iron ore process

Iron Ore Process

Provided by:

Mehdi jafari

Table of Contents

What is Iron Ore?..................................................................................................6

Iron Ore Bonab Steel Complex

What is Iron Ore used for?....................................................................................6

Uses of Special Iron..............................................................................................7

Industrial Applications of Iron Ore........................................................................7

Iron Ore Business.................................................................................................8

How is Iron Ore Processed?..................................................................................8

Distribution in the world.......................................................................................9

Classified Iron Ore...........................................................................................................................9

By Minerals...........................................................................................................9

By Harmful Impurities........................................................................................10

By Grades...........................................................................................................10

By Ore Structure................................................................................................10

By Special Form.................................................................................................10

By Gangue Mineral.............................................................................................11

Magnetite Mining Knowledge.............................................................................11

Magnetite Mining................................................................................................12

Magnetite Beneficiation.....................................................................................12

Magnetite Processing Flow Diagram..................................................................13

Hematite..........................................................................................................................................13

Hematite Mining Knowledge...............................................................................13

Hematite Mining.................................................................................................15

Hematite Beneficiation.......................................................................................15

Simple Tips:........................................................................................................15

Siderite.............................................................................................................................................16

Siderite Mining Knowledge.................................................................................16

Siderite Mining...................................................................................................17

Siderite Beneficiation.........................................................................................17

Pyrite.................................................................................................................................................18

Pyrite Mining Knowledge....................................................................................18

Pyrite Mining......................................................................................................19

Pyrite Beneficiation............................................................................................20

Limonite...........................................................................................................................................20

Limonite Mining Knowledge...............................................................................20

Limonite Mining..................................................................................................21

Limonite Beneficiation........................................................................................21

Goethite............................................................................................................................................22

2 Engineering Department


Goethite Mining Knowledge................................................................................22

Goethite Mining..................................................................................................22

Goethite Beneficiation........................................................................................23

Ilmenite Mining Knowledge................................................................................23

Ilmenite Mining...................................................................................................24

Ilmenite Beneficiation........................................................................................24

Production..........................................................................................................25

Iron Ore Industry...........................................................................................................................25

Overview of Iron Ore Industry............................................................................25

Iron Ore Mining...................................................................................................26

Iron Ore Crushing & Screening...........................................................................26

Iron Ore Haulage and Transportation.................................................................26

Iron Ore Prices....................................................................................................27

Iron Ore Drilling & Blasting........................................................................................................27

Iron Ore Drilling..................................................................................................27

Iron Ore Blasting................................................................................................28

Iron Crushing and Screening.....................................................................................................28

Iron Ore Crushing...............................................................................................28

Iron Ore Screening.............................................................................................30

Iron Ore Grinding...........................................................................................................................31

Iron Ore Grinding Process..................................................................................31

Iron Ore Grinding Mills........................................................................................32

Iron Ore Beneficiation..................................................................................................................33

Methods of Iron Ore Beneficiation......................................................................33

Iron Ore Beneficiation........................................................................................34

Agglomeration of Iron Ore.........................................................................................................35

Overview of Agglomeration................................................................................35

Sintering and Pelletising.....................................................................................36

Iron Ore Pelletizing Technology..........................................................................37

Iron Ore Pelletizing Equipment...........................................................................37

Iron Slag Recycling.......................................................................................................................38

Overview of Slag Recycling................................................................................38

Slag Recycling and Management.......................................................................39

Waste Rock and Ore Piles..................................................................................39

Tailings Impoundments......................................................................................40



Mine Pits and Underground Workings................................................................40

Iron Ore Drilling Plant.........................................................................................40

Iron Ore Blasting Plant.......................................................................................42

Iron Ore Crushing & Screening Plant.....................................................................................43

Primary Crusher.................................................................................................43

Secondary Crusher.............................................................................................44

Tertiary Crusher.................................................................................................45

Vibrating Screen.................................................................................................46

Iron Ore Grinding Mills................................................................................................................46

Iron Ore Grinding Mill.........................................................................................46

MTM Trapezium Grinding Mill.............................................................................46

MTW Trapezium Grinding Mill.............................................................................47

MXB Coarse Powder Mill.....................................................................................47

Raymond Mill......................................................................................................48

SCM Series Super Thin Mill.................................................................................48

Ball Mill...............................................................................................................48

Vertical Roller Mill..............................................................................................49

Iron Ore Beneficiation Plant......................................................................................................49

Beneficiation Plant In Milling Process.................................................................49

Beneficiation Plant In Magnetic Separation........................................................50



What is Iron Ore?

Iron ores are rocks and minerals most of whose deposites are found in sedimentary rocks. They

formed from chemical reactions that combined iron and oxygen in marine and fresh waters. The

ores are usually rich in iron oxides and vary in color from dark grey, bright yellow, deep purple, to

rusty red.

The most important minerals in these iron ore deposits are magnetite (Fe3O4), hematite (Fe2O3),

goethite (FeO(OH)), limonite (FeO(OH).n(H2O)), ilmenite(FeTiO3) , siderite (FeCO3) and Pyrite (FeS2).

These iron ores have been mined to produce almost every iron and steel object that we use today -

from paper clips to automobiles to the steel beams in skyscrapers.

What is Iron Ore used for?

Most of the iron ore that is mined is used for making steel. Raw iron by itself is not as strong and

hard as needed for construction and other purposes. Most of the iron produced is then used to

make steel. Steel is used to make automobiles, locomotives, ships, beams used in buildings,

furniture, paper clips, tools, reinforcing rods for concrete, bicycles, and thousands of other items.



While the other uses for iron ore and iron are only a very small amount of the consumption, they

provide excellent examples of the ingenuity and the multitude of uses that man can create from

our natural resources.

Uses of Special Iron

Powdered iron is mainly used in metallurgy products, magnets, high-frequency cores, auto parts,

catalyst.

Black iron oxide is often used as pigment, in polishing compounds, metallurgy, medicine,

magnetic inks, in ferrites for electronics industry.

Iron blue can be used in paints, printing inks, plastics, cosmetics (eye shadow), artist colors,

laundry blue, paper dyeing, fertilizer ingredient, baked enamel finishes for autos and appliances,

industrial finishes.

Radioactive iron (iron 59) is applied in medicine, tracer element in biochemical and

metallurgical research.

Industrial Applications of Iron Ore

Some types of iron ores according the variety of ores have some special uses / applications in

Industry.

Micaceous iron ore is generally soft and unctuous. It is used in the manufacture of welding rods

(electrodes) and used as a coating material in the preparation of welding rods.

Magnetite is used for the preparation of heavy media in coal-washing plants. It has got distinct

advantage over sand as magnetite particles adhering to coal can easily be separated by teh

magnetic separator.

Bog iron ore is used as purifying and desulphurising material of producer gas and municipal

gases. The ore is filled in purifying tank through which gases are passed and purified.

Spathic ore is used for the production of hydrogen by steam iron contact process. The ore to be

used must have a spongy structure in order to present the maximum surface contact. Generally ore



of light yellow color is preferred. It should not sinter together when subjected to the high

temperature of 1000ºC.

