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difference between beneficiation plant and screening plant of iron ore

beneficiation of iron ore

beneficiation of iron ore

Beneficiation of Iron Ore and the treatment of magnetic iron taconites, stage grinding and wet magnetic separation is standard practice. This also applies to iron ores of the non-magnetic type which after a reducing roast are amenable to magnetic separation. All such plants are large tonnage operations treating up to 50,000 tons per day and ultimately requiring grinding as fine as minus 500-mesh for liberation of the iron minerals from the siliceous gangue.

Magnetic separation methods are very efficient in making high recovery of the iron minerals, but production of iron concentrates with less than 8 to 10% silica in the magnetic cleaning stages becomes inefficient. It is here that flotation has proven most efficient. Wet magnetic finishers producing 63 to 64% Fe concentrates at 50-55% solids can go directly to the flotation section for silica removal down to 4 to 6% or even less. Low water requirements and positive silica removal with low iron losses makes flotation particularly attractive. Multistage cleaning steps generally are not necessary. Often roughing off the silica froth without further cleaning is adequate.

The iron ore beneficiation flowsheet presented is typical of the large tonnage magnetic taconite operations. Multi-parallel circuits are necessary, but for purposes of illustration and description a single circuit is shown and described.

The primary rod mill discharge at about minus 10- mesh is treated over wet magnetic cobbers where, on average magnetic taconite ore, about 1/3of the total tonnage is rejected as a non-magnetic tailing requiring no further treatment. The magnetic product removed by the cobbers may go direct to the ball mill or alternately may be pumped through a cyclone classifier. Cyclone underflows usually all plus 100 or 150 mesh, goes to the ball mill for further grinding. The mill discharge passes through a wet magnetic separator for further upgrading and also rejection of additional non-magnetic tailing. The ball mill and magnetic cleaner and cyclone all in closed circuit produce an iron enriched magnetic product 85 to 90% minus 325 mesh which is usually the case on finely disseminated taconites.

The finely ground enriched product from the initial stages of grinding and magnetic separation passes to a hydroclassifier to eliminate the large volume of water in the overflow. Some finely divided silica slime is also eliminated in this circuit. The hydroclassifier underflow is generally subjected to at least 3 stages of magnetic separation for further upgrading and production of additional final non-magnetic tailing. Magnetic concentrate at this point will usually contain 63 to 64% iron with 8 to 10% silica. Further silica removal at this point by magnetic separation becomes rather inefficient due to low magnetic separator capacity and their inability to reject middling particles.

The iron concentrate as it comes off the magnetic finishers is well flocculated due to magnetic action and usually contains 50-55% solids. This is ideal dilution for conditioning ahead of flotation. For best results it is necessary to pass the pulp through a demagnetizing coil to disperse the magnetic floes and thus render the pulp more amenable to flotation.

Feed to flotation for silica removal is diluted with fresh clean water to 35 to 40% solids. Being able to effectively float the silica and iron silicates at this relatively high solid content makes flotation particularly attractive.

For this separation Sub-A Flotation Machines of the open or free-flow type for rougher flotation are particularly desirable. Intense aeration of the deflocculated and dispersed pulp is necessary for removal of the finely divided silica and iron silicates in the froth product. A 6-cell No. 24 Free-FlowFlotation Machine will effectively treat 35 to 40 LTPH of iron concentrates down to the desired limit, usually 4 to 6% SiO2. Loss of iron in the froth is low. The rough froth may be cleaned and reflotated or reground and reprocessed if necessary.

A cationic reagent is usually all that is necessary to effectively activate and float the silica from the iron. Since no prior reagents have come in contact with thethoroughly washed and relatively slime free magnetic iron concentrates, the cationic reagent is fast acting and in somecases no prior conditioning ahead of the flotation cells is necessary.

A frother such as Methyl Isobutyl Carbinol or Heptinol is usually necessary to give a good froth condition in the flotation circuit. In some cases a dispersant such as Corn Products gum (sometimes causticized) is also helpful in depressing the iron. Typical requirements may be as follows:

One operation is presently using Aerosurf MG-98 Amine at the rate of .06 lbs/ton and 0.05 lbs/ton of MIBC (methyl isobutyl carbinol). Total reagent cost in this case is approximately 5 cents per ton of flotation product.

The high grade iron product, low in silica, discharging from the flotation circuit is remagnetized, thickened and filtered in the conventional manner with a disc filter down to 8 to 10% moisture prior to treatment in the pelletizing plant. Both the thickener and filter must be heavy duty units. Generally, in the large tonnage concentrators the thickener underflow at 70 to 72% solids is stored in large Turbine Type Agitators. Tanks up to 50 ft. in diameter x 40 ft. deep with 12 ft. diameter propellers are used to keep the pulp uniform. Such large units require on the order of 100 to 125 HP for thorough mixing the high solids ahead of filtration.

In addition to effective removal of silica with low water requirements flotation is a low cost separation, power-wise and also reagent wise. Maintenance is low since the finely divided magnetic taconite concentrate has proven to be rather non-abrasive. Even after a years operation very little wear is noticed on propellers and impellers.

