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.
January 25, 2019, the Vale iron mine in Brazil experienced a dam break, which led to the closure of large-scale mines. At the same time, the two major mines in Australia, BHP and Rio Tinto, were affected by the hurricane to reduce their shipments.
Since the end of January this year, iron ore prices have risen sharply, far exceeding the increase in steel and other raw materials. Therefore, iron ore has become the most popular investment in the eyes of investors. In July 2019, the price of iron ore reached more than US$120 per ton.
For the time being, the investment prospect of iron ore is very bright. So what is the global reserves and distribution of iron ore? How much does it cost to build an iron ore processing line? This article will answer you in detail.
The data released by USGS in early 2005 showed that the global iron ore reserves were 160 billion tons, the reserves of mineral iron (ie, iron contained in iron ore) were 80 billion tons and the basic reserves were 180 billion tons.
The worlds iron ore is mainly reserved in Ukraine, Russia, Brazil, China and Australia. The reserves are 30 billion tons, 25 billion tons, 21 billion tons, 21 billion tons and 18 billion tons respectively, accounting for 18.8%, 15.6%, 13.1%, 13.1% and 11.3% of the worlds total reserves respectively.
In addition, Kazakhstan, the United States, India, Venezuela and Sweden also have rich iron ore resources, and their iron ore reserves are 8.3 billion tons, 6.9 billion tons, 6.6 billion tons, 4 billion tons and 3.5 billion tons, respectively accounting for 5.2%, 4.3%, 4.1%, 2.5% and 2.2% of the worlds total iron ore reserves.
The worlds mineral iron is mainly reserved in Brazil, Russia and Australia, with reserves of 14 billion tons, 14 billion tons and 11 billion tons respectively, accounting for 17.5%, 17.5% and 13.8% of the worlds total reserves. The sum of the reserves in the three countries accounts for 48.8% of the total reserves in the world.
Mineral iron reserves and basic reserves are the most representative of the richness of a countrys iron ore resources, so Brazil, Russia and Australia are the worlds richest iron ore resources. At the same time, it shows that although Ukraine and China have large reserves of iron ore, they have more lean ore and less rich ore.
Iron ore resources are mainly reserved in more than10 countries, and 90% of proven reserves are distributed in10 countries and regions. They are: CIS (proven reserves of 114 billion tons, of which Russia is more than 80 billion tons), Brazil (68 billion tons), China (50 billion tons), Canada (over 36 billion tons), Australia (35 billion tons) ), India (17.57 billion tons), the United States (17.4 billion tons), France (7 billion tons), Sweden (3.65 billion tons).
The global iron mine reserves increased from 232 billion tons in 1996 to 370 billion tons in 2006, an increase of 59.5% in 10 years. The total amount of iron ore resources in the world is estimated to exceed 800 billion tons (the amount of iron ore), and the iron content exceeds 230 billion tons and there is still great potential for future discovery.
The major countries of iron ore resources include Brazil, Australia, China, Russia, Kazakhstan, Ukraine, the United States, India, Sweden, and Venezuela. High-grade ore is widely distributed in Brazil, Australia, India and other countries. The low mining cost and relatively high grade of iron ore make these countries the major iron ore suppliers in the world.
Before dry selection, the lean iron ore requires millimeter-scale fine crushing by the fine crusher. If the particle size of the iron ore is not small enough in the crushing stage, low-grade iron ore is difficult to be selected later, which will cause serious waste of resources.
The common problem in the iron ore crushing production line is that the wear parts of the fine crusher are seriously worn out, and the repair and maintenance of the fine crusher are too frequent, which makes the production efficiency of the iron ore crushing production line lower.
Different iron ore has different features. According to these features, the crushers are made of different materials. Therefore, the prices of iron ore crusher are different. However, reasonable crushing processes and crusher can be used to save the cost investment and achieve the required crushing effect.
In the crushing process of lean iron ore, in order to obtain the best process configuration and the lowest crushing cost, it is necessary to master the relationship of particle size among the primary crushing, the secondary crushing and the fine crushing.
For medium and low hardness lean iron ore, the second crushing equipment can use the impact crusher. The iron ore impact crusher utilizes a plate hammer on a high-speed moving rotor to produce a high-speed impact on the iron ore fed into the crushing chamber. The crushed iron ore is thrown at a high speed in the tangential direction toward the counter-attack at the other end of the crushing chamber.