The ore is calcined before use to make it suitable for reduction and oxidation cycles. For the

production of hydrogen, the calcined ore is first reduced at 700-1000ºC by use of water gas or

producer gas. Steam is then passed over it. The ore gets oxidized and the hydrogen is liberated

from the steam. The oxidized ore is then subjected to the reduction cycle by passing water gas

which makes the ore suitable for reuse.

The arrangement for the process of oxidation and reduction cycle is made automatic in the plant to

get the supply of commercial hydrogen which is utilised for the hydrogenation of vegetable oils.

Hydrogenation effects hardening of the oils.

Iron Ore Business

Iron Ore Business is a wide concept of iron ore related business including iron ore prices, iron ore

production, iron ore pricing, iron ore run escape, iron ore etf, iron ore plants, iron ore quarry

machinery, iron ore wholesale, etc.

How is Iron Ore Processed?

The iron ores are often processed by following stages : Ore Reduction (maybe called Ore mining

and crushing ) process, Ore Grinding Process, Iron Ore Beneficiation, Iron Sintering and Pelletizing,

Iron Slag Recycling process. These steps are in normal iron ore production line designs.

The process of iron ore reduction is to make the large blocks of iron ore rocks small enough for the

next ore grinding process, when large blocks are transfered from mines or quarries of iron ores. For

usual condition, ore reduction contains primary crushing, secondary crushing and fine crushing

process. After that , iron ores are usually smaller than 12 mm which is ready for the grinding mill

machines. Then the primary grinding and fine grinding process are done before iron ore

beneficiation.



There are many methods in Iron Ore Beneficiation such as ore washing, gravity separation, flotation

and magnetic separation. For magnetite iron ore, smelting and magnetic separation are often

chosen as suitable methods of magnetite beneficiation. For hematite iron ore, washing and flotation

are nomal methods of hematite beneficiation. For other iron ores , there are also specific methods

of beneficiation according to the mixture of the iron ore minerals.

Distribution in the world

Iron-rich rocks are common worldwide, but ore-grade commercial mining operations are dominated

by the countries listed in the next paragraph. The major constraint to economics for iron ore

deposits is not necessarily the grade or size of the deposits, because it is not particularly hard to

geologically prove enough tonnage of the rocks exist.

According to the yearly production of iron ore, China, Australia, Brazil, India, Russia, Ukraine, South

Africa, Iran, Canada, United States, Kazakhstan, Sweden, Venezuela, Mauritania are the main iron

ore production countries.

Classified Iron Ore

By Minerals

According to the composition of minerals ,Iron ores are classified into magnetite, hematite,

goethite, limonite, siderite, ilmenite, pyrite, etc.

Magnetite , Hardness: 5.5-6.5 , color: iron black ore black, special: strong magnetic.

As it is with magnetite ore, there are several types including Titanomagnetite (FexTiyO4) , Vanadium

magnetite (FeV2O4 / FeVO4 / V2O5) V-Ti magnetite (mixture of both of above), Cr magnetite

(mixed with Cr2O3), Magnesium Magnetite (mixed with MgO).

By Harmful Impurities



By harmful impurities (S, P, Cu, Pb, Zn, V, Ti, Co, Ni, Sn, F, As) ratio of content, iron ores can be

divided into high-sulfur iron ore, low sulfur iron ore, high phosphorus iron Ore, low phosphorus iron

ore and so on.

Harmful impurities are often the minerals that we remove from iron ore in the ore production.

Sometimes for removing these impurities , some special physical or chemical methods of

beneficiation are chosen to filter them.

By Grades

Iron ore is typically classified as High grade (+65% Fe), Medium grade (+62 – 65% Fe) and Low

grade (-62% Fe). Typically, the Integrated Steel Plants(ISPs) use medium/High grade Iron Ore

whereas the Sponge Iron plants require only High Grade iron ore, preferably, with +67% Fe.

By Ore Structure

According to the structure, iron ores can be divided into disseminated ore , stock work

disseminated ores, striped ores, banded ore , dense massive ore, breccia ore, the oolite and bean-

shaped, kidney-shaped, honeycomb, powdery, earthy ores.

By Special Form

(i) Lumpy/Fine Ore: Iron Ore is traded in lumps (i.e. sized ore) or in fines. Production/availability of

lumps is limited by virtue of the natural occurrence and also because of generation of lot of fines

during crushing of large lumps present in the run-of –mines (ROM).

(ii) Natural pellet: It is a term coined by producers in some Asian counties, to designate sized iron

ore used directly in Sponge Iron production.

(iii) Blue Dust: Blue Dust is the name given to naturally occurring, extremely friable, high grade

Hematite Iron Ore powder.

By Gangue Mineral



According to the gangue mineral, iron ores can be divided into quartz-based minerals, amphibole

type, type of pyroxene, plagioclase type, Seri cite chlorite type, skarn, actinolite type, serpentine

type, type and ankerite Jasper-based iron ore.

According to the investment of world minerals, the main iron ores are distributed in the following

countries: Brazil, Australia, Russia, Ukraine, China, India, Venezuela, Canada, Sweden, USA, Iran,

Mauritania, South Africa, Mexico, etc.

Magnetite Mining Knowledge

Physical Properties: Cleavage: Parting on {Ill}, very good. Fracture: Uneven. Tenacity: Brittle.

Hardness == 5.5-6.5 VHN == 681-792 (100 g load). D(meas.) == 5.175 D(calc.) == 5.20 Strongly

magnetic.

Occurrence: A common accessory mineral in igneous and metamorphic rocks, in which magmatic

segregation or contact metamorphism may produce economic deposits. Extensive deposits in

sedimentary banded iron formations; a biogenic product; important detrital deposits.



Distribution: Many localities, even for fine crystals. In Sweden, at Falun, Kiruna, Vastanfors, and

elsewhere. At Arendal, Norway. From Zlatoust and Magnitogorsk, Ural Mountains, Russia. In the

Zillertal, Tirol, Austria. From Traversella, Piedmont, Italy. In Switzerland, at Binntal and

Rimpfischwang, Valais, and elsewhere. In the Gardiner complex, beyond the head of

Kangerdlugssuaq Fjord, Greenland. From Bancroft, Ontario, Canada. In the USA, around Lake

Sanford, Essex Co., and in the Tilly Foster mine, Brewster, Putnam Co., New York; at Magnet Cove,

Hot Springs Co., Arkansas; in the Iron Springs district, Iron Co., Utah. From the Cerro del Mercado,

Durango, Mexico. At Itabira, Minas Gerais, Brazil.

Magnetite Mining

Magnetite is mined using underground mining. It is found in: Austria, Switzerland, South Africa, and

the United States [Franklin, New Jersey, Utah, Arkansas, Vermont].

Magnetite Beneficiation

Solution One

One kind of wet and dry combined magnetite beneficiation process method, mainly for three

magnetic ore processing, and then by wet magnetic material, magnetic field strength of the

selected 400 ~ 1200GS, magnetic roller speed of 60 ~ 320 rev / min, the wet material obtained by



the dehydration products of iron ore, usually iron ore at 35% by this method after magnetic

separation of iron ore iron content of up to 68 ~ 70%, the joint process method, ore than 90%

utilization, process in less water consumption, save water, reduce costs, reduce pollution, magnetic

separation of dust from the dust trapping device will not cause air pollution, this method is a high

production efficiency, product quality, and pollution-free technology with creative methods.

