Our iron ore wet processing plants are proven to successfully deal with silica and alumina contamination in the iron ore, resulting in an increase in the Fe value of the iron ore thereby increasing the efficiency of the steel production process.
Silica requires very high temperatures in the kiln, therefore, increasing energy costs when it is present in the feed to the kilns. Both alumina and silica build up in the kilns as a coating, reducing the efficiency of the kilns over time.
This requires that the kilns be shut down in order to facilitate the removal of this material build up. Our iron ore processing plants target these contaminants and ensure their effective removal from the feed to the kilns. This has the effect of increasing the Fe value of the iron ore allowing for a more efficient steel production process.
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.
The iron ore industries of India are expected to bring new technologies to cater to the need of the tremendous increase in demand for quality ores for steel making. With the high-grade ores depleting very fast, the focus is on the beneficiation of low-grade resources. However, most of these ores do not respond well to the conventional beneficiation techniquesused to achieve a suitable concentrate for steel and other metallurgical industries. The present communication discusses the beneficiation practices in the Indian context and the recent developments in alternative processing technologies such as reduction roasting, microwave-assisted heating, magnetic carrier technology and bio-beneficiation. Besides, the use of new collectors in iron ore flotation is also highlighted.
Iron ore is primarily found as the oxides of iron, notably hematite and magnetite and as hydroxides like goethite and limonite. Small amounts are found as the carbonates in siderite, as sulphides in pyrites and as silicates in chamosite and greenalite. Indian economy is growing steel demand and supply will grow in the same way. As good quality iron ore deposits are depleting very fast beneficiation technologies have to be adopted to meet iron ore demand.. Agglomeration technologies such as Pelletization / Sintering have to be added to Steel Plant so that concentrates can be used as feed material. This paper will give an insight about the potential of pelletization technology of iron ore. Also focus on the present status of iron ore reserves in India, inventory of iron ore pelletization plant, primary data collection by conducting field monitoring for air, water and solid waste Compilation of primary data and assessment of compliance to stipulated norms, Preparation of best practices in Pelletization process for sound environmental management in eastern region of India.
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.
Iron Orebeneficiationsolutions fromMultotecare designed so thateach stage of the mineral beneficiation process, from ROM stockpiles to processed minerals and tailings,reduce overheads and lower your overall cost per ton.
The ore is again screened, with finer particles falls into the screens ceramic lined underpans and coarse particles are conveyed via anover belt magnetic separatorto a Dense Medium Separation Drum. It is then laundered with aceramic linedlaunder before again being screened by coarse waste and coarse iron drain and rinse screens. Refined coarse product can be sampled with ahammer sampler.
The ore from the desliming screen is sent to aDMS cyclonewhere separation sends some of the ore throughsievebend housingsand the more valuable stream to static screens. Waste and coarse material from both these screens go to the magnetic separator, while the balance, medium product, is diverted for use.
A portion of the ore from the desliming screen is sent directly to a sink drain & rinse screen and a jig screen, which separates particles into different quantities based on density. After screening, the waste stream is sent to a floatation screen resulting in waste product, and the mineral rich stream is sent to a sink screen, subsequently producing additional medium product.
As a technology-driven company, our iron ore beneficiation solutions are supported by a team of skilled engineers and metallurgists, with a wealth of process and application knowledge that we use to achieve gold beneficiation at the lowest cost per ton.Get in Touch with Mechanic