Iron ore beneficiation begins with the milling of extracted ore in preparation for further operations to recoveriron values. Milling operations are designed to produce uniform size particles by crushing, grinding,and wet or dry classification. The capital investment and operation costs of milling equipment are high.
Crushing is a multistage process and may use dry iron ore feed. Typically, primary crushing andscreening take place at the mine site. Primary crushing is accomplished by using jaw crusher or gyratorycrushers. Primary crushing yields chunks of ore ranging in size from 6 to 10 inches. Oversize material is passed through additional secondary crushers and classifiers to achieve the desired particlesize.
In iron ore beneficiation operation, the raw iron ore materials will be first reduced to small particle size. It may require crushing the material tomaximize the production of minus 2mm. According to SBMs experience in crushing technology, we recommended the installation of acone crusher to reduce the minus 100mm pebblesand a VSI crusher machine to fine crush the cone crusherproduct.
The iron ore crushers with low price are also used in the industrial minerals, mining, recycling and general quarrying industries. A widerange of materials are processed through SBM iron crushers worldwide. SBM experts can customize crushing solution in iron ore beneficiation according to your requirements. Here are some popular iron ore crusher machine types. Please contact us for more information.
According to different final products applications, varioustypes of crusher equipment are required, such as jaw crusher for primary crushing, impact crusher and hammer crusher for secondary crushing, cone crusher for secondary and tertiary crushing. Iron ore crusher prices are different according to crusher types and production capacities.
The VSI crusher for iron ore beneficiation uses a unique rock-on-rockcrushing action whereby the feed materialgrinds and impacts against itself, minimizingwear costs and maintenance down-time. Thisis especially important in applications such asiron ore processing where the feed material istypically hard and abrasive and wear costs arepotentially very high.
Jaw Crusher Jaw crusher is available with stationary, mobile and portable applications. The jaw crushers combine a high reduction ratio and increased capacity with any feed materials: from extra hard rock to recycled materials. This is achieved through several unique features such as higher crushing speed, optimized kinematics, a longer stroke and easy adjustment.
Impact Crusher Impact crushers are based upon several decades of experience with the impact method. We offer a complete range of impact crushers for stationary, semi-mobile fully mobile applications in both primary and secondary crushing.
Cone Crusher Cone crusher is a stationary crusher. These crushers are hydraulic pressure crushers designed to crush a high ratio for high productivity. Cone crushers are ideal for secondary and fine crushing.
The data recorded by Statistics in 2020 shows that although in 2019 manganese ore price fell to the bottom, the price in 2020 still gets increased to 4.5 U.S. dollars per metric ton unit CIF even under the impact of COVID-19. Manganese ore prices are forecast to remain at global prices by 2020 over the next two years, which is good news to manganese ore suppliers.
Besides, Justin Brown, managing director of Element 25said Manganese has the traditional end uses in steel, and that market is fairly stable". As people's demand for laptops and electric cars increases, the output of lithium batteries has also soared, and the most important element in lithium batteries is manganese.
Manganese ore after the beneficiation process is applied in many respects in our daily lives. Of annual manganese ore production, 90 percent is used in steelmaking, and the other 10 percent is used respectively in non-ferrous metallurgy, chemical industry, electronics, battery, agriculture, etc.
In the metallurgical industry, manganese ore is mostly used for manganese-forming ferroalloys and manganese metal. The former is used as deoxidizers or alloying element additives for steelmaking, and the latter is used to smelt certain special alloy steels and non-ferrous metal alloys. Manganese ore can also be used directly as an ingredient in steelmaking and ironmaking.
When smelting manganese-based iron alloys, the useful elements in manganese ore are manganese and iron. The level of manganese is the main indicator for measuring the quality of manganese ore. The iron content is required to have a certain ratio with the amount of manganese.
Phosphorus is the most harmful element in manganese ore. The phosphorus in steel reduces the impact of toughness. Although sulfur is also a harmful element, it has a better desulfurization effect during smelting, and sulfur is volatilized into sulfur dioxide or enters the slag in the form of calcium sulfide or manganese sulfide.
Applications in Metallurgy Manganese content (%) Ferromanganese (%) Phosphorus manganese (%) Low carbon ferromanganese 36%40% 68.5 0.0020.0036 Carbon Ferro Manganese 33%40% 3.87.8 0.0020.005 Manganese Silicon Alloy 29%35% 3.37.5 0.00160.0048 Blast Furnace Ferromanganese 30% 27 0.005
In the chemical industry, manganese ore is mainly used to prepare manganese dioxide, manganese sulfate, and potassium permanganate. It is also used to make manganese carbonate, manganese nitrate and manganese chloride.