Magnetite Processing Flow Diagram

Hematite

Hematite Mining Knowledge

Physical Properties: Fracture: Uneven to subconchoidal. Tenacity: Brittle; elastic in thin laminate.

Hardness = 5–6 . VHN = 1000–1100 (100 g load). D(meas.) = 5.26 D(calc.) = 5.255.



Occurrence: An accessory mineral in felsic igneous rocks, a late-stage sublimate in volcanic rocks,

and in high-temperature hydrothermal veins. A product of contact metamorphism and in

metamorphosed banded iron formations. A common cement in sedimentary rocks and a major

constituent in oolitic iron formations. Abundant on weathered iron-bearing minerals.

Association: Ilmenite, rutile, magnetite (metamorphic and igneous); goethite, siderite,

lepidocrocite (sedimentary).

Distribution: Widespread. Exceptional crystals from Switzerland, as at Fibbia, St. Gotthard, Uri;

Binntal, Valais; Cavradi, Tavetsch, Graübunden; and many other places. At Ocna de Fier (Mor

ávicza; Vask˝o), Romania. From Rio Marina, Elba, Italy. At Cleator Moor, Cumbria, England. From

Kragerøand Hiassen, Norway. In Brazil, large crystals from Mesa Redonda and Congonhas do

Campo, Minas Gerais; at Itabira and in the Brumado mine, Bahia; at Miguel Burnier, Ouro Prêto.

From the Kuruman district, Cape Province, South Africa. At Nador, Algeria. In the USA, in the

Thomas Range, Juab Co., Utah, and near Quartzsite, La Paz Co., Arizona.

Hematite Mining

Hematite is mined using underground mining. It is mined in England, Mexico, Australia, Canada,

and Brazil.



Hematite Beneficiation

Currently beneficiation of hematite ores is conducted using either direct flotation (hematite

flotation) or indirect flotation (quartz flotation) techniques depending upon the nature of the

available ore bodies. In direct flotation, iron bearing mineral, mostly hematite, is floated using

oleate as collector leaving siliceous gangue, usually quartz, in the tailings. Kick et al. were among

the first to investigate the utility of various collectors in hematite flotation from quartz. In their

extensive study, they concluded that fatty acids and their soaps are superior collectors for

hematite flotation and among these, sodium oleate is the best collector. Rietz , Kihlstedt and Kivalo

et al. have demonstrated the successful use of tall oil in hematite flotation.

Solution One:

Magnetic Separation was first step for the hematite processing. Then Gravity Separation was

processed as the second step.

Solution Two:

Magnetic Separation ---> Flotation Process

Solution Three:

Gravity Separation ----> Magnetic Separation ---> Flotation Process

Related Knowledge:

Magnetic Separation - Gravity Separation - Flotation Process

Simple Tips:

For the crystallization of dense red - magnetite-quartzite, the re-election method widely used

coarse-grained disseminated ore sorting, high intensity magnetic separation or flotation for sorting

of fine ore.

For the red clay - magnetite ore, the main use of washing or dry magnetic separation

Siderite

Siderite Mining Knowledge



Physical Properties: Cleavage: Perfect on {1011}. Fracture: Uneven to conchoidal. Tenacity:

Brittle. Hardness = 3.75–4.25 D(meas.) = 3.96(1) D(calc.) = 3.932

Occurrence: A common component of bedded sedimentary iron ores and metamorphic iron

formations; in hydrothermal metallic veins; rarely in granite and nepheline syenite pegmatite; in

carbonatites; authigenic, and in concretions.

Association: Quartz, barite, fluorite, pyrite

Distribution: Many noted localities worldwide, including: in Germany, from Freiberg and Neudorf,

Harz Mountains, and in the Siegerland district, Westphalia. In Austria, on the Erzberg, near

Eisenerz, Styria, and Hüttenberg-Lölling, Carinthia. From Allevard, Isère, France. In England,

from many mines in Cornwall, as at the Great Onslow Consols mine, St. Breward, Wheal Maudlin,

Lanlivrey, Dolcoath mine, Camborne; from the Virtuous Lady mine, Tavistock, Devon. At

Panasqueira, Portugal. From Ivigtut, Greenland. Very large crystals at Mont Saint-Hilaire, Quebec,

Canada. In the USA, from Bisbee, Cochise Co., and in the Antler mine, Mohave Co., Arizona; at

Leadville, Lake Co., Colorado. From Mosojllacta, Colavi, Bolivia, large crystals. In Brazil, in the Morro

Velho gold mine, Nova Lima, Minas Gerais, and at Pedreira Ataleia, Governador Valadares.



Siderite Mining

Siderite is mined surface or underground

Many noted localities worldwide, including: in Germany, from Freiberg and Neudorf, Harz

Mountains, and in the Siegerland district, Westphalia. In Austria, on the Erzberg, near Eisenerz,

Styria, and Huttenberg-Lolling, Carinthia. From Allevard, Isere, France. In England, from many

mines in Cornwall, as at the Great Onslow Consols mine, St. Breward, Wheal Maudlin, Lanlivrey,

Dolcoath mine, Camborne; from the Virtuous Lady mine, Tavistock, Devon. At Panasqueira,

Portugal. From Ivigtut, Greenland. Very large crystals at Mont Saint-Hilaire, Quebec, Canada. In the

USA, from Bisbee, Cochise Co., and in the Antler mine, Mohave Co., Arizona; at Leadville, Lake Co.,

Colorado. From Mosojllacta, Colavi, Bolivia, large crystals. In Brazil, in the Morro Velho gold mine,

Nova Lima, Minas Geris, and at Pereira Italia, Governador Valadares

Siderite Beneficiation

One kind of siderite ore dressing process includes the following steps:

The first step is the particle size less than 10mm, less than 15% moisture Ling iron ore mine with a

blending capacity of 0-8 weight percent of coal into the kiln; Ling iron ore mine in the same kiln

drying within dry, magnetization, arsenic removal, desulfurization process, rotary speed of 0.8-1.5

rev / min; rotary kiln calcination zone temperature is 800-50 ℃, drying zone temperature of 350-0

℃;

The second step is processed by the steps of baking a mine water cooling; cooling equipment

classification by the classifier, return sand separation with magnetic pulley, pump the overflow was

concentrated to a weak magnetic separator equipment wet magnetic separation, magnetic part of

the final product of iron ore. Of low iron, high-grade brown iron ore mine arsenic for sulfur

impurities in coal blending, drying, roasting, magnetic and off arsenic and sulfur impurities in the

body to complete the same kiln, process simplification, baking grade ore by water quenching after

magnetic separation, after magnetic separation to get high-speed rail grade, low-arsenic and sulfur



impurities in magnetite powder; widely used in the weak magnetic iron-containing minerals

beneficiation of ores and waste.