During this process, the iron ore will collide with each other, causing cracks and looseness. When the iron ore particle size is smaller than the gap between the counterattack plate and the plate hammer, it is discharged outside the machine.
For high-hardness iron ore, a cone crusher can be used for the secondary crushing equipment. The HXJQ short-headed cone crusher can achieve a fine crushing effect of 3 to 13mm, which can fully meet the requirements of dry selection and grinding. However, due to the high hardness of such iron ore, the impact on the wear parts is large, so ordinary crushing equipment is difficult to exert its advantage.
In areas with low power consumption, the sand making machine developed and produced by HXJQ can achieve the fine crushing effect of high hardness and high output iron ore. Not only can the iron ore particle size be reduced to improve the dry selection efficiency, but also the ball mill load and operating cost can be greatly reduced, and the ball mill production capacity can be improved.
The price of iron ore crushing production line is related to various factors such as equipment combination, output level, and quality. Of course, the quotation standards of different manufacturers will also be different. Customers also need to analyze specifically when purchasing.
The comparison found that the price of the iron ore crushing production line of HXJQ Machinery is the most economical and reasonable, ensuring that the production line has a long service life, less failure, high efficiency, good effect, energy-saving and environmental protection, and can keep its price lower than other manufacturers 6% to 7%.
At the same time, the HXJQ configuration plan is all-sided, and there is a wide variety of equipment in HXJQ Machinery. If you are interested in these crushing equipment, please submit your relevant information on the right side, we will arrange a professional engineer to answer your questions.
Iron ore is widely used in all aspects of industrial production and people's life. It is the basic required material of social production and public life. Iron ore can be used to make iron and steel products, ammonia catalyst, natural mineral pigments, feed additives and valuable constructive criticism. Iron ore crushing which ore crushed by force to overcome its internal inter-molecular forces, so that ore block granularity is gradually shrinking. Crushing the ore is essential to the preparation stage before beneficiation, but also to achieve the separation of mineral ore and gangue, accelerating the useful mineral enrichment. In vast majority, the useful minerals and iron ore gangue minerals is closely together with each other and often fine-grained mosaic distribution. Only by pulverized sufficiently, we can make them dissociated with physical processing methods and enriched to obtain high purity iron ore. And then, it can be applied to industry production and life.
The Mohs hardness of Iron ore is 4-5, which belongs to medium-hard materials. Iron ore crushing is very suitable for the use of equipment capable of handling more than medium-hard materials. The selection of Iron ore crusher machine can usually be selected according to the processing requirements of iron ore. The common iron ore crusher includes jaw crusher for iron ore and impact crusher for iron ore.
The former jaw crusher uses integral steel structure of bearing, avoiding unnecessary burden of two type bearing chamber for frame brings. It also enhances the stability of the whole structure. In addition, the heavy eccentric shaft was processed by forging, which ensure jaw crusher has superior reliability. Its "V" type of crushing chamber and the toothed plate is more reasonable. Equipped with a hydraulic oil station, the machine lubrication system can meet the need of every parts and provide protection for the machine to operate safely.
The latter impact crusher made of world-class manufacturing processes. It not only ensures the quality of the rotor parts, but also makes the machine runs more reliable. The hydraulic control system can be quickly adjusts outlet size and grain size. Its automatic hydraulic open device can quickly complete the plate hammer, the replacement of wearing parts, reduce downtime and maintenance time. In the coarse crushing operations, two crushing chamber can simplify the process; in the fine operation in the crushing chamber, three showed extraordinary. Two kinds of cavity can meet the requirements of the vast majority of coarse and fine crushing.
The purpose of developing the iron ore fine crushing machine is to be highly enriched low-grade iron ore and to fully exploit the poor iron ore resources. Iron ore fine crushing machine is the equipment used to processing iron ore to a minimum granularity. At present, the commonly used iron ore crushing machine includes: hammer crusher, efficient crushing machine, roll crusher, cone crusher and super vertical shaft impact crusher developed in recent years. The working principle of crushing machines is different from each other and each with their own characteristics, such as hammer crusher has a simple structure, cheap cost characteristics. Meanwhile, the yield of hammer crushing machine can be subject to certain restrictions and it is only suitable for smaller-scale iron ore production in selected fields. When hammer crusher used in large production more than 100t/h of the crushing operation, the equipment failure rate will be significantly increased, it will dramatically increase the repair and maintenance costs and reduce its applicability.