Since most manganese ore is a fine-grained or fine-grained inlay, and there are a considerable number of high-phosphorus ore, high-iron ore, and symbiotic beneficial metals, it is very difficult to beneficiate.
At present, commonly used manganese ore beneficiation methods include physical beneficiation (washing and screening, gravity separation, strong magnetic separation, flotation separation, joint beneficiation), chemical beneficiation (leaching method) and fire enrichment, etc.
Washing is the use of hydraulic washing or additional mechanical scrubbing to separate the ore from the mud. Commonly used equipment includes washing sieves, cylinder washing machines and trough ore-washing machine.
The washing operation is often accompanied by screening, such as direct flushing on the vibrating screen or sifting the ore (clean ore) obtained by the washing machine to the vibrating screen. Screening is used as an independent operation to separate products of different sizes and grades for various purposes.
At present, the gravity separation is only used to beneficiate manganese ore with simple structure and coarse grain size and is especially suitable for manganese oxide ore with high density. Common methods include heavy media separation, jigging and tabling dressing.
It is essential to recover as much manganese as possible in the gravity concentration zone because its grinding cost is much lower than the manganese in the flotation process, and simple operations are more active.
Because of the simple operation, easy control and strong adaptability of magnetic separation can be used for dressing various manganese ore, and it has dominated the manganese ore dressing in recent years.
Gravity-magnetic separation plant of manganese ore mainly deals with leaching manganese oxide ore, using the jig to treat 30~3 mm of cleaned ore can obtain high-quality manganese-containing more than 40% of manganese. And then can be used as manganese powder of battery raw material.
The jigging tailings and less than 3 mm washed ore are ground to less than 1mm, and then being processed by strong magnetic separator. The manganese concentrate grade would be increased by 24% to 25%, and reaches to 36% to 40%.
Adopting strong magnetic-flotation desulfurization can directly obtain the integrated manganese concentrate product; the use of petroleum sodium sulfonate instead of oxidized paraffin soap as a collector can make the pulp be sorted at neutral and normal temperature, thus saving reagent consumption and energy consumption.
The enrichment of manganese ore by fire is another dressing method for high-phosphorus and high-iron manganese ore which is difficult to select. It is generally called the manganese-rich slag method.
The manganese-rich slag generally contains 35% to 45% Mn, Mn/Fe 12-38, P/Mn<0.002, and is a high-quality raw material to manganese-based alloy. Therefore, fire enrichment is also a promising method for mineral processing for low-manganese with high-phosphorus and high-iron.
Manganese ore also can be recovered by acid leaching for production of battery grade manganese dioxide for low-manganese ores. Leaching of manganese ore was carried out with diluted sulphuric acid in the presence of pyrite in the temperature range from 323 to 363 K.
After processed by hydraulic cone crusher, the smaller-sized manganese ore would be fed to grinding machine- ball mill. It can grind the ore to a relatively fine and uniform particle size, which lays a foundation for further magnetic separation of manganese ore.
It is indispensable grading equipment in the manganese ore beneficiation plant. Because by taking advantage of the natural settling characteristics of ore, a spiral classifier can effectively classify and separate the manganese ore size to help control the amount of grinding required.
The flexibility of flotation is relatively high. You can choose different reagents according to the type and grade of the ore. Although the entire process of froth flotation is expensive, it can extract higher-grade manganese ore.
The magnetic separator is a highly targeted magnetic separation device specially developed for the properties of manganese ore. The device not only has the advantages of small size, lightweight, high automation, simple and reasonable structure, but also has high magnetic separation efficiency and high output.
If you want to beneficiate high-grade manganese ore and maximize the value of manganese concentration, Fote Company is an ore beneficiation equipment manufacturer with more that 35-years designing and manufacturing experience and can give you the most professional advice and offer you all machines needed in the ore beneficiation plant (form crushing stage to ore dressing stage). All machines are tailored to your project requirements.
As a leading mining machinery manufacturer and exporter in China, we are always here to provide you with high quality products and better services. Welcome to contact us through one of the following ways or visit our company and factories.
Based on the high quality and complete after-sales service, our products have been exported to more than 120 countries and regions. Fote Machinery has been the choice of more than 200,000 customers.
