iron ore crushing uk

iron ore | bhp

iron ore | bhp

Air that has been heated to around 1,200 degrees Celsius is injected into the furnace, creating a flame temperature of 2,000 degrees. This converts the iron ore to molten pig iron and slag.

Then, impurities are removed and alloying elements are added. The steel is then cast, cooled and rolled for use in finished products.

Our Western Australia Iron Ore business in the Pilbara region of Western Australia contains five mines, four processing hubs and two port facilities, all of which are connected by more than 1,000 kilometres of rail infrastructure.

iron ore crushing machine in uk

iron ore crushing machine in uk

For each project scheme design, we will use professional knowledge to help you, carefully listen to your demands, respect your opinions, and use our professional teams and exert our greatest efforts to create a more suitable project scheme for you and realize the project investment value and profit more quickly.

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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.

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metso outotec, mineral resources deliver the next generation of crushing - international mining

metso outotec, mineral resources deliver the next generation of crushing - international mining

What will crushing plants of the future look like? Mineral Resources Ltd and Metso Outotec have pondered that question and have since gone on to answer it with the delivery of a modular, scalable and relocatable plant at an iron ore operation owned by one of the worlds biggest miners.

Called NextGen II, the solution represents a ground-breaking approach to delivering safe and reliable production to the hard-rock crushing industry, Mike Grey, Chief Executive of Mining Services for Mineral Resources, says.

We were sitting around the boardroom table with David De Haas, one of our key engineers on this project, and gave him the challenge to come up with a crushing plant that we could literally relocate anywhere very quickly, build on a very small footprint, and have it plug and play, Grey told IM in a recent IM Insight Interview.

A provider of world-class tailored crushing, screening and processing solutions for some of the worlds largest mining companies, CSI specialises in build, own, operate (BOO) projects where it provides both the capital infrastructure and the operational expertise to ensure these crushing plants operate to their potential on site.

Having initially commenced discussions with the global OEM in early 2019 (when it was still Metso), Mineral Resources, later that year, agreed with Metso on the design and delivery of a new type of crushing solution.

The largest bulk commodity operations in the world are made up of multiple pits that get mined over time. As these operations expand, miners are left with a dilemma: extend the haulage time from the pit to the plant or build another plant.

De Haas, collaborating with Metso Outotec, has delivered on the boards brief with the design for a crushing plant able to produce 15 Mt/y using a modular design made up of several stations. The plant can move with the mining, being erected and taken down quickly without the type of in-ground services that can scupper such moves.

The NextGen II is a crushing and screening plant to crush iron ore and produce lump and fine products, he said in the IM Insight Interview. The process starts with a primary station made up of a Metso Outotec apron feeder (below left), followed by a vibrating grizzly scalper. Then starts the size reduction process with a Nordberg C150 jaw crusher (below middle).

The screen was designed specifically for the project offering the compact dimensions that could fit inside the stations footprint. Other customised add-ons included specialised cooling rooms for the lubrication units and extensive steel fabrication works.

Lambert added: Really, the tailoring of design is around the modularity of the different stations. Each station is made up of several modules. All those modules can be pre-assembled and tested in a factory and transported by road to the site. This has been established to enable a fast erection process.

Despite a timeline setback caused by the global pandemic, the 1,500 t of steel needed for the plant construction was built in 16 weeks, starting in March 2020 and ready by July 25 of that year. It was shipped to CSIs Kwinana facility in Western Australia for pre-assembly before delivery to site.

A distinctive blue colour, the plant reflects Mineral Resources commitment to mental health awareness and support, carrying the phone number and colour of Lifeline, a Western Australia-based charity formed to prevent suicide, support people in crisis and reduce the stigmas which can be a barrier to seeking help.

It is really important for us to promote mental health; our fly-in fly-out workforce has matured over some years, but the challenges around working remotely remain, Grey said. It is important that we demonstrate we have the support mechanisms in place to support our workers and their families.

The NextGen II plant is at the forefront of that it is the first thing people see when they come to work and the last thing they see when going home. They can always reflect and make sure their work mates are OK.

The plants operating success has been helped by a local service and support network from both companies, with Metso Outotec providing critical spares and all large rotable refurbishments serviced by CSIs Kwinana facility.

Understanding the challenges and potential delays for parts deliveries due to MRLs remote location, the companies agreed to a specific consignment inventory close to the site to ensure parts availability and exclusivity for MRL to better support the operation.

Working with Metso Outotec on this project has allowed us to define the scope together, rather than remotely, Grey reflected. That allows us to ensure we deliver to the timelines and then make any necessary changes on the run, hand-in-hand. We deliver the solution together.

Lambert added: Metso Outotec is an indisputable leader in crushing and screening technology, as well as plant. However, working with MRL, we learned a lot about improving the design of our station to maximise safety and improve accessibility in a very, very compact environment for high-capacity plant.

The NextGen II plant is very flexible, he said. Each station is individually plugged into the solution, and we can easily upgrade the crusher, the screen, etc throughout the year depending on capacity needs.

Adding or removing some stations could see the throughput reduced or increased, with Lambert even talking about the ability to construct a 30 Mt/y plant that can be built, erected and relocated in the same way as the first 15 Mt/y plant.

In addition, NextGen II, today, is designed for iron ore applications with lump and fine products, he said. If we want, we can add a tertiary crushing stage in order to produce only fines for iron ore. This can match with copper and gold operations also.

There are plenty of gold miners extracting ore from multiple pits that could provide a strong business case for the installation of such a plant. Similarly, there is potential for this working at major open-pit copper mines.

Lambert concluded: There is, for sure, global demand for modular crushing plants. Today, having a fast and safe erection process is a must in many countries and locations. In addition, we have more and more short-term operations emerging in very remote locations, so having the possibility to minimise civil works is key for a lot of our customers.

iron ore mobile crushing plant - henan factory supply best price portable jaw stone crushers plant

iron ore mobile crushing plant - henan factory supply best price portable jaw stone crushers plant

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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.

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iron ore processing plants - iron ore wash plants - cde

iron ore processing plants - iron ore wash plants - cde

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.

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