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Iron Ore Beneficiation Process In Brazil Share

Project Overview

 

Project Background: Brazil has abundant iron ore resources. The goal is to efficiently develop low-grade iron ore to meet the needs of the steel industry.

 

Goal: Increase the grade of iron ore concentrate to more than 65%, and the comprehensive recovery rate ≥85%, to achieve a win-win situation of environmental protection and economic benefits.

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Iron Ore Beneficiation Process In Brazil
Beneficiation Plant
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Introduction to Brazilian Iron Ore Beneficiation Technology

 

Project Overview

    Project Background: Brazil has abundant iron ore resources. The goal is to efficiently develop low-grade iron ore to meet the needs of the steel industry.

    Goal: Increase the grade of iron ore concentrate to more than 65%, and the comprehensive recovery rate ≥85%, to achieve a win-win situation of environmental protection and economic benefits.

 

Core process flow

1. Crushing and screening

    • Adopt the "three-stage one closed circuit" process (coarse crushing + medium crushing + fine crushing), the feed particle size is ≤800mm, and the final product particle size is ≤12mm.

2. Grinding and classification

    • The ball mill and cyclone form a closed-circuit system, and the grinding fineness reaches -200 mesh, accounting for 75%, to ensure that the minerals are fully dissociated.

3. Magnetic separation and purification

    • Staged magnetic separation (coarse separation, fine separation, scavenging separation), using a high-gradient magnetic separator, magnetic field strength ≥1.2T, to reduce impurity content.

4. Dehydration treatment​​

    • Concentrator + filter press combination, concentrate moisture ≤10%, easy to transport and smelt.

 

Key equipment selection​​

1. Crushing equipment​​: jaw crusher (coarse crushing) + hydraulic cone crusher (medium and fine crushing), considering both efficiency and energy consumption.

​​2. Grinding equipment​​: Φ4.5×6.5m overflow ball mill, with high-frequency fine screen to improve classification accuracy.

3. Magnetic separation equipment​​: permanent magnetic drum magnetic separator (coarse separation) and vertical ring high gradient magnetic separator (fine separation).

4. Intelligent system​​: DCS central control system, real-time monitoring of energy consumption, output, and equipment status, reducing manual intervention.Project Overview.

 Hematite processingTailings recoveryIron concentrate purification

Advantage

Iron Ore Beneficiation Process In Brazil:

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The advantages of iron ore process production lines are reflected in their technical integration, resource utilization efficiency, and sustainability. Especially in the context of the current global mining green transformation and intelligent upgrading, advanced process production lines have become the core focus of enterprises to enhance their competitiveness.
 
1. Technical integration advantage: full process optimization
 
Modular design
    Through modular assembly (such as crushing, grinding, sorting, and dehydration modules), it can quickly adapt to different ore body characteristics (such as mixed hematite and magnetite).
 
Multi-technical synergy
    Integrate dry pre-selection, wet re-selection, flotation, and other processes to achieve efficient sorting of complex ores.
 
2. Resource utilization advantage
 
Economically low-grade ore
    Advantages: Bioleaching, microwave activation, and other technologies release the value of traditional abandoned mines.
    Case: China Anshan Iron and Steel Qidashan Ore Dressing Plant uses microwave pretreatment technology to increase the recovery rate of extremely poor hematite with Fe 30% from 48% to 65%, extending the mine life by 15 years.
 
Tailings resource utilization
    Advantages: Tailings reselection + building material utilization to achieve "zero waste".

    Data: Brazil's Vale tailings reselection line recycles more than 2 million tons of iron-containing tailings each year, and processes siliceous tailings into environmentally friendly bricks, with additional income of $80 million per year. 

 

Keywords: Iron ore concentrator case | Low-grade iron ore development | Magnetic separation process | Zero discharge of ore dressing wastewater | Tailings resource utilization | Intelligent concentrator | Mine environmental protection measures | Iron ore project investment return

Iron Ore Concentrator FAQs

 

1. How to purify low-grade iron ore (Fe≤40%) to more than 60%? ​​

Use the combined process of "pre-selection and discarding + multi-stage magnetic separation/flotation". For example:
• Pre-selection and discarding: dry magnetic separation or heavy medium separation, discarding 10-30% of waste rock to improve the grade of the mill;
• Main separation: weak magnetic separation (Fe₃O₄) or flotation (Fe₂O₃) combined with high gradient magnetic separation, the concentrate grade can reach 60-68%, and the recovery rate is ≥85%.

2. How to deal with high content of silicon dioxide (SiO₂) and aluminum oxide (Al₂O₃) in ore?​​

• Desiliconization: reverse flotation (anion collector preferentially adsorbs quartz) or magnetic separation-gravity separation combined process;
• Dealumination: adjust the pH value of the slurry and use selective inhibitors (such as starch) to inhibit the floating of aluminum minerals;
 

3. How to select key equipment for the ore dressing plant? ​​

• Crushing: jaw crusher (coarse crushing) + cone crusher (medium and fine crushing), high-pressure roller mill can reduce the particle size entering the mill;
• Grinding: Φ4.5×6.5m ball mill with cyclone closed circuit, grinding fineness -200 mesh accounts for 75%;
• Sorting: drum magnetic separator for magnetite, flotation column or spiral chute for hematite;
• Dehydration: ceramic filter (water content ≤10%) or filter press (applicable to high mud ore).
 

4. How to reduce energy consumption and maintenance costs for ore dressing?​​

​​​​• ​​More crushing and less grinding​​: High-pressure roller mill replaces traditional fine crushing, and the particle size of the mill is reduced from 12mm to 8mm, and the energy consumption is reduced by 15%;
​​​​• Wear-resistant materials​​: High-chromium alloy lining (lifetime 6-8 months) and ceramic filter plate (maintenance cycle extended by 2 times) are used;
​​​​• Intelligent monitoring​​: The DCS system adjusts the equipment load in real time to prevent over-grinding and idling.

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