In Australia, Brazil, Canada, India , the United States , Bolivia, France, Sweden , Venezuela and other country rich in iron ore resources, scattered distribution of iron ore resources coupled with relatively large land area make the application of traditional iron ore stone crusher and stationary iron ore crushing production line has been limited. Because of this fixed production equipment has high infrastructure costs, so the iron ore mobile crushing plant is widely used in the industry. Iron ore mobile crusher is a new rock crushing machine, which greatly expand the crushing operations in the field. It is equipped with vibrating feeder, jaw crusher, impact crusher, cone crusher and vibrating screens and other equipment. Integrated plant design and good mobility help achieve the simplification of infrastructure installation, reducing the material consumption. It can conduct on-site crushing for first-line material, which greatly reducing the transportation costs. Each device can be used independently, but also can associate with each other to meet product requirements of customers, providing a more flexible process configuration to meet the various requirements of mobile crushing, screening and so on.
Hematite ore, the commonly iron ore used the industrial raw material for iron ore making, with certain magnetism, so most of the hematite process contains a magnetic link. According to the anhydrous medium, the magnetic extracting iron from hematite can be divided into dry magnetic separation and wet magnetic separation. In the iron ore plant, hematite iron ore uses dry separation equipment are mainly magnetic roller and dry permanent magnetic cylinder type magnetic separation machine products, wet magnetic separation equipment of iron ore are mainly vertical ring pulsating high gradient magnetic separation machine, wet permanent magnet drum type magnetic separation machine, etc. Here the common iron ore hematite dry separation equipment were briefly introduced.Magnetic the roller is commonly used in iron ore dry cleaning equipment, usually configured after the middle crushing and throw tailings and waste rock in iron ore hematite crushing process. Magnetic roller can be divided into electromagnetic and permanent magnetic, of which the iron ore hematite permanent magnetic is mainly composed of a magnetic system, roller, magnetic yoke, aluminum rings, belts and other parts, quite in a weak magnetic cylinder installed on the conveyor belt instead of the head wheel, or said in head of belt wheel mounted on the magnet system, the magnetic system wrap angle of 360 degrees. In the process of iron ore hematite selection the hematite is uninformed on the distribution belt, when hematite extracting iron from hematite through the magnetic roller, non magnetic or weak-magnetic particles have small magnetic, and under the combination of centrifugal force and gravity they go from the belt surface into the iron ore hematite tailings products, and magnetic that has strong magnetic force in the movement process is adsorbed on the belt surface, and with the belt moves to the lower part of the magnetic drum, belt surface area magnetic field strength weakened, magnetic particles fall into magnetic products. In plant often by adjusting the plate under the magnetic roller to adjust the product quality and yield.Dry type drum permanent magnetic separator used when extracting iron from hematite, according to the number of the magnetic roller can be divided into the single cylinder and double cylinder. Mainly composed of the roller, magnetic system, box, a feeder, a transmission mechanism etc., and its working principle is approximately the same as magnetic roller, magnetic particles in the drum surface by the strong magnetic force adsorbs on the surface of the cylinder, weak magnetic or non-magnetic mineral magnetic effect is weak, left surface of the cylinder under the gravity and centrifugal force. The magnetic system of iron ore used is composed by strontium ferrite permanent magnet blocks, multiple, small distance, magnetic wrap angle is a 270-degree pole along the circumferential direction n / s alternating arrangement. The characteristics of the magnetic system of dry type permanent magnet cylinder magnetic separator make the magnetic field is not uniform, and the depth of action is limited to the roller surface.Compared to the dry permanent magnetic drum magnetic separator of iron ore hematite when hematite extracting iron from hematite, magnetic roller in iron ore hematite selection is used widely, through the magnetic roller, pre-thrown gangue, and waste ore can effectively reduce the processing capacity of the subsequent operations.
The main material required in steel making process is iron ore. According to the incomplete statistics, 98% of the iron ore mined daily is used to make steel. The global steel industry currently produces 1.7 billion tons of crude steel annually and consumes about 2 billion tons of iron ore.
However, with the limited iron ore resource, effective use of natural resources is the key to sustainable development. Using the reasonable techniques and advanced processing equipment will greatly improve the utilization rate of iron ore resources, thus extending the mining life of iron ore.