In recent years, many sophisticated technologies are developed to method iron ore. As an professional firm in the mining enterprise, we will give our shoppers with high-tech and prime good quality iron ore beneficiation equipment. Our most well-liked merchandise is crushing gear, grinding equipment, sand generating equipment and separating machine. For iron ore crushing, you'll have the ability to select iron ore jaw crusher, cone crusher, impact crusher and grinding mills like ball mill, vertical roller mill and super skinny grinding mill. For iron ore separating, you'll be able to use our magnetic separator, flotation separator or gravity separator.
1. Raw iron ore is exploded from the iron ore mines firstly. Then vibrating feeder will feed iron ores in to the iron ore principal crusher crushing cavity, in which big size raw iron ore is going to be realized into iron ore sand. The iron ore sand is transmitted into secondary crushers by belt conveyors evenly and continuously. Then the out let of secondary crusher is carried into tertiary crusher, in which iron ore will probably be processed into powder size iron ore particles. Iron ore crushing procedure is ended right here;
3. Iron ore beneficiation approach is utilised to enhance the purity to 59% or a lot more. Iron ore beneficiation approach is essential. It tends to make the calcine approach effortless with increased efficiency. The outlet of beneficiation procedure is fine ore. Following sintering with high temperature, iron pellet ore will be calcined inside the blast furnace and lastly processed into iron steel.
As an expert manufacturer of mining equipment, Shanghai ZENITH Mining and Construction Machinery Co., Ltd. can supply you with both comprehensive production line and efficient machine. Our full range of technical services to help you explain to resolve questions and help you improve efficiency of production. Our products have different models and a variety of production capacity. If you want to get more product information (for example: price, production capacity, model), you can consult our professional customer service staff or to see our products section.
Manganese ore is widely used in steel, non-ferrous metallurgy, chemical, electronics, battery, agriculture, etc. industry. More than 90% of the worlds manganese is used in the steel industry. Global terrestrial manganese ore reserves are 6. 800 million tons (manganese metal), most of which is manganese oxide ore, with a production of 16 million tons (manganese metal) in 2017. spent catalyst could be a secondary recover resource of manganese. Chinas manganese ore resources are mainly manganese carbonate ore, and the average grade of ore is only 21. 4%. With the consumption of manganese ore resources, the grade of ore is gradually reduced, which is not only difficult to develop and utilize but also has a large amount of smelting wastewater and waste slag. Therefore, improving manganese resource utilization technology level is of great significance for realizing the conservation and utilization of manganese resources, protecting the ecological environment and promoting the sustainable development of the manganese industry.
The purpose of manganese ore beneficiation is to remove the slime, separate stone and mineral manganese, enrich the low-grade ore, improve the ore grade, reduce the energy and reagent consumption of the smelting process from the source, and then reduce the amount of smelting waste. The methods of mineral manganese processing mainly include washing, gravity separation, strong magnetic separation, flotation, fire enrichment and chemical beneficiation.
There is a large difference in density between useful minerals and gangue minerals, and the density of manganese oxide ore is 3.7 ~ 5g/cm3, the density of manganese carbonate ore is 3.3 to 3.8 g/cm3, the density of gangue minerals such as quartz and calcite is 2.6 to 2.9 g/cm3. The use of re-election technology can achieve the separation between useful manganese ore and gangue minerals, and achieve the purpose of enriching manganese ore to enhance ore grade. The gravity separator equipment mainly includes jig, shaker table and heavy medium hydro-cyclone. For the treatment of manganese ore, a jig and a shaker were used respectively, and the recovery rate of the MnO obtained by the re-selection of the jig was 51. 54%, the recovery rate of shaker gravity separation was 91. 11%
Manganese ore is mostly weakly magnetic. The specific magnetization coefficient of the manganese ore is up to 250106cm 3/g, the tungsten manganese iron ore is 66106 cm3/g, and the manganese carbonate ore is 125106 cm 3/g. Most of the gangue minerals are aluminosilicates, which are non-magnetic. Therefore, manganese ore enrichment can be achieved by strong magnetic separation. The magnetic separation of low-grade manganese ore was studied. After two-step magnetic separation with high magnetic field strength and low magnetic field strength, the ore grade was increased to 45. 8%. The main types of magnetic separators are the high-density magnetic separator, wet magnetic separator, dry magnetic separator.
