Iron Ore Beneficiation Process

About Iron Ore Beneficiation Process

An iron ore beneficiation plant processes raw iron ore to improve its iron content and remove impurities (gangue) such as silica, alumina, and phosphorus. The goal is to produce a high-grade iron ore concentrate (typically >60% Fe) suitable for pelletizing or direct use in blast furnaces.

Types of Iron Ore and Beneficiation Techniques

- Magnetite Ore: High iron content and magnetic properties; primarily processed using magnetic separation.

- Magnetite Ore: Hematite Ore: Lower iron content and non-magnetic; often requires flotation, gravity separation, or a combination of methods.

- Magnetite Ore: Mixed Ores: May require a combination of techniques depending on the composition.

Iron ore benefication plant flow diagram

1.Crushing & screening

A vibrating feeder is to evenly feed iron ore into jaw crusher and secondary cone crusher, then use vibrating screen to screened out to meet the particle size for grinding.

Machine list: hopper, vibrating feeder, jaw crusher, cone crusher or hammer crusher(optional)

2.Grinding & Classifying

The ore has relatively high hardness and extremely fine particle size. It adopts two-stage grinding process, which is ball mill combined with a spiral classifier to achieve the required grinding fineness.

Machine list: electromagnetic vibrating feeder or similar, ball mill, sprial classifier

3.Magnetic Separation:

Separation generally adopts permanent magnet drum type magnetic separator.Most magnetite beneficiation plants often adopt coarse-grained dry magnetic separation tailings. For the ultra-lean magnetite ore with a grade below 20.00%, the ultra-fine crushing-wet magnetic separation tailing process can be used before entering the mill. That is to say, the ore is finely crushed to below 5mm-3mm, and then wet magnetic separation and tailing are carried out with a permanent magnetic field magnetic separator.

Machine list: strong magnetic separator,weak magnetci separator, high efficiency screen etc.

4. Tailings treatment:

The concentrated iron ore is dewatered using thickeners, filters, or centrifuges to reduce moisture content for storage or transportation.In some cases, the beneficiated iron ore is further processed into pellets through pelletizing plants. This involves mixing the concentrate with binders, forming pellets, and firing them in kilns to produce high-grade iron ore pellets.

Machine list: thickener, vacuum filter, pelletizing machine is optional.

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