Iron Ore Beneficiation Process Flow

Iron ore beneficiation is a key process to process raw ore into high-grade iron concentrate. Its core procedures are crushing → grinding → separation → dewatering. Crushing lays the foundation for efficient beneficiation. With professional equipment, Shibang has become a preferred choice in the industry.

1. Iron Ore Beneficiation Process Flow

Crushing and Screening

Large iron ore is evenly fed into primary crushing equipment by vibrating feeder. After primary crushing, materials are screened via vibrating screen, then sent for secondary and fine crushing in closed-circuit circulation to ensure qualified particle size (generally 0-15mm), preparing materials for grinding operation.
Grinding and Classification

Finely crushed materials are delivered to ball mill for grinding. Combined with classifier to form closed-circuit grinding system, raw materials are ground to achieve mineral liberation, with particles below 0.074mm accounting for 60%-90%, avoiding over-grinding and insufficient grinding.

Separation Operation

Low-intensity magnetic separation is commonly used for magnetite. For hematite, mainstream processes include low-intensity magnetic separation-reverse flotation and ultra-fine crushing-wet magnetic separation tailings discarding. Gangue and impurities are removed to raise iron grade above 60%.

Dewatering Treatment

Concentrate is thickened by thickener and dewatered by filter press, producing finished iron concentrate with moisture content below 10%. Tailings are discharged in dry form or used for backfilling to realize eco-friendly production.

2. Core Crushing Equipment of Shibang

Targeting the high hardness feature of iron ore (compressive strength ≤320MPa), Shibang develops three-stage closed-circuit crushing main equipment featuring high efficiency, strong wear resistance, intelligence and energy saving.

 C6X / PEW European Jaw Crusher (Primary Crushing)

Serving as core primary crushing equipment, it handles lump ore of 125-1020mm. Adopting deep V-shaped crushing cavity with no dead zone and large crushing ratio, its maximum hourly output reaches 800 tons. Built with Baosteel steel, heavy eccentric shaft and Timken bearings, it features sturdy structure and long service life, ranking the top choice for primary crushing.

 HST Single-cylinder Hydraulic Cone Crusher (Secondary Crushing)

Applied in secondary crushing, it accepts feeding size ≤350mm with capacity ranging from 45t/h to 600t/h. Discharge opening is adjusted hydraulically with particle size control accuracy up to 1mm. Adopting laminated crushing principle, it produces well-graded finished particles. Equipped with iron passing protection device, it prevents equipment damage from hard foreign materials and ensures stable operation.

3. HPT Multi-cylinder Hydraulic Cone Crusher (Fine Crushing)

It is the key fine crushing equipment suitable for high-hardness iron ore with maximum capacity up to 1200t/h. Multi-cylinder hydraulic structure enhances crushing force, and finished discharge size is controlled within 12mm. Equipped with PLC intelligent control system, it monitors operating parameters in real time with high-precision fault early warning, and greatly prolongs the service life of wear parts.