beneficiation process of iron ore hematite dry separation

hematite separation process

hematite separation process

The early hematite beneficiation is mainly gravity separation with machines of jigger, centrifugal separator, spiral chute, spiral washer, shaking table can be involved and later floatation separation has been used in the hematite iron ore upgrading

The early hematite beneficiation is mainly gravity separation with machines of jigger, centrifugal separator,spiral chute, spiral washer, shaking table can be involved and later floatation separation has been used in the hematite iron ore upgrading with floatation separator and magnetic separator involved. However, these single separation methods can not help to get ideal beneficiation efficiency. In recently decades, combination of magnetic separation and gravity separation, magnetic separation andfloatation separation, gravity separation and floatation separation has been adopted to get high grade hematite iron concentrate.

Hematite is main mineral form of iron oxide and main ore mineral of iron.Hematite coexists with magnetite which can be transformed to hematite by oxidation and remain form of hematite forming the illusion of hematite. Hematite separation process is suitable for complex structure hematite such as hematite and impurities with uneven distribution of particle size, ore with large content of fine particle, ore with small amount of magnetite and the gangue minerals containing quartz or kaolin.The beneficiation process includes stage grinding, coarse-fine particle separation, heavy - Magnetic - anionic reverse flotation process.

1.Hematite ore crushing:in this stage there are also three steps, the hematite ore may go through primary crushing, secondary crushing and fine crushing. Hematite primary crushing equipment includes gyratory crusher, jaw crusher, hammer crusher etc. Hematite secondary and fine crushing plants mainly include cone crusher, ball mill, vertical mill, ultrafine mill etc.

2.Main operation steps in the whole hematite beneficiation process includesorting, gravity separation, floatation, magnetic separation, electrostatic separation, chemical mineral processing etc. There are many plants involves in hematite beneficiation process, such as flotation equipment, magnetic separator, electrostatic separator etc.

Closed circuit grinding consisted of ball mill and cyclone is adopted in the first grinding. This ensures the separation efficiency, particle size and part of qualified concentrate, and it also abandons part of low grade tailings which reduce the grinding volume of medium ore and the loss of metal.

Strong magnetic process recycles fine iron minerals, which can play a dual role of de-sliming and tailings out creating good conditions for flotation. Reverse flotation process system is simple, which can significantly reduce the flotation reagents into pulp and decrease the adverse effect on the flotation process.

dry iron ore beneficiation | iron ore separation - st equipment & technology

dry iron ore beneficiation | iron ore separation - st equipment & technology

Iron ore is the fourth most common element in earths crust. Iron is essential to steel manufacturing and therefore an essential material for global economic development. Iron is also widely used in construction and the manufacturing of vehicles. Most of iron ore resources are composed of metamorphosed banded iron formations (BIF) in which iron is commonly found in the form of oxides, hydroxides and to a lesser extent carbonates.

The chemical composition of iron ores has an apparent wide range in chemical composition especially for Fe content and associated gangue minerals. Major iron minerals associated with most of the iron ores are hematite, goethite, limonite and magnetite. The main contaminants in iron ores are SiO2 and Al2O3. The typical silica and alumina bearing minerals present in iron ores are quartz, kaolinite, gibbsite, diaspore and corundum. Of these it is often observed that quartz is the main silica bearing mineral and kaolinite and gibbsite are the two-main alumina bearing minerals.

Iron ore extraction is mainly performed through open pit mining operations, resulting in significant tailings generation. The iron ore production system usually involves three stages: mining, processing and pelletizing activities. Of these, processing ensures that an adequate iron grade and chemistry is achieved prior to the pelletizing stage. Processing includes crushing, classification, milling and concentration aiming at increasing the iron content while reducing the amount of gangue minerals. Each mineral deposit has its own unique characteristics with respect to iron and gangue bearing minerals, and therefore it requires a different concentration technique.