Flotation is suitable for the treatment of fine-grained manganese ore. Ore size is an important indicator affecting the flotation effect. The development of flotation reagents is the key technology. Traditional flotation collectors mainly include oleic acid, oxidized paraffin soap, naphthenic acid and tart oil. flotation machine for sale.
The natural type of Australia manganese ore is mainly manganese oxide ore, which has two types: primary and oxidized. Manganese minerals mainly include pyrolusite, hard manganese ore, crypto-potassium-manganese ore, and a small amount of manganese earth, black manganese ore, manganese ore, strontium magnesium manganese ore, black zinc manganese ore, galvanized manganese ore and limonite. The gangue minerals are mainly quartz, followed by kaolin, sericite, opal, stone pulp, clay and so on. Australia manganese ore primary manganese ore is only found in sedimentary-reformed deposits, mainly composed of manganese carbonates, sulfides and silicates. The ore type is mainly composed of mixed primary manganese ore, and can be divided into sulphur manganese ore-manganese carbonate ore, sulphur manganese ore-manganese silicate-manganese carbonate ore. Manganese minerals are mainly rhombohedral, sulphur-manganese or eutropha, with a small amount of iron-sulfur-manganese ore, calcium sulphurite and manganese garnet; associated metal minerals such as galena, sphalerite, strontium silver ore Copper ore and pyrite. The gangue minerals are mainly quartz, calcite and chlorite, a small amount of diopside, serpentine and claystone.
Ore material on the grid sieve, screened material flow into the washing machine, then into vibrating classifier, handpick the +30mm grain size to do secondary washing. -30mm +3mm grain size into the mineral jig to get concentrated manganese. The jigging tailings and the -3mm size material is merged into the grinding system which consists of rod mill, vibrating screen, and spiral classifier. -1mm material into the SHP-1000 high-density magnetic separator select out the concentrate manganese, the strong magnetic tailings are cleaned by DPMS wet permanent magnetic strong magnetic separator. JXSC mining machinery manufacturer provides a full set of manganese ore processing machine globally, besides, we do gold wash plant, gold separator machine, portable crusher, gold trommel scrubber, stone crusher, ore dressing equipment, mineral concentrate, etc. contact us to know the latest gold wash plant prices.
India is a major mineral producer in Asia and globally. It is currently a global producer of chromite, coal, iron ore and bauxite. Bauxite is an ore of Aluminium and is a term for sediments rich in alumina but low in alkalis, alkaline earth and silica. The term is also extended to cover lateritic weathering products rich in gibbsite on basalt. The production of aluminium consumes over 90% of world production of bauxite, while the reminder is used for abrasives, chemicals and refractory. The term bauxite ore is applicable to bauxites, which are economically mineable containing not less than 45-50% Al2O3 and not more than 20% Fe2O3, and 3-5% combined silica. The term alumina refers to pure Al2O3 containing 52.9% Al and 47.1% O.
Bauxite deposits originate from weathering or soil formation with enrichment of aluminum. The parent rock of bauxite may be (1) igneous and metamorphic rocks, (2) sedimentary rocks. Bauxite deposits on igneous and metamorphic rock are known to have formed throughout the Earths history on plateaus. Examples of slope type deposits are on : basic to intermediate volcanic rocks, acid metamorphic rocks and charnockites in south India. Conditions which favour and the formation of bauxites are permeability, high temperature climate with continuous rainfall, location of source rock in topographically high and well drained areas, availability of pure rain water than the organic acids which will decrease the quartz dissolution, pH between 4-10, dense vegetation, bacteriological action, a mature topography permitting accumulation of the weathered products and free movement of the water table with minimum erosion.
Beneficiation of ores may be defined as the method of upgrading and enriching the useful mineral content of the ores, by removing undesirable and deleterious components. The processes adopted depend on the physical and chemical characteristics of the ore minerals, to take advantage of properties like specific gravity, magnetism, surface characteristics etc. The beneficiation processes normally employed are washing ; gravity concentration - jigging, heavy media separation, spiraling and tabling ; and magnetic separation and flotation. Most of the bauxite ores are being presently subjected to beneficiation ranging from simple crushing, classification, washing and jigging to heavy media separation, also known as sink-float separation, to achieve higher recovery of saleable ore and to obtain a high grade concentrate.