In last blog, we have introduced a lot of iron ore processing methods and techniques. And this article will recommend you 10 types of iron ore processing equipment, and share you 4 tips to choose suitable machines and manufacturer, hoping you can get some ideas.
PE jaw crusher, referred to as PE crusher, is the most important crushing equipment in mineral processing equipment. The dressing process always follows the principle of "more crushing and less grinding". Therefore, a good primary crushing equipment is crucial to the whole process.
The screening plate of iron ore ball mill has certain screening pressure, which can be adjusted simply according to the requirements of fine powder of the mill; in addition, the screen space is designed reasonably, which can effectively improve the screening efficiency of materials.
The iron ore ball mill scientifically adjusts the grading scheme of the steel ball according to the size, and composition of the materials to be ground, so as to make the particle size of the materials more even.
In view of the above comparison, it is recommended here that the gas-filled agitator flotation machine, in view of the characteristics of iron ore, the gas-filled agitator flotation machine can properly adjust the speed to prevent material sludge. Although it is necessary to configure the pneumatic system in the early stage, it can bring great economic benefits due to less wear and tear in the later use and low cost.
During the classification of iron ore, the vibration frequency of the screen surface is 50Hz, the amplitude is 0 to 2 mm, and the vibration intensity is 8 to 10 times of the acceleration of gravity, which is 2 to 3 times of the vibration intensity of the general vibrating screen.
Therefore, high-frequency screen can work normally without blocking the hole. Meanwhile, the screening efficiency is high, the processing capacity is large, and the grading particle size can reach 0.074 to 1 mm.
It has the features of simple structure, reliable performance, easy to operate and other advantages. The fineness of the finished product can be easily adjusted by the size of the classifier inclination Angle and the rotating speed of the spiral plates.
The machine base adopts channel steel, and the rest of the parts are made of steel plate. The water injection side and the shaft head of screw shaft are made of cast iron to improve the wear-resistance.
According to the principle, a spiral classifier combines into a closed cycle process with ball mill in the beneficiation production. The minerals of the required size are discharged as finished products from the overflow end to the next step and the coarse particles are returned to the ball mill for regrinding.
In the flotation process, the pulp water content of iron ore can be up to 70%-80%. During the dewatering process, filter press not only can greatly reduce the humidity of iron ore (water content can be reduced to 15%) but also can greatly improve the production efficiency and concentrate purity.
In the selection of dressing equipment, customers should consider their own materials, product characteristics and the required production capacity firstly for strict selection so that to buy suitable and reasonable equipment.
Before buying iron ore dressing equipment, model selection is a very important factor to be considered. Users need to consider whether the production capacity of this type of machine is within their capital budget, so as to avoid too large a model and lead to the waste of funds.
After all, the size of the equipment model is one of the main factors influencing its price. The larger the model, the higher the price of the equipment will be, which will also lead to higher production costs.
The size of the site is one of the criteria for the selection of the iron ore dressing machine. If the site is large, the selection of smaller models and equipment will certainly not meet the requirements of production. In addition, if the business needs to be expanded later, the machine should be in a large model.
Especially in the purchase of dryer, ball mill and other equipment, customers should fully consider the production site, and communicate with the manufacturer actively so that to make good cooperation.
It is very necessary to calculate investment in advance. The price of the different equipment is totally different, and the same equipment in different sizes also has different prices. It is recommended that users make budget funds before the purchase of equipment to select more suitable and relatively inexpensive machines.
As a leading mining machinery manufacturer in China, Hongxing Mining Machineryhas over 40 years of experience in design, production and sales. It is a large-scale joint-stock enterprise integrating scientific research, production and sales.
Over the past 40 years, Hongxing Mining Machinery has always kept in mind the original intention, insisted on the quality of products as the foundation, customer satisfaction as the ultimate goal, adhered to the responsible attitude for each product, and dedicated to customer service.
After more than 40 years of vigorous development, Hongxing Mining Machinery's product quality, sales volume and various economic indicators ranked at the forefront of China's mining machinery manufacturers, and the products have been sold to more than 100 countries and regions and won numerous praises.
Iron ores are rocks and minerals from which metallic iron can be economically extracted. The ores are usually rich in iron oxides and vary in color from dark grey, bright yellow, deep purple, to rusty red.
According to the various sources of iron as well as certain economic and safety aspects in regards to its extraction is included, we provide you with a suitable iron ore mining equipment. The course we provide information of Iron ore processing includes comprehensive information on the beneficiation of iron ore including comminution, sintering, upgrading, and pelletizing aspects.
