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Xinhai Mining delivered everything except civil works for an ultra-pure iron concentrate plant in Laiwu, Shandong — testwork, construction drawing design, full equipment manufacture, installation and commissioning, operator training and all installation materials. Built by retrofitting an existing workshop, the 500 t/d line upgrades purchased magnetite fines (TFe ≥ 65%) into ultra-pure and high-purity iron powder products.
Testwork and Product Definition: Xinhai testwork at 91.4% passing 400 mesh, using magnetic separation and six-stage reverse flotation, produced ultra-pure powder at 71.76% Fe with 60.21% yield and 65.36% recovery, and high-purity powder at 70.63% Fe with 28.54% yield and 30.50% recovery, defining the two-product scheme and its impurity limits: acid-insoluble content ≤ 0.20%, Si ≤ 0.08%, Mn ≤ 0.10%, S ≤ 0.020%, P ≤ 0.015%.
Two-Stage Closed-Circuit Grinding: An MQYg2150 overflow ball mill with a hydrocyclone group and electromagnetic screens forms the first stage, grinding to 90% passing 325 mesh; an MQYg1870 mill with a second hydrocyclone group closes the second stage at 90% passing 400 mesh.
Five-Stage Magnetic Cleaning: Second-stage ground pulp passes five stages of magnetic cleaning on double-drum separators with a magnetic dewatering tank, while the magnetic tailings are scavenged by drum separators to recover remaining iron.
Desulfurization and Reverse Flotation: The magnetic concentrate is treated through one desulfurization flotation stage followed by six reverse flotation stages; flotation froth combined with scavenger magnetic concentrate forms the high-purity powder, and the reverse flotation concentrate forms the ultra-pure powder.
Product and Tailings Dewatering: Each product is dewatered through a concentration magnetic separator and a ceramic filter to about 12% moisture; tailings are thickened in an inclined-plate thickener and filter-pressed to about 20% moisture, with all overflow and filtrate settled and returned to the circuit.
Construction drawings were completed in December 2022, and the plant was brought into production in early 2024 with both products meeting their specification targets. The project marked Xinhai's first ultra-pure iron concentrate application, extending its flowsheet experience beyond conventional iron ore processing.
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