INDUSTRY 01

Non-ferrous Mining

01 / MINING

Ore dressing slurry, overflow & underflow density control for improved recovery.

3 applicable products 4 application cases
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Overview

In non-ferrous mining, slurry density is the core control variable from crushing and grinding through flotation and tailings. Concentrators rely on accurate concentration data to dose reagents, maintain mill load and optimize flotation recovery. Pisonics meters are deployed across copper, lead, zinc, molybdenum, gold/silver, bauxite and nickel concentrators.

Typical challenges

  • Highly abrasive slurry that wears wetted parts
  • Variable particle size — insertion-style meters clog easily
  • Wide diurnal and seasonal variation requires self-adapting calibration
  • Plant-wide integration needs stable signals and uniform protocols

Recommended solutions

Measurement pointPrincipleModels
Mill discharge / cyclone feedUltrasonic acoustic impedancePS7000
Flotation rougher / scavengerUltrasonicPS7000
Tailings thickener underflowUltrasonic + DPPS7000 / PS7300
RECOMMENDED PRODUCTS

Products that fit this industry

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PS7000

Slurry density meter

The PS7000 series ultrasonic acoustic‑impedance slurry density meter completely eliminates the radiation safety risks and cumbersome environmental‑approval maintenance costs associated with conventional gamma‑ray density meters. By employing an innovative chirp acoustic‑impedance analysis algorithm, it overcomes measurement blind spots in complex operating conditions, enabling high‑precision continuous measurement.
PS7010

Acoustic attenuation density meter

The PS7010 series ultrasonic acoustic-attenuation slurry density meter employs a dual-probe through-beam measurement configuration, addressing the challenges of retrofitting aging pipelines and monitoring in hazardous‑area environments. The instrument leverages the energy attenuation of ultrasonic waves as they propagate through the slurry to accurately determine the slurry’s density and concentration, making it ideal for industries such as chemical processing, sugar refining, and mining.
PS7600

Microwave concentration/density meter

The PS7600 series online microwave density meter accurately captures the phase shift and amplitude attenuation of microwaves in the medium, thereby providing real-time measurements of slurry concentration, density, and moisture content. Employing a non‑nuclear, zero‑radiation microwave phase‑shift method coupled with Pt‑100 temperature compensation, it is ideally suited for challenging applications such as flue‑gas desulfurization in thermal power plants and coal‑washing slurries.
APPLICATION CASES

Cases in this industry

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Slurry density meter · PS7000

Online Measurement of Slurry Density in Non-ferrous Metallurgical Beneficiation Plants

In nonferrous metal concentrators, fluctuations in slurry density directly affect metal recovery rates and energy consumption. The PS7000 concentration meter employs ultrasonic non-contact measurement technology and features a flanged direct‑insertion installation, eliminating the wear and fouling issues common to conventional instruments, ensuring long‑term stable operation, and operating entirely without radiation, thus obviating the need to obtain a Radiation Safety License.

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Slurry density meter · PS7000

Density Control of Heavy-Medium Suspensions in Coal Washing

In the heavy‑medium coal‑washing process, even slight variations in slurry density can significantly affect the ash content of the clean coal product. Conventional concentration meters, such as nuclear‑based and tuning fork types, suffer from radiation safety concerns, frequent maintenance requirements, and slow response times. Pisonics’ PS7000 acoustic impedance density meter, employing a non‑contact probe and a Chirp algorithm, delivers high‑frequency, stable density measurements, ensuring precise control by the DCS system, thereby enhancing clean coal quality and reducing media consumption.

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Slurry density meter · PS7000

Density Measurement of Salt Lake Brine Potash Fertilizer Evaporation-Crystallization Solid-Bearing Two-Phase Flow

In the potash‑extraction process from salt‑lake brine, the highly corrosive chloride‑rich environment and complex multiphase flow patterns often cause conventional density meters to fail repeatedly. Pisonics’ PS7000 acoustic‑impedance concentration meter features a fully PTFE‑lined design and a ceramic probe, offering exceptional corrosion resistance and insensitivity to bubbles, crystals, and flash vaporization. This ensures stable density measurement in solid–liquid two‑phase flows, significantly enhancing both the plant’s economic efficiency and product quality.

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Slurry density meter · PS7000

Mine Tailings Backfill Stations and Grinding Circuit Density Measurement

In mine tailings‑filling stations and grinding circuits, density control of high‑concentration paste slurries is critical. Conventional instruments struggle to meet these requirements due to issues such as wear and sluggish response. Pisonics’ PS7000 employs non‑contact measurement, with a response time of less than one second and a ceramic probe life of up to five years, thereby completely eliminating problems of wear and blockage, improving metal recovery rates, and reducing energy consumption.

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Voices from this industry

"After switching to the PS7000, our overflow density readings finally stabilized — we stopped tuning reagent dosing by feel. The unexpected win was not having to clean the sensor weekly; our previous radiometric meter needed window-wiping almost daily in the scaling slurry."

Director Li
Mineral Processing Workshop Director
A certain copper mining enterprise

"We used to run a transmission-type density meter; bubbles in the slurry kept dropping the signal and the probes were worn out after six months. Two-plus years into PS7000, neither bubbles nor wear are issues — it's basically zero-maintenance. The labor and spare-parts savings alone are significant."

Director Zhang
Mineral Processing Workshop Director
A certain iron ore beneficiation plant in Xinjiang
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Industry FAQ

Can density still be measured online when mining slurry exceeds 80°C?

Yes.

The Pisonics standard tuning fork density meter PS7400 has a measurement range of 0–150°C, and the standard ultrasonic concentration meter PS7000 covers 0–120°C, which can accommodate most slurry-based hydrometallurgical processes.

For extreme conditions such as high-pressure acid leaching (HPAL) at temperatures above 200°C, we offer custom high-temperature models with titanium alloy or Hastelloy wetted parts, paired with remote transmitters to isolate the electronic components.

Common temperature ranges include: ambient‑temperature slurry (≤ 60°C) / heated flotation (60–90°C) / atmospheric leaching (90–110°C) / high‑pressure leaching (150–250°C) / autoclaves (≥ 250°C, requiring special customization). Please specify the maximum operating temperature when requesting a quote.

Mining hydrometallurgy slurry is hot and corrosive — can online meters still work?

Yes. The Pisonics density meter offers tiered temperature and corrosion solutions.

Temperature ratings:

  • Normal-temperature slurry ≤ 60°C—standard configuration;
  • Heated flotation 60–90°C—select the standard model;
  • Atmospheric leaching 90–110°C—select the high-temperature model;
  • High-pressure acid leaching (HPAL) 150–250°C—requires customization (use titanium or Hastelloy for wetted materials, and equip with a remote transmitter to isolate the electronic components);
  • Autoclaves ≥ 250°C—special customization.

Corrosion-resistant solutions:

  • Weak corrosion → 316L;
  • Strong acids and alkalis → 2205 duplex stainless steel, Hastelloy C‑276, titanium, or PTFE lining;
  • High-abrasion slurry → ceramic probe + PTFE lining.

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