The iron ore is distributed in Algeria,Egypt,Ghana,Kenya,Nigeria,South Africa,Sudan,Zambia,Zimbabwe,China,Russia,Australia,New Zealand,France,Germany,Iceland,Italy,Luxembourg,Netherlands,Norway,Spain,Sweden,Switzerland,Ukraine,United Kingdom,Canada,Cuba,Mexico,United States,Brazil,Chile,Peru,Venezuela,
Iron ores are typically used for the production of iron. Then the iron produced is to make steel. Steel is used to make automobiles, locomotives, ships, beams used in buildings, furniture, paper clips, tools, reinforcing rods for concrete, bicycles, and thousands of other items. It is the most-used metal by both tonnage and purpose.
Mining and processing of iron ore involves coarse crushing and screening. Iron ore is beneficiated by crushing and then separating the iron from the gangue minerals through screening. This is usually so efficient that lower grade ore can be treated especially when the magnetite is quite coarse. Common iron ore crushers are jaw crusher, cone crusher and fine jaw crusher.
You will obtain three kind of iron ore particles after screening, respectively of 75~12mm, 12~2mm, 2~0mm in size. The largest ore particles pass to dry magnetic separation with shaking chute, the middle ones are moved to dry magnetic separator with coarse jigging, and the smallest to wet magnetic separator with fine jigging. The middlings produced by three processes are moved to screening process. The tailings of wet magnetic separation will be discharged directly.
After the second crushing machine, iron ore particles are moved to secondary crushing and the first ball mill grinding. With fine ore particles, it is more efficient to upgrade iron ore. Wet ball mill and fine ore crushers are used during this process.
The obtained iron ore mines materials are moved to flotation desulfurization process, then to weak magnetic separation. The obtained product is iron ore concentrate. And low iron content material is discharged as tailings. You will also obtain sulphide concentrate as by-product through flotation desulfurization.
NO Equipment Model Motor(KW) Number Hopper LC3000X4000 1 I Vibrating Feeder ZSW-38096 11 1 II Jaw crusher PE-600900 55 1 III Impact crusher PF1214 132 1 Vibrating screen 3YA1860 22 1 Total Power (KW) 220
Iron ore processing plant works the initial physical treating part. Usually, sbm iron ore processing plants used in india include iron ore crusher, grinding mill, beneficiation plants and other assistant equipments.
Chinese Shanghai SBM design the iron ore mining process flow chart including crushing, screening, washing and grinding process for the iron ore mine in India, Mauritania, Mexico, Ethiopia, Brazil, Malaysia, Mongolia, Philippines, Egypt, Australia, Sri Lanka, UAE, Liberia, Nigeria, Guinea, Angola, Indonesia, Iran, Zimbabwe, Sweden, Pakistan, South Africa, Saudi Arabia, USA, Uganda, Colombia, Peru and Canada.
In the United States, almost all of the iron ore that is mined is used for making steel. The same is true throughout the world. Raw iron by itself is not as strong and hard as needed for construction and other purposes. So, the raw iron is alloyed with a variety of elements (such as tungsten, manganese, nickel, vanadium, chromium) to strengthen and harden it, making useful steel for construction, automobiles, and other forms of transportation such as trucks, trains and train tracks.
While the other uses for iron ore and iron are only a very small amount of the consumption, they provide excellent examples of the ingenuity and the multitude of uses that man can create from our natural resources.
Powdered iron: used in metallurgy products, magnets, high-frequency cores, auto parts, catalyst. Radioactive iron (iron 59): in medicine, tracer element in biochemical and metallurgical research. Iron blue: in paints, printing inks, plastics, cosmetics (eye shadow), artist colors, laundry blue, paper dyeing, fertilizer ingredient, baked enamel finishes for autos and appliances, industrial finishes. Black iron oxide: as pigment, in polishing compounds, metallurgy, medicine, magnetic inks, in ferrites for electronics industry.
In accordance with the characteristics of mineral composition, structure, construction and mining, sorting, Metallurgical and process iron ore is divided into two major categories of the type of natural and industrial type.
1) According to the iron-bearing mineral species can be divided into: magnetite ore, hematite iron ore, the illusion, or semi martite iron ore, vanadium-titanium magnetite ore, limonite, siderite iron ore as well as by one of two or iron mineral composition of two or more kinds of mixed ore.