As a leader in the mining industry, SBM can provide equipment from the ore bauxite career in India. Bauxite ore beneficiation production line mainly including crushing equipment, grinding equipment and separation equipment . For bauxite ore crushing, you can choose from our bauxite ore crusher jaw crusher, cone ore bauxite and bauxite ore crusher. For bauxite ore crushing, we can offer to treat bauxite ore ball bauxite ore super thin mill, bauxite ore vertical mill and so on. Shortly after crushing and grinding, you can select magnetic separator and flotation separator to separate. Others included in the production line of bauxite ore optional equipment are vibrating screen, belt conveyor, grader, rotary dryer, vibrating separator and so on. Because we are professionals in the mining and processing of bauxite, we can design and manufacture bauxite ore production line according to your requirement.
The process of breaking the ore blocks with a particle size of 500-1500mm from the mine to a particle size of 5-25mm. The methods include crushing, crushing, chopping, etc., generally in three stages: coarse crushing, medium crushing, and fine crushing.
The particle size of the immersion dye in the ore of the beneficiation machinery and the separation method used are determined. Commonly used grinding equipments include rod mills, ball mills, self-grinding machines and semi-self-grinding machines. High energy consumption for grinding operations, usually about half of the total energy consumption for beneficiation
According to the size of the sieve surface, the material is divided into different particle size levels called sieving, which is often used to process materials with coarser particle size. According to the different sedimentation speed of particles in the medium (usually water), the materials are divided into different grades of equal reduction, called classification, and used for materials with smaller particle sizes. Screening and grading are to separate materials of suitable particle size during the crushing process, or divide the materials into different particle size levels for selection.
In order to avoid clogging of the crushing and screening equipment by the mud in the mud-containing mineral raw materials, ore washing is required. If the raw materials contain soluble useful or harmful ingredients, they must also be washed. Ore washing can be carried out in a scrubbing machine or in a screening and grading equipment.
After the crushing operation, the mineral raw materials enter the sorting operation to separate useful minerals from gangue, or separate useful minerals from each other. This is the main part of beneficiation. The sorting operations include heavy sorting, flotation, In the medium (mainly water) flow, the difference in the specific gravity of the mineral raw material particles is used for classification. The suitable particle size range for re-election is wide, from a few hundred millimeters to less than one millimeter, with low beneficiation cost and less environmental pollution. Where the particle size of the mineral is within the above range and the specific gravity difference between the components is large, gravity selection is the most suitable. Sometimes, reselection (mainly heavy medium selection, jig selection, etc.) can be used to pre-select to remove part of the waste rock, and then use other methods to reduce the cost of mineral processing. Use the difference of water wettability (hydrophobicity or hydrophilicity) on the surface of various mineral raw materials to distinguish. Usually refers to froth flotation. There are few natural hydrophobic minerals. Collectors are often added to the ore slurry to enhance the hydrophobicity of the minerals to be floated; various regulators are added to improve selectivity; foaming agents are added and aerated to generate bubbles to make hydrophobic The mineral particles are attached to the bubbles and float up and separate. Flotation can usually process materials smaller than 0.2-0.3mm. In principle, it can select various mineral raw materials. It is a widely used method. Flotation can also be used to separate smelting intermediate products, ions in solution, and treat wastewater. Make use of the different magnetic properties of mineral particles to distinguish in a non-uniform magnetic field. Strong magnetic minerals (magnetite and pyrrhotite, etc.) are separated by a weak magnetic field magnetic separator; weak magnetic minerals (hematite, siderite, ilmenite, wolframite, etc.) are separated by a strong magnetic field magnetic separator Sorting. The structure of magnetic separator includes drum type, belt type, rotating ring type, disc type, induction roller type and so on. Magnetic pulleys are used to pre-select massive strong magnetic ore. The main development trend of magnetic separation is to solve the problem of recovery of fine-grained weakly magnetic minerals. Use the difference in electrical properties of mineral particles to select in a high-voltage electric field. Mainly used to sort conductor, semiconductor and non-conductor minerals. According to the electric field, the electric separator can be divided into electrostatic concentrator, corona concentrator and composite electric field electric separator; according to the charging method of ore particles, it can be divided into contact electrified separator, corona electrified separator and friction electrified separator. The electrical separator has a narrow processing particle size range, low processing capacity, and raw materials need to be dried, so the application is limited; but the cost is not high, the separation effect is good, and the pollution is low; it is mainly used for the selection of coarse concentrates, such as separation white Tungsten ore, cassiterite, zircon, rutile, ilmenite, tantalum niobium, monazite, etc. Electric separation is also used for classification and dust removal of mineral raw materials. The development trend of electrical separation is to develop equipment with large processing capacity and high efficiency in selecting fine-grained materials. Prominer has been devoted to mineral processing industry for decades and specializes in mineral upgrading and deep processing. With expertise in the fields of mineral project development, mining, test study, engineering, technological processing.
