As one of the earliest, most widely used metals in the world, iron ore is an important
raw material for iron and steel production. At present, iron ore resources are
decreasing day by day, which is characterized by more lean ore than rich ore, more
associated ore and complex ore composition. Xinhai Mining, as a mineral processing
equipment manufacturer with over-20-year experience, provides responsible iron ore
processing technologies by different type of iron ores.
Because of the strong magnetism of magnetite, the extraction of iron from
magnetite is weak magnetic separation technology. The magnetite iron ore processing maninly
It is suitable for the extraction of iron from simple single magnetite. It
can be divided into successive-grinding weak magnetic separation process and
stage-grinding weak magnetic separation process. Successive-grinding weak
magnetic separation process is suitable for extraction of iron from
magnetite with coarse grain or high grade iron. Stage-grinding weak magnetic
separation process is suitable for extraction of iron from low grade
magnetite with fine grain.
Single Weak Magnetic Separation Process
It mainly points at the extraction of iron ores which are difficult to
increase its fineness or with many SiO2 impurities. It includes weak
magnetic-cation anti-flotation separation process and magnetic-positive
anion flotation separation process.
Weak Magnetic - Flotation Separation Process
It is mainly dealing with the extraction of iron ores with multiple metals
and complex iron ore.
Weak Magnetic - Strong Magnetic - Flotation Separation Process
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Hematite is weak magnetic ore, which can be easier separation by flotation
than magnetite. In the old days, hematite was separated by gravity separation, however it
was weed out for unreachable capacity. Now Hematite iron ore processing is as follows:
Commonly, weak magnetic separation can be added before strong magnetic separation to
remove the strong magnetic ore or impurity in raw ore. Then strong magnetic
separation is used to separating hematite, which is also the work flow of the
mixture of magnetite and hematite.
Hematite is easier to floated than magnetic, which could be separated by positive
flotation. As the density of iron ore is much higher than that of gangue mineral,
gangue mineral is more likely to attach to the foam than iron ore. Therefore, for
the extraction of iron ore, reverse flotation is more advantageous than positive
flotation. When the magnetite content mixed in hematite is higher, reverse flotation
is a more convenient method for the extraction of iron ore.
In the process of high intensity magnetic-flotation, a part of gangue mineral in the
ore is firstly removed by high intensity magnetic separation, and then the coarse
concentration of high intensity magnetic separation is sent to the flotation to
obtain the final qualified concentrate.
Limonite is one of the main type of iron ores, but its iron content is
lower than magnetite and hematite, and it is a secondary iron ore. At present, the
industrial application of limonite iron ore processing includes:
The single separation process of lignite is mainly used for the lignite with high iron
content and good selectivity, which can be divided into a single magnetic separation
process and a single gravity separation process. The single gravity separation process
is used to deal with the extraction of iron ore with coarser grain size, and the
equipment is selected according to the grain size of the ore. Single magnetic separation
process generally refers to a single strong magnetic separation process, this process
has a strong adaptability to the ore, the concentrate is easy to concentrate and filter,
but it is not suitable for fine grade slime.
The combined iron ore processing technology only used for limonite, includes
magnetization - magnetic separation process, flotation - strong magnetic separation
process, gravity separation - strong magnetic separation process, etc., which are used
for the extraction of iron from limonite with relatively complex composition. The
specific iron ore processing technology shall be determined after the mineral processing
test has proved the ore properties.
Like limonite, siderite is a low-grade iron ore that is unstable. The iron ore processing
technology used in siderite concentrator are gravity separation and strong magnetic
separation. Different siderite has different iron ore processing methods. The extraction of
iron from single siderite with coarse grain size is suitable to be treated with single
gravity separation, single strong magnetic separation and combined process including two
kinds of iron ore processing technologies. For the extraction of iron from siderite with
fine grain size, effective extraction of iron include roasting magnetic separation, strong
magnetic separation, flotation or magnetic flotation combined process.
Siderite containing magnetite can be separated by a combined iron ore processing method of
weak magnetic separation and gravity separation, strong magnetic separation, or flotation in
series, or a more complex iron ore processing method.
Iron ore processing capacity is huge, iron ore tailings account for about half of the
total metal tailings, in recent years due to the increasing awareness of environmental
protection and tailings accidents, whether from the perspective of comprehensive
utilization of resources or from the perspective of environmental protection and safety,
iron ore tailings treatment is a problem that needs attention.
To avoid resource waste and tailings accidents at the source, the main treatment methods
of iron ore tailings at present are: tailings reprocessing, tailings dry stacking and
full tailings consolidation and filling method.
Tailings Reprocessing: Effectively increasing product rate and
recovery rate, comprehensive utilization of iron ore resources.
Tailings Dry Stacking: Reducing the cost of tailings pond and the
risk of accidents and pollution.
Tailings Consolidation and Filling Method: Utilization of tailings,
protecting terrain and environment.
Stage grinding(2 stages) + stage separation(6 stages magnetic
separation) + iron concentrate dewatering + tailings magnetic and gravity separation
+ grinding + flotation separation of sulfur and titanium.
Grid Ball Mill
Permanent Magnetic Drum Magentic Separator
High-efficiency Vibrating Screen
XPA Slurry Pump
Spiral Helix Chute
One stage grinding + two-block classification + close-circuit
grinding + four-block magnetic separation + concentrate dewatering + tailings
Wet Cylinder Ball Mill
Strong magnetic separation: two-and-half-block close circuit
crushing and screening + strong magnetic separation
Verse flotation: two-and-half-block close circuit crushing and
screening + verse flotation
Weak magnetic separation: two-and-half-block close circuit
crushing and screening + one stage pre-magnetic separation for tail tossing + one
stage close circuit grinding + two-block weak magnetic separation
Circular Vibrating Screen
Overflow Ball Mill
High Gradient Magnetic Separator
XCF Flotation Cell
KYF Flotation Cell
Wet Magnetic Separator
Anhui 600t/d Iron Ore Processing Plant
Inner Mongolia 2500t/d Iron Ore Processing Plant
Yunnan 100t/d Iron Ore Processing Plant
Xinhai Mining has set up a mine design institute and a mine research institute, with
an experienced team of experts, and has applied for many patents (some invention
patents are under examination and approval). The technical indexes of mineral
processing are guaranteed.
Till now, Xinhai Mining has accomplished over 2000 mine design, research and
equipment supplying projects. Among them, there are over 500 mineral processing
EPC+M+O projects. Xinhai Mining has technologies and experiences for over 70 kinds
Pointed at different problem during mine construction, Xinhai Mining put forward
mineral processing EPC+M+O service, supplying close-circuit service from mineral
processing test and mine design, equipment manufacturing and purchasing, reaching
standard and production, to mine management and operation.
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