A further advantage offered by flotation is the possibility of initially grinding coarser and producing a middling in the flotation section for retreatment. In place of initially grinding 85 to 90% minus 325, the grind if coarsened to 80-85% minus 325-mesh will result in greater initial tonnage treated per mill section. Considerable advantage is to be gained by this approach.

Free-Flow Sub-A Flotation is a solution to the effective removal of silica from magnetic taconite concentrates. Present plants are using this method to advantage and future installations will resort more and more to production of low silica iron concentrate for conversion into pellets.

ore beneficiation plant / crush-grind-extract/factory price

ore beneficiation plant / crush-grind-extract/factory price

For many years of accumulation in experiences and improvement on services and machinery, HongXing Mining machinery now is able to offer you the most efficient plant with minimum initial investment and operational cost.

Separation of desired minerals from unwanted minerals by chemicals, common is froth flotation. The core machine is a flotation machine Applied material: feldspar, bauxite, manganese ore, phosphate ore, etc

Gravity beneficiation is separating mineral according to the specific gravity of the material. Spiral chute, spiral classifier and shaking table are usually used. Applied material: gold ore, manganese ore, alluvial gold.

Maison Malaiti, a customer from Zambia, consulted us about a 30 tons per hour gold ore beneficiation plant. He said that the content of gold in the rocks as picked on random is 1.5 ppm. Because he is a greenhand in mining, our engineer recommended him the PE-250400 Jaw crusher, 18306400 Ball mill, 2FG-15 Spiral classifier, JJF-20 Flotation Machine, Spiral chute,etc.

We compared many companies and their machines are reasonably priced. Within a month, my project was designed, installed, guided, and run. I am very satisfied with their pre-sales, installation and after-sales services.

At the end of last year, a Sudanese customer consulted us about a beneficiation plant for processing gold tailing. He wants to get more gold through the Gold CIL Plant. His tailing concentration is 5%. According to this parameter, our engineer customized a dedicated Gold CIL Plant for him.

I think their machines have reached the level I want and I will continue to work with them. This year I will make partnership with owner of tailing from any African country as we are going to treated it by new method to (CIL) get more gold.

characterization and beneficiation of dry iron ore processing plant reject fines to produce sinter/pellet grade iron ore concentrate | springerlink

characterization and beneficiation of dry iron ore processing plant reject fines to produce sinter/pellet grade iron ore concentrate | springerlink

Characterization and beneficiation of dry iron ore processing plant reject fines of Khondbond region, India, was investigated. Different characterization techniques viz. size analysis, size-wise chemical and density analysis, X-ray diffraction analysis, sink-float analysis, thermo gravimetric analysis, scanning electron microscopy, and QEMSCAN were carried out. Based on characterization results, two process flow sheets comprising wet screening followed by conventional gravity concentration and two stage classification with different beneficiation routes were used to recover the iron values from reject fines containing 58.73% Fe, 5.54% Al2O3, and 6.6% SiO2. Finally, suggested flow sheet comprising of two stage classification and advance gravity concentration followed by the combination of grinding, classification, and froth flotation produced iron concentrate of 2.36% Al2O3 with 75.8% yield which can be used in sinter/pellet making.

Dixit P, Tiwari R, Mukherjee AK, Banerjee PK (2015) Application of response surface methodology for modeling and optimization of spiral separator for processing of iron ore slime. Powder Technol 275:105112

Vinod K, Jadhav GN, Khosla NK et al. (2010) Implication of process mineralogy for beneficiation of low grade iron ore resources containing high alumina from eastern part of India. Proceedings of the XI International Seminar on Mineral Processing Technology, 1, pp. 8291

Manser RJ, Barley RW, Wills BA (1991) The shaking table concentrator-the influence of operating conditions and operating parameters on mineral separation-the development of a mathematical model for normal operating conditions. Miner Eng 4:369381

Prasad N, Ponomarev MA, Mukherjee SK et al. (1988) Introduction of new technologies for beneficiation of Indian hematite ores, reduction of losses and increase in their quality. E Forssberg (Ed.), XVI International Mineral Processing Congress, pp. 13691380

Dixit, P., Makhija, D., Mukherjee, A.K. et al. Characterization and Beneficiation of Dry Iron Ore Processing Plant Reject Fines to Produce Sinter/Pellet Grade Iron Ore Concentrate. Mining, Metallurgy & Exploration 36, 451462 (2019). https://doi.org/10.1007/s42461-018-0006-x

henan mining machinery and equipment manufacturer - difference between sinter plant amp beneficiation

henan mining machinery and equipment manufacturer - difference between sinter plant amp beneficiation

vsi crusher plant compney; brown coal processing in australia; gold mobile crusher sales; dick stone s angle grinder fixture jig for knives; price jaw crusher indonesia;Spesifikasi hot sinter crusher; ... The mobile crushing plant has the advantages of easy transportation, ... Beneficiation Equipments.