In the medium (mainly water) flow, the difference in the specific gravity of the mineral raw material particles is used for classification. The suitable particle size range for re-election is wide, from a few hundred millimeters to less than one millimeter, with low beneficiation cost and less environmental pollution. Where the particle size of the mineral is within the above range and the specific gravity difference between the components is large, gravity selection is the most suitable. Sometimes, reselection (mainly heavy medium selection, jig selection, etc.) can be used to pre-select to remove part of the waste rock, and then use other methods to reduce the cost of mineral processing.
Use the difference of water wettability (hydrophobicity or hydrophilicity) on the surface of various mineral raw materials to distinguish. Usually refers to froth flotation. There are few natural hydrophobic minerals. Collectors are often added to the ore slurry to enhance the hydrophobicity of the minerals to be floated; various regulators are added to improve selectivity; foaming agents are added and aerated to generate bubbles to make hydrophobic The mineral particles are attached to the bubbles and float up and separate. Flotation can usually process materials smaller than 0.2-0.3mm. In principle, it can select various mineral raw materials. It is a widely used method. Flotation can also be used to separate smelting intermediate products, ions in solution, and treat wastewater.
Make use of the different magnetic properties of mineral particles to distinguish in a non-uniform magnetic field. Strong magnetic minerals (magnetite and pyrrhotite, etc.) are separated by a weak magnetic field magnetic separator; weak magnetic minerals (hematite, siderite, ilmenite, wolframite, etc.) are separated by a strong magnetic field magnetic separator Sorting. The structure of magnetic separator includes drum type, belt type, rotating ring type, disc type, induction roller type and so on. Magnetic pulleys are used to pre-select massive strong magnetic ore. The main development trend of magnetic separation is to solve the problem of recovery of fine-grained weakly magnetic minerals.
Use the difference in electrical properties of mineral particles to select in a high-voltage electric field. Mainly used to sort conductor, semiconductor and non-conductor minerals. According to the electric field, the electric separator can be divided into electrostatic concentrator, corona concentrator and composite electric field electric separator; according to the charging method of ore particles, it can be divided into contact electrified separator, corona electrified separator and friction electrified separator. The electrical separator has a narrow processing particle size range, low processing capacity, and raw materials need to be dried, so the application is limited; but the cost is not high, the separation effect is good, and the pollution is low; it is mainly used for the selection of coarse concentrates, such as separation white Tungsten ore, cassiterite, zircon, rutile, ilmenite, tantalum niobium, monazite, etc. Electric separation is also used for classification and dust removal of mineral raw materials. The development trend of electrical separation is to develop equipment with large processing capacity and high efficiency in selecting fine-grained materials.
Prominer has been devoted to mineral processing industry for decades and specializes in mineral upgrading and deep processing. With expertise in the fields of mineral project development, mining, test study, engineering, technological processing.
After crushing, grinding, magnetic separation, flotation, and gravity separation, etc., iron is gradually selected from the natural iron ore. The beneficiation process should be as efficient and simple as possible, such as the development of energy-saving equipment, and the best possible results with the most suitable process. In the iron ore beneficiation factory, the equipment investment, production cost, power consumption and steel consumption of crushing and grinding operations often account for the largest proportion. Therefore, the calculation and selection of crushing and grinding equipment and the quality of operation management are to a large extent determine the economic benefits of the beneficiation factory.
There are many types of iron ore, but mainly magnetite (Fe3O4) and hematite (Fe2O3) are used for iron production because magnetite and hematite have higher content of iron and easy to be upgraded to high grade for steel factories.
Due to the deformation of the geological properties, there would be some changes of the characteristics of the raw ore and sometimes magnetite, hematite, limonite as well as other types iron ore and veins are in symbiosis form. So mineralogy study on the forms, characteristics as well as liberation size are necessary before getting into the study of beneficiation technology.
