Magnetite Separation Production Line

【Case】

Case 1

A magnetite in Inner Mongolia, the main mental mineral was magnetite with disseminated structure and fine particle distribution. The iron content was about 12-16%. This plant adopted the grinding-weak magnetic process and obtained 65% concentrate grade and 90% recovery rate, but the operation cost is too high after a long time running. It authorized Xinhai to reform the process. Xinhai did not only keep the original indexes, but also reduce the operation costs. Indexes comparison as follow

Comparison of Reformation	Process	Iron Concentrate Grade /%	Iron Concentrate Recovery Rate /%
Before Reformation	Three stages grinding, Three stages magnetic separation	65.58	90.15
After Reformation	Stages grinding, stages separation	67.81	92.69

Due to the low grade of the iron ore, the stages grinding and stages separation could reduce energy consumption. Cost saving is the key of developing the mine. The fine grinding process has guide significance for similar iron ore

Case 2 —— Shanxi 1,200t/d Iron Mineral Processing Plant

Project Introduction:  

The Shanxi 1,200t/d iron mineral processing plant was an EPC+M+O project.

Our Solution:  

Two-stage closed-circuit crushing and screening-two-stage closed-circuit grinding and classification-magnetic separation process of one-stage roughing and three-stage concentration concentrates and tailings filtering and dewatering.

Crushing and screening: the final product size was -12mm. Advanced and cost-effective equipment was adopted;crushing and screening processes shared the plant for convenience; the crushing product was fine so that crushing and grinding costs were cut.

Grinding and classification: the first- and second-grinding fineness was -200 mesh (67%) and -325 mesh (88.47%) respectively. Bearing-drive energy-saving ball mill was adopted so that grinding costs were significantly reduced. Upgraded spiral classifier and fine screen were adopted in the first- and second-stage classification respectively to control the particle size strictly.

Magnetic separation: one-stage roughing and three-stage concentration. (Xinhai rubber pump was used to transport slurry.)

Concentrates and tailings transportation: iron concentrates were dehydrated in the permanent magnetic filter and then transported by belt conveyor to the iron concentrates powder dump, and tailings flowed by gravity to the ditch outside the plant.

Project Results:

The project adopted advanced, sound and energy-saving equipment and simple auxiliary facilities to cut construction costs and increase output. There was no environmental pollution, meaning that no waste water was discharged.

Case 3 —— Anhui 600t/d Iron Mineral Processing Plant

Project Introduction:

As the ore properties were complicated, Xinhai carried out a series of mineral processing tests. After the comparison among them, an ideal process was identified for the ore.

Our Solution:

Two-stage grinding-six-stage magnetic separation-iron concentrates dewatering-gravity concentration for magnetic tailings-regrinding-sulfur and titanium flotation and separation.

Grinding and separation: two-stage grinding-six-stage magnetic separation.

Iron concentrates dewatering: iron concentrates were pumped to the permanent magnetic filter and dehydrated together with already produced concentrates; filtrate returned to the system for recycling and filter cake was transported by belt conveyor at three times to the dump.

Sulfur and titanium separation: gravity concentration-regrinding-flotation.

Project Results:  

While increasing the efficiency of resources exploration, Xinhai paid attention to environmental protection. Effective solutions were adopted to address the spread of dust and noise and the disposal of waste water and tailings so that green development of the mine was ensured.