Copper ore, as a foundational material for electronics, renewable energy, and infrastructure, typically has a Mohs hardness of 6–7 and contains just 0.5–2% copper in its raw state. To extract valuable copper efficiently, the first critical step—crushing—must reduce large ore lumps (up to 1.5 meters in diameter) to uniform particles suitable for subsequent beneficiation. This process not only directly impacts grinding efficiency (accounting for 40–60% of total energy consumption) but also determines mineral liberation and final copper recovery rates.
Liming Heavy Industry, with three decades of expertise in mining equipment, has developed a mature three-stage closed-circuit crushing system tailored to copper ore's high hardness and abrasiveness. By integrating advanced 颚式,cone, and screening equipment, the company adheres to the "more crushing, less grinding" principle, which reduces energy consumption by 20–30% compared to traditional processes. This article focuses on Liming's core crushing equipment, process design, and on-site project outcomes, revealing its targeted solutions for copper ore processing challenges.
Copper ore's physical properties—high hardness, uneven composition, and tendency to produce fines—demand a systematic crushing approach. Liming's three-stage closed-circuit process (rough crushing → intermediate crushing → fine crushing + screening) ensures stable particle size distribution, minimizes over-crushing, and lays the groundwork for efficient downstream processing.
The process begins with rough crushing: Raw copper ore is fed into a jaw crusher via a vibrating feeder, reducing lumps from 1–1.5m to 100–200mm. This stage prioritizes handling capacity and equipment durability to withstand the impact of large ore blocks.
Next is intermediate crushing: Crushed material is screened, and oversize particles are sent to a single-cylinder hydraulic cone crusher, which further reduces the ore to 30–50mm. This step balances efficiency and particle shape, reducing wear on subsequent equipment.
The final fine crushing stage uses multi-cylinder hydraulic cone crushers to produce particles of 0–15mm (typically 0–12mm for grinding feed). A vibrating screen classifies the output; oversize material returns to the fine crusher, forming a closed circuit that guarantees consistent product granularity.
This design follows two core principles:
Graded crushing: Matching equipment to ore size minimizes energy waste and equipment wear.
Closed-circuit control: Real-time screening ensures no oversize material enters the grinding system, optimizing subsequent processing efficiency.

Liming's copper ore crushing equipment lineup is engineered for high hardness, continuous operation, and easy maintenance, with each model tailored to a specific crushing stage.
The C6X series jaw crusher is Liming's flagship rough crushing equipment, designed to handle the largest and hardest copper ore lumps. Its key features include:
Robust structural design: The detachable, weld-free frame uses high-strength steel, reducing transportation weight by 15% while improving structural rigidity. This design withstands the repeated impact of 1.2m-diameter ore blocks, ensuring 95%+ operational availability in harsh mining environments.
Optimized crushing chamber: The deep, curved chamber adopts a "V-shaped" structure that increases the crushing ratio to 6:1–8:1, reducing the need for secondary crushing. In Xinjiang's copper mines, it consistently reduces 1m ore lumps to 150mm in one pass.
Dual wedge adjustment system: Unlike traditional shim adjustment, this system allows quick discharge opening adjustments (from 10–100mm) without stopping production, adapting to varying ore hardness and downstream requirements.
Integrated shock absorption: Elastic limit shock absorbers reduce vibration by 30%, protecting the foundation and extending equipment life by 20% compared to conventional jaw crushers.
Suitable for ores with compressive strength ≤300MPa, the C6X series is the primary choice for rough crushing in large-scale copper mines, with models ranging from C6X75 to C6X130, covering hourly capacities of 50–1,000 tons.
For medium-hard to hard copper ore, the HST single-cylinder hydraulic cone crusher delivers high efficiency and easy maintenance, making it ideal for intermediate crushing. Its standout attributes include:
Hydraulic integration technology: The integrated hydraulic system combines overload protection, discharge adjustment, and cavity clearing functions. If uncrushable debris (e.g., steel) enters the chamber, the system automatically lifts the mantle, 排出异物,and resumes operation—reducing downtime by 80% compared to spring cone crushers.
High-capacity design: The large-diameter eccentric shaft and optimized stroke (16–30mm) increase throughput by 20–30% over similar models. In Guangdong's 8,000-ton-per-day (TPD) copper processing line, the HST160 model achieves 180–220t/h with stable discharge of 30–50mm.
Intelligent control: Equipped with a PLC control system, it monitors load, temperature, and oil pressure in real-time. Operators can adjust parameters remotely, ensuring consistent output even as ore hardness fluctuates.
Low maintenance cost: The integral frame and centralized lubrication system reduce maintenance time by 40%. Wear parts (concave and mantle) use high-chromium alloy, extending service life to 3–6 months in copper ore applications.
The HST series covers capacities of 50–600t/h, with discharge sizes adjustable from 10–60mm, making it versatile for both intermediate crushing and fine crushing in small-to-medium mines.