1. Magnetite ore stage grinding-magnetic separation process The stage grinding-magnetic separation process mainly utilizes the characteristics of magnetite that can be enriched under coarse grinding conditions, and at the same time, it can discharge the characteristics of single gangue, reducing the amount of grinding in the next stage. In the process of continuous development and improvement, the process adopts high-efficiency magnetic separation equipment to achieve energy saving and consumption reduction. At present, almost all magnetic separation plants in China use a large-diameter (medium 1 050 mm, medium 1 200 mm, medium 1 500 mm, etc.) permanent magnet magnetic separator to carry out the stage tailing removing process after one stage grinding. The characteristic of permanent magnet large-diameter magnetic separator is that it can effectively separate 3~0mm or 6~0mm, or even 10-0mm coarse-grained magnetite ore, and the yield of removed tails is generally 30.00%~50.00%. The grade is below 8.00%, which creates good conditions for the magnetic separation plant to save energy and increase production.
2.Magnetic separation-fine screen process Gangue conjoined bodies such as magnetite and quartz can be enriched when the particle size and magnetic properties reach a certain range. However, it is easy to form a coarse concatenated mixture in the iron concentrate, which reduces the grade of the iron concentrate. This kind of concentrate is sieved by a fine sieve with corresponding sieve holes, and high-quality iron concentrate can be obtained under the sieve.
There are two methods for gravity separation of hematite. One is coarse-grained gravity separation. The geological grade of the ore deposit is relatively high (about 50%), but the ore body is thinner or has more interlayers. The waste rock is mixed in during mining to dilute the ore. For this kind of ore, only crushing and no-grinding can be used so coarse-grained tailings are discarded through re-election to recover the geological grade.
The other one is fine-grain gravity separation, which mostly deals with the hematite with finer grain size and high magnetic content. After crushing, the ore is ground to separate the mineral monomers, and the fine-grained high-grade concentrate is obtained by gravity separation. However, since most of the weak magnetic iron ore concentrates with strong magnetic separation are not high in grade, and the unit processing capacity of the gravity separation process is relatively low, the combined process of strong magnetic separation and gravity separation is often used, that is, the strong magnetic separation process is used to discard a large amount of unqualified tailings, and then use the gravity separation process to further process the strong magnetic concentrate to improve the concentrate grade.
Due to the complexity, large-scale mixed iron ore and hematite ore adopt stage grinding or continuous grinding, coarse subdivision separation, gravity separation-weak magnetic separation-high gradient magnetic separation-anion reverse flotation process. The characteristics of such process are as follows:
(1) Coarse subdivision separation: For the coarse part, use gravity separation to take out most of the coarse-grained iron concentrate after a stage of grinding. The SLon type high gradient medium magnetic machine removes part of the tailings; the fine part uses the SLon type high gradient strong magnetic separator to further remove the tailings and mud to create good operating conditions for reverse flotation. Due to the superior performance of the SLon-type high-gradient magnetic separator, a higher recovery rate in the whole process is ensured, and the reverse flotation guarantees a higher fine-grained concentrate grade.
(2) A reasonable process for narrow-level selection is realized. In the process of mineral separation, the degree of separation of minerals is not only related to the characteristics of the mineral itself, but also to the specific surface area of the mineral particles. This effect is more prominent in the flotation process. Because in the flotation process, the minimum value of the force between the flotation agent and the mineral and the agent and the bubble is related to the specific surface area of the mineral, and the ratio of the agent to the mineral action area. This makes the factors double affecting the floatability of minerals easily causing minerals with a large specific surface area and relatively difficult to float and minerals with a small specific surface area and relatively easy to float have relatively consistent floatability, and sometimes the former has even better floatability. The realization of the narrow-level beneficiation process can prevent the occurrence of the above-mentioned phenomenon that easily leads to the chaos of the flotation process to a large extent, and improve the beneficiation efficiency.
(3) The combined application of high-gradient strong magnetic separation and anion reverse flotation process achieves the best combination of processes. At present, the weak magnetic iron ore beneficiation plants in China all adopt high-gradient strong magnetic separation-anion reverse flotation process in their technological process. This combination is particularly effective in the beneficiation of weak magnetic iron ore. For high-gradient strong magnetic separation, the effect of improving the grade of concentrate is not obvious. However, it is very effective to rely on high-gradient and strong magnetic separation to provide ideal raw materials for reverse flotation. At the same time, anion reverse flotation is affected by its own process characteristics and is particularly effective for the separation of fine-grained and relatively high-grade materials. The advantages of high-gradient strong magnetic separation and anion reverse flotation technology complement each other, and realize the delicate combination of the beneficiation process.
The key technology innovation of the integrated dry grinding and magnetic separation system is to "replace ball mill grinding with HPGR grinding", and the target is to reduce the cost of ball mill grinding and wet magnetic separation.
