original equipment technology and keep abreast of the innovative ideas and application results of mineral processing technology of other domestic and foreign enterprises, learn from them and optimize them for their development.

Core Equipment Upgrade

1. Flotation Machine: Aerated mechanical stirring type (such as KYF type) is the mainstream, and large-scale (single tank volume up to 320m³) reduces unit energy consumption.
2. Classification Equipment: Hydrocyclone is combined with a high-frequency fine screen to improve the classification accuracy to -0.038mm, accounting for more than 85%.

Intelligent Transformation

1. An online ore particle size analysis system based on machine vision to adjust grinding parameters in real time.
2. Digital twin technology is applied to flotation process simulation, and the fault prediction accuracy is increased to 90%.

Future Trends

1. Short-process equipment integration: For example, integrated “grinding-flotation” modules reduce intermediate steps.
2. New energy adaptation: Electric flotation columns combined with photovoltaic energy storage systems reduce carbon emissions.

Conclusion

The continuous development of lead-zinc ore beneficiation technology has shifted towards high efficiency, eco-friendliness, and automation, driven by increasing demand for sustainable mineral processing. Innovative reagent systems, optimized flotation flowsheets, and smart equipment configurations have demonstrated industrial feasibility in enhancing metal recovery while lowering operational costs. Future research should focus on the deep processing of refractory ores, the implementation of AI-driven process optimization, and the integration of renewable energy in beneficiation plants. By adopting these advancements, the lead-zinc mining industry can achieve higher economic and environmental benefits, ensuring long-term competitiveness in a resource-conscious global market.