Magnetite Beneficiation Process

1. For single magnetite ores, the weak magnetic separation process is commonly used. The ore composition is usually simple, and the grinding and magnetic separation stages depend on the particle size of the ore: a. When the grinding particle size is more than 0.2mm, a one-stage grinding-magnetic separation process is often employed in iron ore magnetic separation plants.
   b. When the grinding particle size is less than 0.2mm, a two-stage grinding-magnetic separation process is typically adopted.
   c. In arid and water-scarce areas, magnetite concentrators may opt for a dry grinding-dry magnetic separation process.
   d. For poor-rich magnetite or rich magnetite ore, a dry magnetic separator is generally utilized to remove gangue. This is followed by a grinding-magnetic separation process to obtain a concentrated product.
2. Magnetite ore containing multiple metals often includes silicate or carbonate minerals and may be associated with cobalt pyrite, chalcopyrite, and apatite. In such cases, a combined process of weak magnetic separation and flotation separation is commonly used: a. In the weak magnetic separation-flotation process, the main focus is on recovering iron concentrate.
   b. In the flotation-weak magnetic separation process, the primary goal is to recover sulfide or apatite minerals.

To obtain a high-grade concentrate, the magnetite concentrate can be further processed through methods such as flotation or fine screening. Additionally, considering processes like tailings reprocessing can help improve recovery rates.

Magnetite Processing Plant

1.Crushing & Screening:

• A vibrating feeder is used in front of the crusher to evenly feed mineral raw materials into the jaw crusher.
• Vibrating screens are used to separate the raw ore based on the desired particle size for crushing.
• For high-grade magnetite, a closed circuit is typically used to obtain magnetite ore with the required particle size.
• For low-grade magnetite, three-stage open-circuit or three-stage closed-circuit operations are employed for ore crushing.

2.Grinding & Classifying:

• Due to the relatively high hardness and fine particle size of the ore, a two-stage grinding process is employed. This involves using a ball mill along with a spiral classifier to achieve the desired grinding fineness.

3.Magnetic Separation:

• Magnetic separation is achieved using a permanent magnet drum-type magnetic separator.
• Coarse-grained dry magnetic separation is commonly used in magnetite beneficiation plants.
• For ultra-lean magnetite ore (grade below 20.00%), an ultra-fine crushing-wet magnetic separation tailing process can be utilized. This involves finely crushing the ore below 5mm-3mm and then carrying out wet magnetic separation and tailing using a permanent magnetic field magnetic separator.

4.Tailings Treatment:

• After obtaining the magnetite concentrate, the tailings must be concentrated and dehydrated.
• The dried mineral products can be obtained by passing the tailings through a dryer.