Magnetite Iron Ore Processing Plant

Energy-efficient magnetic beneficiation plants using wet drum separators to achieve high-grade iron concentrate with high recovery.

1. Process Overview & Flowchart Explanation

The Magnetite Iron Ore Processing Plant processes low-grade magnetite ores (20-35% Fe) into premium blast furnace or pellet-feed concentrate (>65% Fe). Large ore is crushed by a primary PE Series Jaw Crusher and secondary/tertiary HST Single Cylinder Hydraulic Cone Crushers down to -12 mm. Pre-magnetic cobbing removes barren country rock early to save milling energy.

The crushed ore is ground in a Mineral Processing Ball Mill in closed circuit with a Spiral Classifier. The pulp flows through a 3-stage permanent Wet Drum Magnetic Separator circuit: Concurrent CTS tanks for roughing, Counter-current CTN tanks for scavenging, and Semi-counter-current CTB tanks for fine cleaning. The magnetic concentrate is dewatered on a High Frequency Dewatering Screen into high-grade iron ore concentrate.

2. Technical Advantages & Features

• High Concentrate Grade & Recovery: Upgrades low-grade 25% Fe feed into 65-68% Fe super-grade iron concentrate with over 90-95% magnetic recovery.
• Permanent Rare-Earth Magnets: NdFeB permanent magnets offer stable 1000-3000 Gauss field strength with zero magnetic decay over 10+ years.
• Multi-Tank Process Adaptability: CTS/CTN/CTB tank options ensure maximum rejection of quartz gangue while minimizing magnetic particle loss.
• Low Operating Cost: Pure physical magnetic separation requires zero chemical reagents, dramatically lowering cost per ton of concentrate.