HPGRs orhigh-pressure grinding rollshave made broad advances into mining industries. The technology is now widely viewed as a primary milling alternative, and there are several large installations commissioned in recent years. After these developments, anHPGRsbased circuit configuration would often be the base case for certain ore types, such as very hard, abrasive ores.
The wear on a rolls surface is a function of the ores abrasivity. Increasing roll speed or pressure increases wear with a given material. Studs allowing the formation of an autogenous wear layer, edge blocks, and cheek plates. Development in these areas continues, with examples including profiling of stud hardness to minimize the bathtub effect (wear of the center of the rolls more rapidly than the outer areas), low-profile edge blocks for installation on worn tires, and improvements in both design and wear materials for cheek plates.
With Strip Surface, HPGRs improve observed downstream comminution efficiency. This is attributable to both increased fines generation, but also due to what appears to be weakening of the ore which many researchers attribute to micro-cracking.
As we tested , the average yield of 3mm-0 and 0.15mm-0 size fraction with Strip Surface was 78.3% and 46.2%, comparatively, the average yield of 3mm-0 and 0.3mm-0 with studs surface was 58.36% and 21.7%.
These intelligently engineered units are ideal for classifying coarser cuts ranging from 50 to 200 mesh. The feed material is dropped into the top of the classifier. It falls into a continuous feed curtain in front of the vanes, passing through low velocity air entering the side of the unit. The air flow direction is changed by the vanes from horizontal to angularly upward, resulting in separation and classification of the particulate. Coarse particles dropps directly to the product and fine particles are efficiently discharged through a valve beneath the unit. The micro fines are conveyed by air to a fabric filter for final recovery.
Air Magnetic Separation Cluster is a special equipment developed for dry magnetic separation of fine size (-3mm) and micro fine size(-0.1mm) magnetite. The air magnetic separation system can be combined according to the characteristic of magnetic minerals to achieve effective recovery of magnetite.
After rough grinding, adopt appropriate separation method, discard part of tailings and sort out part of qualified concentrate, and re-grind and re-separate the middling, is called stage grinding and stage separation process.
According to the characteristics of the raw ore, the use of stage grinding and stage separation technology is an effective measure for energy conservation in iron ore concentrators. At the coarser one-stage grinding fineness, high-efficiency beneficiation equipment is used to advance the tailings, which greatly reduces the processing volume of the second-stage grinding.
If the crystal grain size is relatively coarse, the stage grinding, stage magnetic separation-fine sieve self-circulation process is adopted. Generally, the product on the fine sieve is given to the second stage grinding and re-grinding. The process flow is relatively simple.
If the crystal grain size is too fine, the process of stage grinding, stage magnetic separation and fine sieve regrind is adopted. This process is the third stage of grinding and fine grinding after the products on the first and second stages of fine sieve are concentrated and magnetically separated. Then it is processed by magnetic separation and fine sieve, the process is relatively complicated.
At present, the operation of magnetic separation (including weak magnetic separation and strong magnetic separation) is one of the effective means of throwing tails in advance; anion reverse flotation and cation reverse flotation are one of the effective means to improve the grade of iron ore.
In particular, in the process of beneficiation, both of them basically take the selected feed minerals containing less gangue minerals as the sorting object, and both use the biggest difference in mineral selectivity, which makes the two in the whole process both play a good role in the process.
Based on the iron ore processing experience and necessary processing tests, Prominer can supply complete processing plant combined with various processing technologies, such as gravity separation, magnetic separation, flotation, etc., to improve the grade of TFe of the concentrate and get the best yield. Magnetic separation is commonly used for magnetite. Gravity separation is commonly used for hematite. Flotation is mainly used to process limonite and other kinds of iron ores
Through detailed mineralogy study and lab processing test, a most suitable processing plant parameters will be acquired. Based on those parameters Prominer can design a processing plant for mine owners and supply EPC services till the plant operating.
Prominer has been devoted to mineral processing industry for decades and specializes in mineral upgrading and deep processing. With expertise in the fields of mineral project development, mining, test study, engineering, technological processing.
Dewo machinery can provides complete set of crushing and screening line, including Hydraulic Cone Crusher, Jaw Crusher, Impact Crusher, Vertical Shaft Impact Crusher (Sand Making Machine), fixed and movable rock crushing line, but also provides turnkey project for cement production line, ore beneficiation production line and drying production line. Dewo Machinery can provide high quality products, as well as customized optimized technical proposal and one station after- sales service.
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