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Henan 1,500 t/d Silver–Lead–Zinc Polymetallic Expansion Project: Xinhai Mining’s Benchmark in Green and Intelligent EPC Delivery
In today’s global mining industry, efficiency, green production, and intelligent management have become defining priorities for enterprises seeking both profitability and sustainability. The Henan Fande 1,500 t/d silver–lead–zinc polymetallic mine expansion project, designed and delivered by Xinhai Mining, has emerged as a showcase of how modern mineral processing can meet stringent international standards while overcoming complex site and environmental challenges.
The client, a Canadian publicly listed company, already operated two 900 t/d beneficiation lines with a combined capacity of 1,800 t/d. To support its strategic development goals and market expansion, the company decided to construct a third series beneficiation line with a design capacity of 1,500 t/d. The project demanded not only technical excellence but also flawless execution, as the construction had to proceed alongside the uninterrupted operation of the existing production lines.
Against tight schedules, limited site space, and the natural challenges of Henan’s rainy season, Xinhai Mining leveraged its full-chain strengths—from mine research and engineering design to equipment manufacturing and EPC management—to deliver a state-of-the-art flotation line in just 198 days.
The deposit is a complex silver–lead–zinc–gold polymetallic orebody, with silver and lead as the dominant valuable components. This multi-metallic composition called for a precise beneficiation flowsheet to ensure selective recovery, maximize metal yields, and secure optimal economic returns.
Xinhai’s mineral processing engineers developed a tailored process route after careful study of the ore characteristics and existing plant configuration. The final flowsheet integrated grinding, classification, flotation, thickening, and dewatering systems, designed not only for efficiency but also for compatibility with the existing infrastructure.
• Construction of a new grinding workshop on the western side of the plant.
• Installation of a MQG3645 lattice-type ball mill to expand milling capacity.
• Paired with a φ350×8 hydrocyclone cluster to achieve precise classification.
• Grinding fineness: –0.074 mm, accounting for 60–65%, consistent with the existing lines for stable downstream flotation performance.
The flotation flowsheet adopted a priority flotation approach, emphasizing lead recovery first, followed by zinc recovery from the lead tailings.
• Lead flotation: 1 rougher, 3 scavengers, 3 cleaners.
• Zinc flotation: 1 rougher, 4 scavengers, 3 cleaners.
This stepwise separation ensured efficient multi-metal recovery and improved beneficiation indexes.
• A new φ18 m center-drive thickener installed for zinc concentrate thickening.
• Two existing φ20 m high-efficiency thickeners repurposed for lead concentrate thickening.
• Optimal reallocation of equipment resources guaranteed concentrate handling capacity.
• Addition of a 36 m² ceramic filter for zinc concentrate dewatering.
• Low-energy, high-precision filtration reduced moisture content, lowered water consumption, and contributed to the project’s green production goals.
The project was far from straightforward. Xinhai Mining’s team confronted three major difficulties:
1. Rainy Season Construction Risks
The site in Luoyang, Henan, experiences heavy rainfall between mid-April and mid-October. With the project spanning April to November 2024, continuous storms posed threats to soil stability, drainage, and scheduling.
2. Complex Foundation Conditions
Early surveys revealed subsidence risks caused by uneven waste rock particle size distribution, collapsible clay soils, and insufficient compaction during initial ground treatment. These factors endangered long-term plant stability.
3. Narrow Construction Site and Limited Material Storage
As an expansion within an existing beneficiation plant, space was highly constrained. Logistics for equipment staging, material storage, and transport coordination demanded innovative solutions.
1. Innovative Process and Equipment Design
• Added a #3 fine ore bin as a buffer to balance ore feeding.
• Implemented an intelligent waste-rejection system, directly conveying –15 mm fines from the raw ore stockyard to fine ore bins, improving ore utilization and stability.
• Upgraded crushing and conveying with re-routed belts to ensure flexible ore allocation.
• Introduced advanced gravity recovery technology (Knelson concentrator), boosting overall metal recovery.
2. Foundation Reinforcement
• Abandoned conventional backfilling methods due to high risk.
• Adopted structural reinforcement and grouting techniques to strengthen the base.
• Successfully eliminated subsidence risks and created a secure foundation for new workshops and equipment.
3. Smart Construction Logistics
• Employed a “small-batch, multi-frequency procurement” model to manage site space limitations.
• Established an efficient drainage system and flood response plan to maintain continuous rainy-season construction.
• Coordinated demolition and new construction in parallel, ensuring the two existing 900 t/d lines operated normally throughout.
Despite the one-month delay caused by foundation treatment, Xinhai Mining still delivered the project in 198 days, thanks to:
• Round-the-clock operations: day-and-night construction to maintain progress.
• Cross-disciplinary coordination: parallel civil works, equipment installation, and utility construction.
• Scientific scheduling: real-time progress monitoring and dynamic resource allocation.
This high-speed execution became known as “Xinhai Speed”, ensuring the client’s production ramp-up aligned with market opportunities.
1. Customized and Efficient Design
Tailor-made beneficiation flowsheet, integrating intelligent waste rejection and optimized flotation, delivered higher recovery rates while maintaining energy efficiency and environmental compliance.
2. Overcoming Geotechnical and Climatic Obstacles
By tackling the “narrow, rainy, soft” triple challenge—limited space, heavy rain, and soft foundation—Xinhai demonstrated adaptability and technical leadership.
3. Record Construction Speed
Completed in just 198 days, the project set a new benchmark for polymetallic mine EPC projects under extreme schedule constraints.
4. Standardized Management and Zero Major Accidents
• Triple-layer quality inspection system ensured reliability.
• Comprehensive safety protocols achieved a record of zero major incidents.
• Weekly progress reviews and incentive mechanisms kept over 1,000 workers and hundreds of processes moving like precision gears.
The Henan 1,500 t/d silver–lead–zinc polymetallic expansion project is more than a successful EPC delivery—it is a testament to how Xinhai Mining integrates research, design, equipment manufacturing, and project management into a seamless chain of value.
By achieving stable production within 198 days, under severe environmental and engineering challenges, Xinhai once again proved its ability to deliver large-scale, green, intelligent mineral processing plants on time and to international standards.
This project not only expands the client’s production capacity but also provides the industry with a replicable model for high-efficiency, sustainable, and intelligent mine construction.
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