Ore beneficiation equipment, sand making equipment, crushing equipment and powder grinding equipment, which are widely used in various industries such as metallurgy, mine, chemistry, building material, coal, refractory and ceramics.

prospects of utilization of waste dumped low-grade limestone for iron making: a case study - sciencedirect

prospects of utilization of waste dumped low-grade limestone for iron making: a case study - sciencedirect

Low grade dumped limestone sample having high silica of 8.1%, 36.8% CaO, and 3% Al2O3 has been studied with the aim to reduce the silica level to below 3% for its utilization in iron making. Beneficiation study of the sample was initiated with desliming of the feed sample of 100m to remove the siliceous ultrafine particles and to improve the feed quality. Flotation study was carried out by column flotation technique varying the collector dosage, superficial air flow velocity and froth depth to assess their effect on silica reduction and CaO recovery. It was observed that increased collector dosage and superficial air velocity increases the recovery of CaO, and increase in the froth depth reduces the mass flow and silica content in the concentrate. The best result was found at 1.25cm/sec superficial air velocity, 25cm froth depth, 1.25 kgpt collector dosage and concentrate assayed 47.3% CaO, 2.8% silica with 72% CaO recovery.

beneficiation process and separation method,crushing grinding screening and classification | prominer (shanghai) mining technology co.,ltd

beneficiation process and separation method,crushing grinding screening and classification | prominer (shanghai) mining technology co.,ltd

The process of breaking the ore blocks with a particle size of 500-1500mm from the mine to a particle size of 5-25mm. The methods include crushing, crushing, chopping, etc., generally in three stages: coarse crushing, medium crushing, and fine crushing.

The particle size of the immersion dye in the ore of the beneficiation machinery and the separation method used are determined. Commonly used grinding equipments include rod mills, ball mills, self-grinding machines and semi-self-grinding machines. High energy consumption for grinding operations, usually about half of the total energy consumption for beneficiation

According to the size of the sieve surface, the material is divided into different particle size levels called sieving, which is often used to process materials with coarser particle size. According to the different sedimentation speed of particles in the medium (usually water), the materials are divided into different grades of equal reduction, called classification, and used for materials with smaller particle sizes. Screening and grading are to separate materials of suitable particle size during the crushing process, or divide the materials into different particle size levels for selection.

In order to avoid clogging of the crushing and screening equipment by the mud in the mud-containing mineral raw materials, ore washing is required. If the raw materials contain soluble useful or harmful ingredients, they must also be washed. Ore washing can be carried out in a scrubbing machine or in a screening and grading equipment.

After the crushing operation, the mineral raw materials enter the sorting operation to separate useful minerals from gangue, or separate useful minerals from each other. This is the main part of beneficiation. The sorting operations include heavy sorting, flotation,

In the medium (mainly water) flow, the difference in the specific gravity of the mineral raw material particles is used for classification. The suitable particle size range for re-election is wide, from a few hundred millimeters to less than one millimeter, with low beneficiation cost and less environmental pollution. Where the particle size of the mineral is within the above range and the specific gravity difference between the components is large, gravity selection is the most suitable. Sometimes, reselection (mainly heavy medium selection, jig selection, etc.) can be used to pre-select to remove part of the waste rock, and then use other methods to reduce the cost of mineral processing.

Use the difference of water wettability (hydrophobicity or hydrophilicity) on the surface of various mineral raw materials to distinguish. Usually refers to froth flotation. There are few natural hydrophobic minerals. Collectors are often added to the ore slurry to enhance the hydrophobicity of the minerals to be floated; various regulators are added to improve selectivity; foaming agents are added and aerated to generate bubbles to make hydrophobic The mineral particles are attached to the bubbles and float up and separate. Flotation can usually process materials smaller than 0.2-0.3mm. In principle, it can select various mineral raw materials. It is a widely used method. Flotation can also be used to separate smelting intermediate products, ions in solution, and treat wastewater.

Make use of the different magnetic properties of mineral particles to distinguish in a non-uniform magnetic field. Strong magnetic minerals (magnetite and pyrrhotite, etc.) are separated by a weak magnetic field magnetic separator; weak magnetic minerals (hematite, siderite, ilmenite, wolframite, etc.) are separated by a strong magnetic field magnetic separator Sorting. The structure of magnetic separator includes drum type, belt type, rotating ring type, disc type, induction roller type and so on. Magnetic pulleys are used to pre-select massive strong magnetic ore. The main development trend of magnetic separation is to solve the problem of recovery of fine-grained weakly magnetic minerals.

Use the difference in electrical properties of mineral particles to select in a high-voltage electric field. Mainly used to sort conductor, semiconductor and non-conductor minerals. According to the electric field, the electric separator can be divided into electrostatic concentrator, corona concentrator and composite electric field electric separator; according to the charging method of ore particles, it can be divided into contact electrified separator, corona electrified separator and friction electrified separator. The electrical separator has a narrow processing particle size range, low processing capacity, and raw materials need to be dried, so the application is limited; but the cost is not high, the separation effect is good, and the pollution is low; it is mainly used for the selection of coarse concentrates, such as separation white Tungsten ore, cassiterite, zircon, rutile, ilmenite, tantalum niobium, monazite, etc. Electric separation is also used for classification and dust removal of mineral raw materials. The development trend of electrical separation is to develop equipment with large processing capacity and high efficiency in selecting fine-grained materials.

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.

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