Common siderite mineral processing equipment, including crusher, ball mill, spiral classifier, high

gradient magnetic separator and magnetic separator and other equipment, machinery

manufacturing Co., Ltd. Zhengzhou Huachang professional siderite mineral processing equipment

manufacturers, welcomed the new old users to visit our factory inspection siderite and siderite ore

beneficiation process, we will be the most perfect diamond iron ore beneficiation process to work

for you, siderite ore

Pyrite

Pyrite Mining Knowledge

Physical Properties: Fracture: Conchoidal to uneven. Tenacity: Brittle. Hardness = 6–6.5 VHN =

1505–1520 (100 g load). D(meas.) = 5.018 D(calc.) = 5.013 Paramagnetic; a semiconductor.

Occurrence: Formed under a wide variety of conditions. In hydrothermal veins as very large

bodies, as magmatic segregations, as an accessory mineral in igneous rocks, in pegmatite; in

contact metamorphic deposits, also in metamorphic rocks; as diagenetic replacements in

sedimentary rocks.

Association: Pyrrhotite, marcasite, galena, sphalerite, arsenopyrite, chalcopyrite, many other

sulfides and sulfosalts, hematite, fluorite, quartz, barite, calcite.



Distribution: The most abundant and widespread sulfide. Only a few localities for large or fine

crystals can be mentioned. From Rio Marina, on Elba, and at Traversella, Piedmont, Italy. From

Ambasaguas and Navajun, Logro˜no Province, Spain, sculptural groups of crystals. At Aktchitao,

Kazakhstan. In the USA, in the Ibex mine, Leadville, Lake Co., Colorado; in Illinois, as "suns" at

Sparta, Randolph Co.; very large crystals from the Santo Ni˜no mine, near Duquesne, Santa Cruz

Co., Arizona. In Pennsylvania, at the French Creek mines, Chester Co., and in the Carleton talc

mine, Chester, Windsor Co., Vermont. From Butte, Silver Bow Co., Montana; at the Spruce claim,

King Co., Washington; as "bars" from the Buick mine, Bixby, Iron Co., Missouri. In Peru, from many

districts, with exceptional crystals from the Quiruvilca mine, La Libertad, and Huanzala, Huanaco.

Pyrite Mining

Pyrite is mined with underground mining. It can be dangerous to mine pyrite. If it combines with

oxygen and water, it becomes sulfuric acid, and sinks into the ground. Then it travels into aquifers,

rivers, and streams and kills everything in it. After they get the pyrite ore out of the ground, it is

heated. This takes the iron and sulfur out of it. It is mined all over the world. The most pyrite comes

from the United States, Italy, Russia, Sweden, and Peru.

Pyrite Beneficiation



Solution One

Raw Pyrite Ores ---> Raw Ores Crushing Screening Process ---> Raw Ores Grinding Process ---> Ore

Washing---> Ore Magnetic Separation ---> Flotation Process --> Recycling Process

Solution Two

Raw Pyrite Ores ---> Raw Ores Crushing Screening Process ---> Grinding Process ---> Ore Washing

---> Ore Flotation ---> Recycling Process

Limonite

Limonite Mining Knowledge

Physical Properties:Lustre: Earthy; Colour: Light brown to brown, may be yellowish-brown;

Streak: Yellowish brown to red; Hardness (Mohs): 4 - 5.5; Comment: Massive may be very soft.

Occurrence:A very common material in the oxidized zones of iron-bearing deposits, it is produced

by the decomposition of many iron minerals, particularly pyrite, with water being retained in

varying amounts.

Association: Magnetite, hematite, siderite, pyrite.

Distribution: Gold bearing limonite gossans were productively mined in the Shasta County,

California mining district. Similar deposits were mined near Rio Tinto in Spain and Mount Morgan in

Australia. In the Dahlonega gold belt in Lumpkin County, Georgia gold was mined from limonite rich



lateritic or saprolite soil. The gold of the primary veins was concentrated into the limonites of the

deeply weathered rocks. In another example the deeply weathered iron formations of Brazil served

to concentrate gold with the limonite of the resulting soils.

Limonite Mining

Limonite is mined with surface mining or underground mining.

Limonite Beneficiation

Solution One

Limonite Raw Ores ---> Ore Crushing Screening ---> Weak Magnetic Separation ---> Gravity

Separation ---> Flotation Process

Solution Two

Limonite Raw Ores ---> Ore Crushing Screening ---> Strong magnetic Separation ---> Roasting

Other Solutions

There are some other solutions with the conbination of magnetic separation and other separation

processes. If you are insterested in the Limonite Processsing Beneficiation Solutions, please contact

with Online Agent!!

Goethite

Goethite Mining Knowledge



Physical Properties: Cleavage: {010}, perfect; {100}, less perfect. Fracture: Uneven. Tenacity:

Brittle. Hardness = 5–5.5 VHN = 667 (100 g load). D(meas.) = 4.28(1) D(calc.) = 4.18

Occurrence: A common weathering product derived from numerous iron-bearing minerals in

oxygenated environments; an important component of ore in weathered iron deposits. Also a

primary precipitate in hydrothermal, marine, and bog environments upon oxidation of reduced iron-

bearing waters.

Association: Lepidocrocite, hematite, pyrite, siderite, pyrolusite, manganite, many other iron and

manganese-bearing species.

Distribution: Widespread; some localities for good crystals include: from Siegen, North Rhine-

Westphalia, and near Giessen, Hesse, Germany. At Pˇr´ıbram, Czech Republic. Exceptional crystals

from the Restormel mine, Lanlivery; the Botallack mine, St. Just; and elsewhere in Cornwall,

England. From Chaillac, Indre-et-Loire, France. In the USA, from the Pikes Peak district and

Florissant, El Paso Co., Colorado; an ore mineral in the Lake Superior district, as at the Jackson

mine, Negaunee, and the Superior mine, Marquette, Marquette Co., Michigan.

Goethite Mining

Goethite is mined with underground mining.

Goethite Beneficiation

The precipitation of goethite iron removal technology developed by the Belgian Laoshan Barron

factory Vieille Montagne and industrialization, known as the VM method. Successfully precipitated

goethite key is to maintain a low concentration of Fe3 + in the solution

Mainly Processes

Goethite Raw Ores ---> Crushing Screening Process ---> Grinding Milling Process ---> Washing ---



Ilmenite Mining Knowledge

Physical Properties: Fracture: Conchoidal to subconchoidal. Tenacity: Brittle. Hardness = 5–6

VHN = 566–698 (100 g load). D(meas.) = 4.72 D(calc.) = 4.789 Weakly magnetic.

Occurrence: A common accessory mineral disseminated in igneous rocks, such as granites,

gabbros, and kimberlites; in granite pegmatites, carbonatites, and high-grade metamorphic rocks;

may attain economic concentration in layered mafic intrusions and in "black sand" placer deposits.

Association: Magnetite, hematite, rutile, ulv¨ospinel, pyrrhotite, apatite

Distribution: Widespread; well-crystallized from numerous localities. In the Vishnevy-Il'men

Mountains, Southern Ural Mountains, Russia, large crystals; from the Lovozero massif, Kola

Peninsula. In Norway, at Tellnes and Snarum; large crystals from Kragerøand Arendal. From Binntal,

Valais, Switzerland. At St. Cristophe, Bourg d'Oisans, Is`ere, France. In the USA, at Quincy, Norfolk

Co., Massachusetts; from Litchfield, Litchfield Co., Connecticut; large crystals from the Lake Sanford

area, Essex Co., New York. At Allard Lake, Quebec; Bancroft, Ontario; and elsewhere in Canada.

