1) Single Magnetic Iron Ore Beneficiation Process
The majority of iron minerals in the single magnetite ore are magnetite with simple composition, which is often processed by weak magnetic separation method for the beneficiation of iron ore. For the large and medium sized magnetic separation plant, using one stage grinding, magnetic separation method when the grinding particle size is greater than 0.2 mm. using two stage grinding, magnetic separation method when the grinding particle size is less than 0.2 mm. Using the stage grinding, magnet...
2) Polymetallic Magnetic Iron Ore Beneficiation Process
The gangue minerals of polymetallic magnetic iron contain silicate or carbonate minerals, and are often associated with polygonum cobalt pyrite, chalcopyrite and apatite. Generally, using the weak magnetic separation and flotation combined process for the beneficiation of iron ore, that is, using the weak magnetic separation to recover the iron, and using the flotation to recover sulfide or apatite. The principle flow of polymetallic magnetic iron ore beneficiation process is divided into two...
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1） Single Weak Magnetic Iron Ore Beneficiation Process
It includes metamorphic, sedimentary, hydrothermal and weathered typed hematite, siderite, limonite and hematite siderite. This kind of ore has many kinds, and wide range of disseminated size. There are two main processes used in the beneficiation of iron ore.
2) Polymetallic weak magnetic iron ore beneficiation process
It mainly includes hydrothermal type and sedimentary type phosphorus or sulfide containing hematite or siderite, which are often processed by gravity separation, flotation, strong magnetic separation or combined processes for the beneficiation of iron, and then the flotation is used to recover the phosphorus or sulfide.
1) Single magnetic iron hematite beneficiation process
The iron minerals in the ore are magnetite and hematite or siderite, which are often embedded in fine grains. Gangue is mainly quartz, some contain more iron silicate. The proportion of magnet in ore varies from surface to depth. There are two kinds of magnetic iron hematite or magnetic iron siderite beneficiation processes used for beneficiation of iron ore.
The process used for beneficiation of iron ore of this kind of ore is the most complicated one in iron ore. Recovery of weak magnetic iron ore by gravity separation, flotation or strong magnetic separation and recovery of associated components by flotation. Last: 3 Cautions of Flotation Machine Daily Maintenance Next: What Are the Flotation Processes Used in the Extraction of Copper Lead Zinc Ore?
Magnetic Separation and Iron Ore Beneficiation. Magnetic separation is an old technique for the concentration of iron ores and for the removal of tramp iron. Since 1849, a number of patents on magnetic separation have been issued in USA, and texts of some of the patents before 1910 describe a variety of magnetic separators for mineral processing.
The subject of iron ore beneficiation in many kinds of iron ore is magnetite beneficiation. The common magnetite beneficiation processes mainly include a single magnetic separation process and low intensity magnetic separation reverse flotation process.
Crushing is done in the conventional manner in 2 or 3 stage systems to approximately all minus ¾ inch which is considered good feed for subsequent wet rod and ball mill grinding. The primary rod mill discharge at about minus 10 mesh is treated over wet magnetic cobbers where, on average magnetic taconite ore, about 1/3 of 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.
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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. Magnetic separation on average ores with 25 to 30% iron results in about 1/3 of the total tonnage ending up in final concentrate.
The ironconcentrate 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 ead 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 Flow Flotation Machine will effectively treat 35 to 40 LTPH of iron concentrates down to the desired li...
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 the thoroughly washed and relatively slime free magnetic iron concentrates, the cationic reagent is fast acting and in some cases no prior conditioning ead 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 is also helpful in depressing the iron. Typical requirements may be as follows: Armac 12..0.10 0.15 lbs/ton Gum 9072..1.0 lbs/ton Heptinol0.025 lbs/ton One operation is presently using Aerosurf MG 98 Amine at the rate of .06 lbs/ton and 0.05 lbs/ton of MIBC . Total reagent cost in this case is approximately 5½ 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 ead 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 i...
In the iron ore beneficiation process where magnetite is present in the ore, an accurate volumetric flow rate is necessary in order to determine the mass flow measurement to balance the grinding and separation circuits. CiDRAs SONARtrac® flow meter delivers stable, accurate flow readings as well as a longer meter life and a lower overall ...