2) Press the harmful impurities (S, P, Cu, Pb, Zn, V, Ti, Co, Ni, Sn, F, As) content of the high and low, can be divided into high-sulfur iron ore, iron ore of low sulfur, high phosphorus iron ore, low phosphorus iron ore.
3) According to the structure, the structure can be divided into disseminated ore stockwork disseminated ores, striped ore, banded ore, the dense massive ore, brecciated ore and oolitic, bean-shaped, kidney-shaped honeycomb , powder, earthy ore.
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.
We know that not all Iron Ore deposits are the same and changing commodities prices are placing higher demands on producers to sweat the assets through process improvements, and increase revenues by converting tailings. Thats why understanding your project objectives and opportunities is our first step in developing solutions that transform your ores into valuable commodities. This holds true for all projects that we are involved in and forms the basis for our ongoing work in developing and delivering innovative and cost effectiveprocess solutionsacross the project lifecyclethat transform your ore bodies into valuable commodities.
To be confident in investing in a project, you need to know that the separation process will work on start-up and throughout the life of the operation. We give you certainty by testing representative samples and analysing the results beyond basic calculations to deliver innovative and cost effective process flowsheets that maximise the grade and recovery of valuable minerals including Magnetite, Hematite and Goethite.
Customers value our 75 years experience in metallurgical testing, whether performed in our extensive metallurgical test laboratory in Australia or, under our direction, in partner test laboratories in the USA, South Africa, Brasil and India.
We routinely test samples as small as 100 grams for characterisation and specific gravity fractionation, through to larger samples up to 2000 kg for bench and pilot scale testing and flowsheet development. We also have the capability to create multi-stage pilot scale circuits to treat bulk samples (80-100 tonnes) for process testing and circuit optimisation and our test equipment includes the latest gravity, electrostatic and magnetic equipment.
High grade concentrates and high recovery of iron ore can be achieved using effective feed preparation systems (typically controlled crushing, screening, milling, classification and slimes removal) in combination with cost effective, efficient metallurgical separation.
Hard rock hematite deposits often require a combination of milling, screening and on occasion, fine classification to prepare a finely sized (-1.0mm), liberated feed for beneficiation by gravity separation. This is typically followed by re-grinding of the tailings to liberate more hematite for further iron unit recovery by magnetic separation.
WHIMS are also often employed to recover fine hematite from spiral circuit tailings. The inclusion of medium intensity magnetic drum separation (MIMS) in combination with jigging may be considered for the beneficiation of the 6-1mm fraction of some friable ore bodies.
Having developed an effective and optimised flowsheet, you need a plant that safely and effectively applies this flowsheet to the ore body to extract high grade iron ore whilst delivering high availability, with low capital and low operational expenditure.
For this reason our equipment is designed and manufactured using the latest technologies and is fully tested in processing operations to ensure maximum performance. This means that when we release new process equipment you can be assured that it will be fit for purpose and cost effective.
A good example is the engineering we completed for ArcelorMittals projects in Canada and Africa. The specific ore required our teams to design a High Capacity wash water spiral which becames the HC33.
As a world leader in process solutions we have delivered some of the largest and most complex projects including design of the worlds largest wet concentrating plant at the ArcelorMittal project, and the design and supply of two tailings treatment beneficiationplants for Arrium in Australia.
Bayan Obo is rich in iron, rare earth, niobium and other metals. Iron is one of the main minerals here. Iron is harder than most stones. According to the traditional iron ore processing process, the jaw crusher is used for rough crushing, and the ore is subjected to primary rolling from large pieces to small pieces. The counter-attack crusher performs the second crushing, and finally the cone crusher controls the size of the ore particles. Minimize the loss of the crusher.
Raw material is directly sent to the jaw crusher by the vibrating feeder for coarse crushing treatment;Further crushing by impact crusher;The vibrating screen effectly screens the small iron ore into different particles.
Reasonable production line design and good stability.Large capacity, excellent performance, high production efficiency.Recoup the costs in short term.Low maintenance cost, simple operation, safe and reliable.
The mobile sand making machine is composed of crushing, screening, conveying, and power control system, and can be divided into a tire-type mobile sand making machine and a crawler-type mobile sand making machine.It is very suitable for unfixed production sites or small working space, flexible transition and convenient operation, which can save a lot of transportation costs.