From Arkaroola Bore, Flinders Ranges, and near Bimbowrie, South Australia.

Ilmenite Mining



Ilmenite is mined with underground mining. The ilmenite mining process is similar to normal metal

ore mining process. With the help of mining equipment such as drilling blasting equipment, the

ilmenite is mined from underground. Then trucks transport the raw blasted ores into the crushing

screening site.

Ilmenite Beneficiation

The ilmenite beneficiation is mainly to separate the titanium from the titanium-iron oxide mineral.

The titanium is of high value for its industrial use. Titanium can be alloyed with iron, aluminum,

vanadium, molybdenum, among other elements, to produce strong lightweight alloys for aerospace

(jet engines, missiles, and spacecraft), military, industrial process (chemicals and petro-chemicals,

desalination plants, pulp, and paper), automotive, agri-food, medical prostheses, orthopedic

implants, dental and endodontic instruments and files, dental implants, sporting goods, jewelry,

mobile phones, and other applications.

Solution One

Raw ilmenite ores ---> crushing screening process ---> grinding process ---> flotation ---> Roasting

Process ---> Recycling

Solution Two

Raw ilmenite ores ---> crushing screening process ---> grinding process ---> ore washing --->

magnetic separation ---> Flotation Process ---> Electrostatic Separation ---> Recycling



Production

The only source of primary iron is iron ore, used directly, as lump ore, or converted to briquettes,

concentrates, pellets, or sinter. At some blast furnace operations, ferrous scrap may constitute as

much as 7% of the blast furnace feedstock. Scrap is extensively used in steelmaking in electric arc

furnaces and in iron and steel foundries, but scrap availability can be an issue in any given year. In

general, large price increases for lump and fine iron ores and iron ore pellets through mid- 2009

were commensurate with price increases in the alternative—scrap. The ratio of scrap to iron ore

import prices has greatly increased since the end of 2009, causing the relative attractiveness of

scrap compared to iron ore to decrease to levels of 2008. The ratio of scrap to iron ore price still

remains markedly below levels seen between 2003 and 2007.

Iron Ore Industry

Overview of Iron Ore Industry

Iron Ore Industry is a concept that contains iron ore mining, quarrying, crushing, grinding, iron ore

beneficiation, ore reduction, iron ore transporting, trading, primary production, iron ore prices, iron

ore production plant, wholesale , iron ore shipping, ore slag recycling, pollution solution, iron ore

specific solution, etc.

Iron Ore Mining

Mine Production (2009): 2356t

Major Countries: China, Brazil, Australia

Major Companies: Vale (formerly CVRD), BHP Billiton, Rio Tinto

Key Uses: Steel industry

Main process: Drilling, Blasting, Excavation

Iron Ore Crushing & Screening



In earlier mechanized opencast mines, processing involved was crushing to required size and

separation of various products by dry screening. With the increasing emphasis on cleaner product,

wet screening has come in vogue in place of dry screening. Small capacity crushers have now given

place to large capacity crushers with improved reduction ratio. From Jaw crushers, mine operations

have switched over to gyratory and cone crushers where closely sized materials are required. Since

steel plants are switching over to sinter, iron ore fines are now finding market and full recovery of

these fines, classifiers, hydro cyclones and filters are increasingly used. For obtaining iron ore

concentrates from low grade ore various processing routes of gravity separation, flotation and

magnetic separations are in practice through out the world and India too.

Iron Ore Haulage and Transportation

At global level, high horse power (2400hp) and large capacity dumpers up to 350T have already

been in service. In advanced countries, trolley assisted dumpers of 120 T and unto 170 T are in use

in view of the spiraling fuel costs, faster cycle and better productivity.

Iron Ore Prices

Iron Ore Trading especially iron ore price is a world trading issue for all the iron consumption

countries.

Iron Ore prices are expected to rise during the 2010 through 2011 period. Expected price increases

are anticipated to range between 10% up to 60%, in some cases, as new contracts for iron ore

delivery are negotiated.

This is good news for all iron ore miners, as it will continue their growth period forward.

Iron Ore Drilling & Blasting

Iron Ore Drilling



Many drillers adopt their chosen method of both hole-making and hole clearing and become

experts over time. Long and successful careers are had by working within the method of

drilling/hole clearing chosen. These drillers identify themselves by their chosen methods: "cable

tool driller" "mud rotary driller" "environmental/geotechnical driller."

Mechanical hole making methods:

Cable tool:

For a cable tool drill to operate the drill string must have these four components: drilling cable -

swivel socket - drill stem - drill bit

Auger drilling:

Often used for site investigation, environmental and geotechnical drilling and sampling, auger

drilling can be an efficient drilling method.

Rotary Drilling:

Rotary drilling uses a shape, rotating drill bit to dig down through the Earth's crust. Much like a

common hand held drill, the spinning of the drill bit allows for penetration of even the hardest rock.

The idea of using a rotary drill bit is not new.

Iron Ore Blasting

Using a platform, the shot firers charged the holes with explosives and electronic detonators then

initiated the blast. The bottom row of holes would be the first part of the sequence to be detonated;

this was to ensure there was sufficient clearance at the face for the remaining rock to fall as a pile,

and not to project outward of the tunnel.



Iron Crushing and Screening

Iron Ore Crushing

Iron Ore Crushing Process is main to crush / break large blocks of iron ore into small blocks. When

large blocks are transported from iron ore mines , the crushing process is ready for rocks crushing.

This process is the main part of crushing and breaking the big iron ore ores into small bits with iron

ore crushing plant. According to the investigation, most of iron ore mines choose to buy Jaw

Crusher to carry on the coarse crushing, and buy Cone Crusher to complete the secondary breaking

or medium crushing , crushing the medium rock into bits.

Normal Process of Iron Ore Crushing. If you want to see specific iron ore process , welcome to visit

specific iron ore part.

Primary Crushing:

What primary crushing process considers is always suitable capacity and fine crushing ratio. Jaw

Crusher is popular used as primary crusher in primary crushing process for jaw crusher is large

capacity , easy maintenance, cheap price, easy spare parts.



Primary crushing is usually completed by a jaw crusher consisting of a heavy metal plate which

moves backwards and forwards against a fixed plate (these are the "jaws"). The moving plate is

kept in motion and given its crushing energy by a large flywheel. The crusher is wider at the top

than at the bottom. Rock from the quarry face is fed into the top of the crusher and crushed rock

falls out of the bottom of the jaws. The size of the crushed stone which passes through the jaws is

partly governed by the gap set at the bottom of the jaws, though larger size rocks can pass through

if the rock being crushed is slabby or elongate in shape. Large scale gyratory crushers can also be

used.

Secondary Crushing:

Secondary crushing process is often to make iron ores be smaller and fine shape. Impact Crusher or

Gyratory crusher is usually selected as secondary iron ore crusher. Then the blocks of iron ore

continues to be small.