Magnetic separation is typically used in the beneficiation of high grade iron ores where the dominant iron minerals are ferro and paramagnetic. Wet and dry low-intensity magnetic separation (LIMS) techniques are used to process ores with strong magnetic properties such as magnetite while wet high-intensity magnetic separation is used to separate the Fe-bearing minerals with weak magnetic properties such as hematite from gangue minerals. Iron ores such goethite and limonite are commonly found in tailings and does not separate very well by either technique.

Flotation is used to reduce the content of impurities in low-grade iron ores. Iron ores can be concentrated either by direct anionic flotation of iron oxides or reverse cationic flotation of silica, however reverse cationic flotation remains the most popular flotation route used in the iron industry. The use of flotation its limited by the cost of reagents, the presence of silica and alumina-rich slimes and the presence of carbonate minerals. Moreover, flotation requires waste water treatment and the use of downstream dewatering for dry final applications.

The use of flotation for the concentration of iron also involves desliming as floating in the presence of fines results in decreased efficiency and high reagent costs. Desliming is particularly critical for the removal of alumina as the separation of gibbsite from hematite or goethite by any surface-active agents is quite difficult. Most of alumina bearing minerals occurs in the finer size range (<20um) allowing for its removal through desliming. Overall, a high concentration of fines (<20um) and alumina increases the required cationic collector dose and decreases selectivity dramatically. Therefore desliming increases flotation efficiency, but results in a large volume of tailings and in loss of iron to the tailings stream.

Dry processing of iron ore presents an opportunity to eliminate costs and wet tailings generation associated with flotation and wet magnetic separation circuits. STET has evaluated several iron ore tailings and run of mine ore samples at bench scale (pre-feasibility scale). Significant movement of iron and silicates was observed, with examples highlighted in the table below.

The results of this study demonstrated that low-grade iron ore fines can be upgraded by means of STET tribo-electrostatic belt separator. Based on STET experience, the product recovery and/or grade will significantly improve at pilot scale processing, as compared to the bench-scale test device utilized during these iron ore trials.

separation process of iron ore,iron ore magnetic separation machine,iron ore beneficiation design | prominer (shanghai) mining technology co.,ltd

separation process of iron ore,iron ore magnetic separation machine,iron ore beneficiation design | prominer (shanghai) mining technology co.,ltd

At present, there are about 300 kinds of iron-bearing minerals found in nature. According to their chemical composition, iron ore can be divided into magnetite, hematite, limonite and siderite; The specific magnetic susceptibility of the material is different, and iron ore is divided into strong magnetic and weak magnetic minerals, which also provides a basis for the selection. The beneficiation process of iron ore of different nature is also completely different.

Multimetal-containing magnetite gangue minerals often contain silicate and carbonate minerals, cobalt pyrite, chalcopyrite or apatite, etc. It is recommended to use a combined weak magnetic separation-flotation process, that is, use weak magnetic separation The process first recovers iron, and then uses the flotation process to recover sulfide or apatite, which is conducive to obtaining higher beneficiation indexes.

Generally, the combined process of weak magnetic separation and flotation is also divided into two types: weak magnetic separation-flotation and flotation-weak magnetic separation. The difference between these two processes lies in the destination of the conjoined magnetite and sulfide.

This shows that under the same grinding particle size, the combined process of flotation and magnetic separation can obtain iron concentrates with low sulfide content and sulfide concentrates with high recovery rate.

Single weakly magnetic iron ore mainly includes hematite, siderite, limonite, and hematite (spiegelite)-siderite ore. Due to the variety of minerals involved in this kind of minerals and a wide range of particle sizes, the beneficiation method will be more complicated, often using gravity separation, flotation, strong magnetic separation or their combined processes.

The flotation process is mainly used for the separation of fine-grained and particulate weakly magnetic iron ore, including two process flows of positive flotation and reverse flotation. Among them, the positive flotation process is suitable for quartz hematite ore without easy pumice gangue, and the reverse flotation process is suitable for ore with easy flotation gangue.

