Do You Really Understand Mineral Processing Testing?

Mineral processing testing is a crucial component of overall plant services and serves as an important technical basis for the construction and operation of mineral processing plants. 

Carrying out mineral processing testing effectively is an essential technical foundation for offering customers multi-faceted and multi-level services, including design services, renovation 

services, and resource evaluation. For customers, conducting appropriate mineral processing testing is the optimal method for rationally investing in and developing mineral resources 

while avoiding technical risks.

So, how much do you really know about mineral processing testing?

Through a conversation with a laboratory technician, you will gain a more comprehensive understanding of mineral processing testing.

Q: In our work, we’ve noticed that some customers believe testing is not necessary. What are your thoughts on this?

A:Indeed, some customers may consider testing unimportant, unnecessary, or even resist it—perhaps due to cost concerns or other considerations. I believe it’s essential to first have 

an objective understanding of the role of mineral processing testing. Testing is an important, and in fact, the only way to determine the optimal process flow and separation indicators 

for ore treatment.

As an engineering practice, mineral processing can certainly draw on experiences from similar types of ores or plants of comparable scale. However, due to variations in the natural 

properties of ores and geographical conditions of mining areas, the suitable process and product solutions for each customer can differ significantly. Therefore, such references have 

their limits.

Adhering to a scientific, objective, and responsible approach, we recommend mineral processing flowsheets to customers—especially when providing overall plant services—only after 

completing corresponding test studies and conducting detailed comparisons of various solutions.

Thus, we advise customers to not only rely on empirical judgment but also recognize the scientific necessity of testing. This will significantly help in avoiding technical risks, reducing 

operational costs, and increasing profitability.

Q: Prior to testing, how much ore sample do we generally require from the customer?
A: The amount of ore required for testing varies depending on the type of ore and the scale of testing. For laboratory-scale exploratory tests, except for certain ore types with inherently low industrial grades, the sample size is usually controlled within the range of 30–50 kg.

Q: That amount isn’t small. Why is such a large sample needed?

A: Because during testing, a single condition test generally requires 3–5 test points, with each point needing 500 g or 1000 g of ore sample. Since a complete test process involves multiple conditions, the total sample requirement for a systematic test becomes quite substantial.

Q: To ensure the representativeness of the ore sample, what suggestions do you have regarding sampling?
A: During the customer’s sampling process, the following aspects should be considered:

• Number of Sampling Points
  The number of sampling points should be as many as possible, while also taking into account site conditions. For an industrial grade or natural type of sample, there should be no fewer than 3–5 sampling points.

• Layout of Sampling Points
  Sampling points should be determined based on comprehensive geological study of the deposit and the requirements for sample representativeness. Choose locations that adequately represent the characteristics of the ore under study and where existing exploration engineering quality is good, while also considering construction and transport conditions. Make full use of existing exploration works (such as tunnels or drill cores) for sampling and avoid, if possible, creating dedicated sampling excavations.

  
  

• Effective Control of Sampling Points

  Prefer exploration sites that contain the most complete range of industrial grades and natural types of ore. This allows more sampling points to be arranged within fewer sampling works, reducing the overall sampling workload. Sampling points should be roughly evenly distributed across various parts of the ore body and not overly concentrated. Along the strike of the ore body, there should be sampling points at both ends and the middle; along the dip direction, points should be located at the surface, shallow depths, and deeper sections. For very large ore bodies, consider staged sampling—that is, focus sampling points mainly in areas scheduled for early-stage mining.

Since the customer is responsible for the representativeness of the ore sample, we generally recommend that customers engage professionals to carry out the sampling.

Q: What does a typical test usually include?

A: Generally, a systematic test includes ore property determination and mineral processing tests. 

Among these, ore property studies mainly involve:

• Semi-quantitative spectral analysis of the ore

• Multi-element analysis

• Mineralogical identification

• Particle size screening analysis

• Determination of ore grindability work index or grindability

• Measurement of physical properties of the ore

The main contents of mineral processing tests include:

• Comparative tests of process schemes

• Condition tests for various stages of the separation process

• Locked-cycle and open-circuit tests of the full process

• Inspection of mineral processing products

• Reagent cost analysis