These operate on the principle of a steel mantle mounted on an eccentric bearing and vertical shaft

assembly. Rotation of the eccentric assembly makes the mantle gyrate within a static outer

concave. There is a gap between the mantle and the concave. The shape of the gap is tapered

towards the base. As the mantle gyrates inside the concave, the gap between it and the concave at

any one point opens and closes on each gyration, this produces the required crushing action. Stone

is fed in at the top and crushed product falls out from the bottom of the cone.

Tertiary Crushing:

Tertiary crushing is to crush and pulverize the iron ores small enough (usually 10mm-250mm). So

Tertiary crusher must be (hydraulic / CS /spring) cone crusher or high pressure grinding roller mill ,



both of which can crush or pulverize small iron ores into smaller enough for the iron ore grinding

process.

Iron Ore Screening

Iron ore screening process is to select different size of iron ore particles to send them to primary

crusher / secondary crusher / tertiary crusher. What is used most for iron ore screening is vibrating

screen.

Each stage of crushing produces progressively smaller sized stones. In order to produce a usable

end-product, the crushed rock has to be screened into various size categories. Crushed and

screened rock is called aggregate. Screening is carried out at various stages in the crushing

process. Screens are basically box frames into which sheets of screen meshes of the required

apertures are inserted, clamped and tensioned. Screens are usually "multi-deck", i.e., two or more

screen meshes are stacked vertically within the screen frame. The whole screen is coupled to its

support frame by springs or resilient rubber mountings. Screens are made to vibrate by a rotating

transverse shaft. The shaft is machined to be unbalanced, and when driven by an electric motor by

v-belts, the required vibratory motion to agitate the aggregate is imparted. Screen decks are

mounted at an angle so that the aggregate moves down them. Aggregate is fed onto the high end

of the top deck and the vibration causes the aggregate to jiggle down the screen until it either

drops through a mesh aperture or falls off the end of a deck. The aggregate is then sorted or

'screened' according to the mesh sizes fitted, from large aperture mesh at the top, to small

aperture mesh at the bottom.



The vibrating screen is a kind of sieving equipment of international advanced level, developed by

our company on the basis of carrying on the advantages of traditional screens and absorbing the

outstanding technology from US.

It is widely used for grading and screening materials in the following fields: minerals, quarry,

building materials, water conservancy and hydropower, transportation, chemical industry, smelting

and so on.

To cope up with the need of higher production of iron ore, blasting materials are also being

developed / manufactured at the same pace.

Iron Ore Grinding

Iron Ore Grinding Process

Iron Ore Grinding Process is the process to grinding or pulverize iron ore particle into iron ore

powder or even smaller.

If you want to see specific iron ore process , welcome to visit specific iron ore pages.

Normal grinding process for Iron Ore:

Primary Grinding:

Primary grinding process is optional when it is used in many mineral powder grinding process.

When it goes to iron ore primary grinding , Raymond mill / rod mill / ball mill are all suitable primary

grinding mill for iron ore grinding.



Secondary Grinding:

Secondary grinding process is really the fine grinding process to refine the iron ore powder . For

iron ore secondary grinding, ball mill / scm supper powder mill / vertical roller mill (large scale) are

all suitable for iron ore powder production.

Iron Ore Grinding Mills

As what i said above, iron ore grinding mills are fine powder making machines. Ball mill for iron ore

is widely used in all over world. Raymond mill / rod mill is newly star grinding powder mill. SCM

super powder mill is easy to refine particles for fine thin powder. Vertical mill is large scale powder

making machines.

Iron Ore Beneficiation

Methods of Iron Ore Beneficiation

Washing:

Sometimes washing can be called a beneficiation process. In washing process, sand washer can



wash the powder for the next stage.

Gravity Concentration/Beneficiation:

Gravity concentration is used to suspend and transport lighter gangue (nonmetallic or no valuable

rock) away from the heavier valuable mineral. This separation process is based primarily on

differences in the specific gravities of the materials and the size of the particles being separated.

Values may be removed along with the gangue material (tailings) despite differences in density if

the particle sizes vary.

Gravity beneficiation (concentration) is a flow of processes including pre-process , gravity

beneficiation, pro-process. Pre-process of G-B is processes containing crushing and grinding ,

washing and desshanghai, screening or hydraulic classification. Gravity Process is the main process

of G-B including several gravity units. Pro-process is to complete the processed of concentrate

dehydration, tailing transmission and storage.

Magnetic Separation :

Magnetic separation is most commonly used to separate natural magnetic iron ore (magnetite)

from a variety of less-magnetic or nonmagnetic material. It is a mineral dressing method based on

the differences between magnetic minerals, realize uneven magnetic separation.

Typically, magnetic separation involves three stages of separation: cobbling, cleaning/roughing,

and finishing. There are many different magnetic separation plants such as permanent magnetic

separation, electronic magnetic separation, weak magnetic separators, medium magnetic



separators, strong magnetic separators, etc.

Flotation:

Flotation is a technique where particles of one mineral or group of minerals are made to adhere

preferentially to air bubbles in the presence of a chemical reagent. This is achieved by using

chemical reagents that preferentially react with the desired mineral. Several factors are important

to the success of flotation activities. These include uniformity of particle size, use of reagents

compatible with the mineral, and water conditions that will not interfere with the attachment of the

reagents to the mineral or air bubbles.

Pre-process preparation is necessary such as crushing and grinding, washing. Then flotation

individual stages are : 1. pulp adjustment and flotation reagents to join ; 2. stir companion and

caused a lot of bubbles ; 3. bubble mineralization ; 4. mineralized foam layer formation and blow

out .

Flotation process is a more complex mineral processing process, and its influencing factors can be

divided into not adjustment factors (undressed ore properties and the production water quality)

and adjustable factors (flotation process, grinding fineness and pulp density, pulp ph value,

flotation reagents system).

Iron Ore Beneficiation

Iron ore is upgraded to a higher iron content through concentration. Iron ore is being beneficiated

all round the world to meet the quality requirement of Iron and Steel industries. However, each

source of Iron ore has its own peculiar mineralogical characteristics and requires the specific

beneficiation and metallurgical treatment to get the best product out of it. The choice of the

beneficiation treatment depends on the nature of the gangue present and its association with the

ore structure. Several techniques such as washing, jigging, magnetic separation, advanced gravity

separation and flotation are being employed to enhance the quality of the Iron ore.



For hematite: Due to the high density of hematite relative to silicates, beneficiation usually involves

a combination of crushing and milling as well as heavy liquid separation. This is achieved by

passing the finely crushed ore over a bath of solution containing bentonite or other agent which

increases the density of the solution. When the density of the solution is properly calibrated, the

hematite will sink and the silicate mineral fragments will float and can be removed.

For magnetite: (Here we refers to the process of Qidashan Iron Mine of China, which is low grade of

magnetite.) Design 1: Stage Crushing, Stage Ore Grinding, Gravity Concentration, Magnetic

Separation, Anionic reverse flotation ; Design 2: Stage Crushing, Stage Ore Grinding, Gravity

Concentration, Magnetic Separation, Acid are flotation.

For ilmenite: (Referring to low grade ilmenite mines in China) Design 1 (old design) : Strong

magnetic separation, Gravity Concentration, the flotation. Design 2 : Primary cast tail, selection,

middling’s wave bed grinding reelection again.