However, due to the low grade of strong magnetic separation concentrates of most weak magnetic iron ore, and the low processing capacity of the gravity separation process unit, the combined process of strong magnetic separation and gravity separation is often used, that is, the strong magnetic separation process is first used to discard a large amount of waste. Qualified tailings, and then use the gravity separation process to further process the strong magnetic concentrate to improve the grade of the concentrate.

Polymetallic weakly magnetic iron ore refers to phosphorus-containing hematite and siderite ore. Most concentrators will first use gravity separation, flotation, strong magnetic separation or a combined process to recover iron minerals, and then use the flotation process to recover phosphorus or sulfide.

It is not difficult to see that due to the large variety and complex nature, most iron ore will use multiple combined beneficiation processes to obtain ideal beneficiation indicators. It is recommended that mine owners must do a good job of beneficiation tests, and rationally choose the appropriate iron ore beneficiation process based on the final report results.

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 ore beneficiation technology and process,gravity and magnetic separation | prominer (shanghai) mining technology co.,ltd

iron ore beneficiation technology and process,gravity and magnetic separation | prominer (shanghai) mining technology co.,ltd

Iron ore is one of the important raw materials for the production of pig iron and steel in the iron and steel industry. There are many types of iron ore. According to the magnetic properties of the ore, it is mainly divided into strong magnetism and weak magnetism. In order to improve the efficiency and production capacity of ore dressing and meet the smelting production requirements of iron and steel plants, appropriate and technology should be selected according to the different properties of different iron ore during beneficiation to achieve better beneficiation effects.

The composition of iron ore of a single magnetite type is simple, and the proportion of iron minerals is very large. Gangue minerals are mostly quartz and silicate minerals. According to production practice research, weak magnetic separation methods are often used to separate them. In a medium-sized magnetic separation plant, the ore is demagnetized and then enters the crushing and screening workshop to be crushed to a qualified particle size, and then fed to the grinding workshop for grinding operations. If the ore size after grinding is greater than 0.2 mm, one stage of grinding and magnetic separation process is adopted; if it is less than 0.2 mm, two stages of grinding and magnetic separation process are adopted. In order to increase the recovery rate of iron ore as much as possible, the qualified tailings may be scavenged and further recovered. In areas lacking water resources, a magnetic separator can be used for grinding and magnetic separation operations.

Because magnetite is easily depleted under the effect of weathering, such ores are generally sorted by dry magnetic separator to remove part of gangue minerals, and then subjected to grinding and magnetic separation to obtain concentrate.

The magnetite in the polymetallic magnetite is sulfide magnetite, and the gangue mineral contains silicate or carbonate, and is accompanied by cobalt pyrite, chalcopyrite and apatite. This kind of ore generally adopts the combined process of weak magnetic separation and flotation to recover iron and sulfur respectively.

Process flow: the ore is fed into the magnetic separator for weak magnetic separation to obtain magnetite concentrate and weak magnetic separation tailings, and the tailings enter the flotation process to obtain iron and sulfur.

The common process flow in actual production is: the raw ore is fed into the shaft furnace for roasting and magnetization, and after magnetization, it is fed into the magnetic separator for magnetic separation.

Gravity separation and magnetic separation are mainly used to separate coarse-grained and medium-grained weakly magnetic iron ore (20~2 mm). During gravity separation, heavy medium or jigging methods are commonly used for the gravity separation of coarse and very coarse (>20 mm) ores; spiral chutes, shakers and centrifugal concentrators for medium to fine (2~0.2mm) ores, etc. Reselect method.

In magnetic separation, the strong magnetic separator of coarse and medium-grained ore is usually dry-type strong magnetic separator; the fine-grained ore is usually wet-type strong magnetic separator. Because the grade of concentrate obtained by using one beneficiation method alone is not high, a combined process is often used:

Combination of flotation and magnetic separation: the magnetite-hematite ore of qualified particle size is fed into the magnetic separator for weak magnetic separation to obtain strong magnetic iron ore and weak magnetic tailings, and the tailings are fed into the magnetic separator for weak magnetic separation. In strong magnetic separation, strong magnetic separation tailings and concentrate are obtained, and the concentrate is fed to the flotation machine for flotation to obtain flotation iron concentrate tailings.