Agglomeration of Iron Ore

Overview of Agglomeration

After concentration activities, agglomeration is used to combine the resulting fine particles into

durable clusters. The iron concentrate is balled in drums and heated to create a hardened

agglomerate. Agglomerates may be in the form of pellets, sinter, briquettes, or nodules. The

purpose of agglomerating iron ore is to improve the permeability of blast furnace feed leading to



faster gas-solid contact in the furnace . Agglomerating the ore prior to being sent to blast furnaces

reduces the amount of coke consumed in the furnace by increasing the reduction rate.

Sintering and Pelletising

Two types of agglomerated products are commonly produced/used in the industry namely Sinter

and Pellet. Accordingly the processes are known as Sintering and Pelletising respectively.

Sinter : Sinter is a clinker like aggregate which is normally produced from relatively coarser fine

iron ore (normally –3mm) mixed with coke breeze (-3mm), limestone dolomite fines (-3mm) and

other metallurgical return wastes from the plant. Sinter is a much preferred input/raw material in

blast furnaces. It improves BF operation and productivity and reduces coke consumption in blast

furnace. Presently, more than 70% hot metal in the world (in India 50%) is produced through the

sinter.

Pellet: Pellets are normally produced in the form of globules from very fine iron ore (normally –100

mesh) and mostly used for production of Sponge Iron in gas based plants, though they are also

used in blast furnaces in some countries in place of sized iron ore.

Iron Ore Pelletizing Technology



Today, however, pellets account for more than 97 percent of all agglomeration products

Pelletizing operations produce a "green" (moist and unfired) pellet or ball, which is then hardened

through heat treatment. These pellets are normally relatively large (3/8 to 1/2 inch) and usually

contain at least 60 percent iron. Pellets must be strong enough to withstand abrasion during

handling, transport, and high temperature treatment within the furnace. It is also important for the

material to be amenable to relatively rapid reduction (removal of oxygen) in the blast furnace.

Bentonite is often added as a binder to form green pellets prior to agglomeration .

In addition to iron, pellet constituents can include silica, alumina, magnesia, manganese,

phosphorus, and sulfur. Additives such as limestone or dolomite may also be added to the

concentrate in a process Mining Industry Profile: Iron known as "fluxing," prior to balling to improve

blast furnace recovery (Weiss 1985). In the past, these constituents were added in the blast

furnace. However, the development of fluxed pellets, which incorporate the flux in the pellet

material, has been shown to increase furnace efficiency.

Iron Ore Pelletizing Equipment

The first step in pelletizing iron concentrates is forming the pellets. This is usually accomplished in

a series of balling drums or discs. The pellets are formed by the rotating of the drums, which act to

roll the iron concentrate into balls. One of three different systems may then be used to produce

hardened pellets:

Travelling Grate—Is used to produce pellets from magnetite concentrates obtained from taconite

ores. Green pellets are fed to a travelling grate, dried, and preheated. The pellets then proceed to



the ignition section of the grate where nearly all the magnetite is oxidized to hematite. An updraft

of air is then used to cool the pellets.

Shaft Furnace—Green pellets are distributed across the top of a furnace by a moving conveyor belt,

then pass vertically down the length of the furnace. In the furnace, the pellets are dried and heated

to 2400 F. The bottom 2/3 of the furnace is used to cool the pellets using an upward-rising air

stream. The pellets are discharged from the bottom of the system through a chunkbreaker.

Grate Kiln—Combines the grate technique with a rotary kiln. No fuel material is incorporated into or

applied to the pellets in this process. The pellets are dried and preheated on a travelling grate

before being hardened by high-temperature heating in the kiln. The heated gas discharge from the

kiln is recycled for drying and preheating.

Agglomeration generates byproducts in the form of particulates and gases, including compounds

such as carbon dioxide, sulfur compounds, chlorides, and fluorides that are driven off during the

production process. These are usually treated using cyclones, electrostatic precipitators (wet and

dry), and scrubbing equipment. These treatment technologies generate either a wet or a dry

effluent, which contains valuable iron units and is commonly recycled back into the operation

Iron Slag Recycling

Overview of Slag Recycling

As is noted in the previous section, a variety of wastes and other materials are generated and

managed by iron mining operations.



Some, such as waste rock and tailings, are generally considered to be wastes and are managed as

such, typically in on-site management units. Even these materials, however, may be used for

various purposes in lieu of disposal. Some quantities of waste rock and tailings, for example, may

be used as construction or foundation materials at times during a mine's life. Many other materials

that are generated and/or used at mine sites may only occasionally or periodically be managed as

wastes. These include mine water removed from underground workings or open pits, which can be

recirculate for on-site use but also can be discharged to surface waters.

Slag Recycling and Management

Waste Rock and Ore Piles

Overburden and waste rock removed from the mine are stored or disposed of in unlined piles

onsite. These piles may also be referred to as mine rock dumps or mine dumps. As appropriate,

topsoil may be segregated from overburden and mine development rock, and stored for later use in

reclamation and revegetation. Ore is stored in piles at the mine or mill before beneficiation.

Tailings Impoundments

Tailings are the discarded material resulting from the concentration of ore during beneficiation

operations. Tailings are characterized by fine particle size and varying mineralogical and chemical



composition . The disposal of tailings requires a permanent site with adequate capacity for the life

of the mine. Tailings ponds or impoundments are created to dispose of these wastes. Literature

consulted for this report suggests that only impoundments are used in the iron ore industry.

Mine Pits and Underground Workings

In addition to wastes generated during active operations, pits and underground workings may be

allowed to fill with water when the mine closes or stops operation, since the need for dewatering is

over.

Drilling & Blasting Plant

Iron Ore Drilling Plant

There are different requirements relating to drilling equipment, drilling tools and drilling

applications depending on the type of bench blasting operation. In open-pit mining and quarrying,

the emphasis is normally on longterm performance and hole quality, whereas a general contractor

or drilling contractor operating in a variety of conditions is likely to pay more attention to the

flexibility and terrain-handling features of the equipment. But for all equipment users, economy,

reliability, ergonomics and ease of use are of vital importance.

In planning the blasting pattern, careful consideration must be given to the type and size of loading

equipment. In wheel loader operations the rock pile should preferably be long and shallow with

blasting planned to produce a loose pile. Front-shovel characteristics on the other hand are best

supported by higher, peaked rock piles. This can be achieved with a V-type initiation pattern.



Surface drilling top-hammer unit for open-pit mining, quarrying and large construction

projects

eg Tamrock Ranger 500, 600 and 700.

Features: powerful hydraulic rock drill, turning superstructure, large reach, good terrain handling,

ergonomic operator controls, FOPS/ROPS cabin with joystick controls for drilling, rod cassette and

tramming.

Hole diameter range: 64–115mm

Surface drilling top-hammer unit for construction projects and quarrying

eg Tamrock Pantera 800, 900, 1100 and 1500.

Features: powerful hydraulic rock drill, zoom boom, sturdy construction, ergonomic operator

controls, high production capacity, FOPS/ROPS cabin with joystick controls for drilling, rod cassette

and tramming.