Combined gravity separation and magnetic separation: similar to the combined flow of flotation and magnetic separation, only the flotation is replaced by gravity separation, and the products are gravity separation concentrate and tailings. These two combined methods can improve the concentrate grade.

The above are mainly the common separation methods and technological processes of strong and weak magnetic iron ore. The composition of natural iron ore is often not so simple, so in actual production, it is necessary to clarify the mineral composition, and use a single sorting method or a joint sorting method according to the corresponding mineral properties. Only in this way can the beneficiation effect be improved.

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 ore mine dry separation process - xinhai

iron ore mine dry separation process - xinhai

We have rich hematite resources and mainly about 18% of our total iron ore mine.iron ore minebelongs to refractory iron ore and iron ore mining process usually with strong magnetic separation or flotation separation. Before strong magnetic and flotation separation, iron ore mining generally uses dry primary process. Its aims usually are: throwing most of the iron ore mine tailings to reduce the quantity of ore, therefore, reduceiron ore miningprocessing cost; selecting strong magnetic iron ore mine, reducing following mineral processing capacity, separate strong magnetic iron ore mine and prevent blockage.

To discard iron ore mine tailings for the purpose of iron ore mine dry primary process,magnetic roll type permanent magnetic separatoris generally use when processing iron ore mining. When it works iron ore mine will be brought to magnetic roll by the feeder and nonmagnetic iron ore mine will drop into the tank under the inertia force action; while magnetic iron ore mine will be adsorbed on the belt of magnetic roll. With the rotation of belt, magnetic iron ore mine will be brought far from magnetic region and drop into another tank. The adjustment of yield and grade of magnetic iron ore mine and nonmagnetic is usually achieved by the baffle between magnetic product tank and nonmagnetic product.

In order to select strong magnetic iron ore mine, magnetic drum (magnetic pulley) is commonly used in iron ore mine dry separation. At work, the iron ore mine is evenly given to the belt. When the iron ore mine is passed through the cylinder with the belt, the nonmagnetic or magnetic particles are out of the belt under the action of centrifugal inertia and gravity; The magnetic particles are absorbed on the belt by the magnetic force, and the lower part of the cylinder is brought to the cylinder. When the belt is stretched out, the magnetic field strength is weakened and the magnetic product is reduced. The yield and quality of the magnetic products are controlled by adjusting the position of the separating plate mounted on the cylinder.

Xinhai has various specifications of the magnetic drum ofiron ore miningequipment, and it can be used as a preselection of iron ore mine dry primary process to select strong magnetic minerals. Xinhai production of the iron ore mining separation equipment has advantages like excellent beneficiation index, quality, and service system. It has been applied in many mines at home and abroad, and iron ore mining equipment Xinhai produced has been unanimously praised. Selecting magnetic separation equipment, find Xinhai!

the beneficiation techniques for 5 types of iron ores in vietnam | hxjq

the beneficiation techniques for 5 types of iron ores in vietnam | hxjq

In the past decades, infrastructure construction has promoted the development of steel and played a huge role in economic take-off in Vietnam. However, limited by the beneficiation techniques and processes, the production of steel can't satisfy the requirements of construction.

Most of the iron mines are located in the northern regions and all are distributed in the coastal areas. Vietnam's iron ore has an outstanding advantage of high grade which can save a lot of beneficiation processes and bring more development value.

In general, the crushing process consumes about 8% to 10% of the whole energy consumption, and grinding process accounts for about 45% to 55% as well, among which the power cost, and the costs of mill's balls and liner accounts for 90% of the beneficiation fees.

According to the above table, it can be seen that continuous grinding low-intensity magnetic separation high-intensity magnetic separation anionic reverse flotation process can achieve the highest iron recycling rate.