Hole diameter range: 76–152mm

Iron Ore Blasting Plant



Drill and blast at the designated slope lines according to the blasting plan. Perform presplitting to

obtain smooth faces in the rock and shale formations. Perform the presplitting before blasting and

excavating the interior portion of the specified cross section at any location. The Department may

allow blasting for fall benches and haul roads prior to presplitting when blasting is a sufficient

distance from the final slope and results are satisfactory to the Engineer. Use the types of

explosives and blasting accessories necessary to obtain the required results.

Free blast holes of obstructions for their entire depth. Place charges without caving the blast hole

walls. Stem the upper portion of all blast holes with dry sand or other granular material passing the

3/8-inch sieve. Dry drill cuttings are acceptable for stemming when blasts are more than 800 feet

from the nearest dwelling.

Iron Ore Crushing & Screening Plant



Iron Ore Crushing Plant

Iron Ore Crushing can be completed in three or four steps, primary crushing (first step), secondary

crushing(second step), tertiary crushing (third step) and, in some iron ore quarries, a quaternary

crushing (fourth step). Crushed rocks of iton ores , or product, is transported along the process line

on conveyor belts or down chutes.

The crusher plant is fed by a chute and vibrating feeder. The base of the feeder is made of steel

"grizzly" bars and it is here that the first screening operation is actually done. Fine material and

dust produced by the blast, along with any remaining subsoil or weathered rock from the top of the

quarry face, drops through the bars onto a separate conveyor belt and onto a stockpile. This

screened material is called scalping’s and is used as rock fill.

Primary Crusher

Primary Crusher is crusher that is used in primary crushing process ie jaw crusher.



Jaw crusher used high strength steel, forming a casting, with wear, compression, and long life.

Mainly for crushing large, medium and small stones and the corresponding objects.

Secondary Crusher

Secondary Crusher is crusher that is used in primary crushing process ie gyratory or cone crusher ,

impact crusher.

Impact crusher used for the broken side not exceeding 500mm, the compressive strength of not

more than 360Mpa a variety of materials. Granite, limestone, gravel, which are better applicability.

Cone crusher is the crusher to produce the best performance for a variety of crushing process: from

the special crushing to the crushing, breaking from the fixed to mobile crusher station.

Tertiary Crusher

Tertiary Crusher is crusher that is used in tertiary crushing process usually referring to cone

crusher, VSI Crusher (Vertical Shaft Impact Crusher) or HPGR (High Pressure Grinding Roll).



This series cone crusher is widely used in metallurgical industry, construction industry, and the

phosphate industry, is suitable for crushing hard and medium hard ore, such as copper ore,

limestone, granite...

Vsi crusher used for highway, railway, high-rise construction, municipal, hydroelectric dam

construction, concrete mixing plant, provide high-quality sand and gravel aggregate.

The HPGR - grinding is achieved by an advanced type of grinding roll. Particles are broken by

compression in a packed particle bed, and not by direct nipping of the particles between the 2 rolls.

Iron Ore Screening Plant

Screening is carried out at various stages in the crushing process. Screens are basically box frames

into which sheets of screen meshes of the required apertures are inserted, clamped and tensioned.

Screens are usually "multi-deck", i.e., two or more screen meshes are stacked vertically within the

screen frame. The whole screen is coupled to its support frame by springs or resilient rubber

mountings. Screens are made to vibrate by a rotating transverse shaft. The shaft is machined to be

unbalanced, and when driven by an electric motor by v-belts, the required vibratory motion to

agitate the aggregate is imparted.



Vibrating Screen

Vibrating screens of this series are mainly composed of screen box, screen mesh, vibrator,

damping spring device, base, etc. The vibrator is on the side panel of the screen box and can be

driven by the generator through joint or belt to rotate and produce centrifugal inertial force to

make the screen box vib.

Iron Ore Grinding Mills

Iron Ore Grinding Mill

As a leading global manufacturer of crushing and milling equipment, we offer advanced, rational

solutions for any size-reduction requirements, including quarry, aggregate, grinding production and

complete plant plan. We also supply individual crushers and mills as well as spare parts of them.

MTM Trapezium Grinding Mill

MTM trapezium grinding mill are designed to crush and grind stones and non-metallic products

such as kaolin, gypsum into powder. It adopts the ladder-shapper roller and ring improving

crushing eddiciency and produce a typical product size of 1.6 mm to 0.038 mm when operating in

open circuit and in closed circuit with a screen or other sizing device.



MTW Trapezium Grinding Mill

MTW european trapezium grinding machine is mainly applied to the powder processing of mineral

products in industries of metallurgy, construction, chemistry, and mining etc. The grinding mill

machine can produce powder from non-flammable and non-explosive mineral materialssuch as

barite, limestone, quartz, calcite, granite, porcelain clay, basalt, gypsum etc.

MXB Coarse Powder Mill

MXB coarse powder grinding mill is used for pre-processing of various crushable non-flammable

and non-explosive brittle materials with Mohs under 9. MXB coarse powder grinder machine is

widely applied in quartz sand, silica sand, foundry sand, fine sand and other sand abrasive industry.

It is also applied in industries of mining, construction, metallurgic, road building and water

Raymond Mill



In the Raymond grinding plant, the stuff for grinding is loaded into the grinding chamber of the

main frame evenly and continuously. The stuff is grinded when roller rolls. The rough powder will

be put back to grinder for regrinding. The fine powder flows into the product cyclone collector

together with airflow and is expelled from the powder output pipe as product.

SCM Series Super Thin Mill

On the basis of more than 15 years' production experience of Shibang company, we absorb

technology advantages from the same field abroad and domestic, organizing elite powder

processing experts to investigate, research, try again and again; finally, we develop this high-

efficiency and low-cost SCM Series Super Thin Grinding Mill.

Ball Mill

Ball mills are used primary for single stage fine grinding, regrinding, and as the second stage in two

stage grinding circuits. According to the need of customers, ball mill can be either wet or dry

designs. These mills are sized from 2 t/h to 30 TPH for wet grinding and from 0.5 t/h to 30 TPH for

dry grinding. Ball mills have been designed in standard sizes of the final products between 0.074

mm and 0.4 mm in diameter.



Vertical Roller Mill

The high-efficiency, energy-saving LM Series vertical mill can simultaneously handle pulverizing,

drying, sizing and air jet transport. This series vertical mill has the high grinding efficiency,

meaning a 50% reduction in per-unit power consumption over ball mills. The particle size

adjustments of this vertical mill are simple, with minimal noise and vibration.

Iron Ore Beneficiation Plant

SBM supplies all the equipments needed in beneficiation. SBM beneficiation plant is necessary in

the mineral beneficiation or ore beneficiation. SBM ore beneficiation plant includes magnetic

separators and gravity separators. SBM magnetic separator includes magnetic ore separator and

common magnetic separator and gravity separator includes shaking table and jigger machine. SBM

have other mineral beneficiation plants like stone crusher, grinding mill, vibrating screen and sand

washing machine. If you want any beneficiation plant, SBM will supply your demand with best

service and best quality.

Beneficiation Plant In Milling Process

Hydro cyclone



Beneficiation Plant In Magnetic Separation

Cobber / Magnetic separator

Cleaners / Scavengers

Finishers

Rotary drum separator

Magnetic pulley



Roll separator

Cross belt separator

Ring-type separator


iron ore process

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