Process one requires fine grinding, which makes the ore ground to the particle size of all the basic monomers for separation by continuous grinding, preventing re-grinding of the stage grinding process and saving more energy.

At the same time, with the increase of mining depth, the FeO content in ore changes greatly. Because high-intensity magnetic separation and anionic reverse flotation have strong adaptability to the fluctuation of FeO content, the whole process can adapt to the change of FeO content to the maximum extent.

At present, the most advanced beneficiation technique of siderite is bulk flotation, which can highly improve the recycling rate of iron and get some copper concentrates and sulfur concentrates, and the detailed process is as follows:

Theoretically, being rich in crystal water, limonite has a low grade. The iron concentrates can hardly be reached up to 60% according to physical dressing. Meanwhile, limonite is easy to be sliming and seriously loses, which results in a lower recycling rate of iron.

Limonite is crushed into the size of 3 mm and sent to the ball mill for grinding into 200 mesh, setting the pulp density of 50% to 60%. After screening by the high-frequency screen of 200 mesh, the pulp density is adjusted into 20% to 25%, and the larger iron particles are sent back to the ball mill for further grinding.

Add about 100g to 200g of inhibitor and 100g-150g collector into the adjusted pulp, stir for 2 to 3 minutes, and take reversely flotation for 10-12 minutes at normal temperature and PH=7 to obtain high-grade limonite concentrates.

Sulfur and phosphorus associated with iron ore is more harmful to iron ore' applications, and when processing and smelting iron ore, sulfur and phosphorus are more difficult to remove. When there is a certain amount of sulfur and phosphorus in the iron and steel, it will seriously damage the mechanical properties of steel products.

The experiment shows that the highest grade of iron concentrate can be obtained by the process of stage grinding high-gradient strong magnetic separation discarding tails flotation to remove phosphorus reverse flotation.

Vietnam's iron ore is widely distributed and abundant in reserves, but the comprehensive processing technology and economic level are relatively lower, resulting in the low utilization rate of iron ore resources, and even a large number of iron minerals are not developed.

Choosing suitable ore processing technology and special production equipment can not only give full play to the advantages of iron ore resources, but also be able to deeply explore the value of different grades of iron ore.

With more than 40 years of development, Hongxing Mining Machinery as a professional processing equipment manufacturer produces various mining machines by mature advanced technology. And all the machines' quality can be guaranteed.

All the dressing equipment adopts innovative technology and improves the backward equipment to reduce the energy consumption in the production process. The equipment is made of new wear-resistant material, which can effectively extend the service life of the equipment and save production resources.

beneficiation of hematite iron ore - fodamon machinery

beneficiation of hematite iron ore - fodamon machinery

Also known as red hematite ore of its chemical formula is Fe2O3, which is a weakly magnetic iron minerals, magnetite floatability than good, one of the main raw material is iron. The main mineral processing technology have re-election, and strong magnetic separation or flotation process and use a variety of mineral, and there have been post-low intensity magnetic separation magnetic roasting process. Early hematite mineral processing generally use more re-election process, mainly jig, centrifugal concentrator, spiral chute, spiral concentrator, shaking and other mineral processing capacity because of their small, beneficiation of low grade, low recovery rate gradually Later, the development of red iron ore out of the flotation process and the high intensity magnetic separation process mainly paraffin oxide soap is for the collector of the flotation process and to electromagnetic annulus Intensity Magnetic Separator for sorting equipment, high intensity magnetic separation process. But the sorting specifications have not reached a satisfactory result. In recent years, the mineral hematite has achieved rapid development, the main mineral processing technology are: electromagnetic pulsating high gradient magnetic separator is represented by strong magnetic beneficiation process and represented by series of anti-flotation beneficiation process. Especially the use of magnetic flotation process to make some of mine co-hematite sorting reached grade of iron concentrate and iron ore recovery satisfaction index.

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