Iron Ore Process

Provided by:
Mehdi jafari

Iron Ore

Bonab Steel Complex

Table of Contents
What is Iron Ore? ...................................................................................................6 What is Iron Ore used for? ......................................................................................6 Uses of Special Iron ...............................................................................................7 Industrial Applications of Iron Ore .........................................................................7 Iron Ore Business ...................................................................................................8 How is Iron Ore Processed? ....................................................................................8 Distribution in the world ........................................................................................9 Classified Iron Ore............................................................................................................................. 9 By Minerals ............................................................................................................9 By Harmful Impurities ..........................................................................................10 By Grades ............................................................................................................10 By Ore Structure...................................................................................................10 By Special Form....................................................................................................10 By Gangue Mineral ...............................................................................................11 Magnetite Mining Knowledge ...............................................................................11 Magnetite Mining .................................................................................................12 Magnetite Beneficiation ........................................................................................12 Magnetite Processing Flow Diagram .....................................................................13 Hematite ............................................................................................................................................. 13 Hematite Mining Knowledge ................................................................................13 Hematite Mining ..................................................................................................15 Hematite Beneficiation .........................................................................................15 Simple Tips: .........................................................................................................15 Siderite ................................................................................................................................................ 16 Siderite Mining Knowledge ...................................................................................16 2 Engineering Department

Iron Ore

Bonab Steel Complex

Siderite Mining.....................................................................................................17 Siderite Beneficiation ...........................................................................................17 Pyrite.................................................................................................................................................... 18 Pyrite Mining Knowledge ......................................................................................18 Pyrite Mining........................................................................................................19 Pyrite Beneficiation ..............................................................................................20 Limonite.............................................................................................................................................. 20 Limonite Mining Knowledge .................................................................................20 Limonite Mining ...................................................................................................21 Limonite Beneficiation..........................................................................................21 Goethite .............................................................................................................................................. 22 Goethite Mining Knowledge .................................................................................22 Goethite Mining ...................................................................................................22 Goethite Beneficiation ..........................................................................................23 Ilmenite Mining Knowledge ..................................................................................23 Ilmenite Mining ....................................................................................................24 Ilmenite Beneficiation...........................................................................................24 Production ...........................................................................................................25 Iron Ore Industry ............................................................................................................................. 25 Overview of Iron Ore Industry ..............................................................................25 Iron Ore Mining ...................................................................................................26 Iron Ore Crushing & Screening .............................................................................26 Iron Ore Haulage and Transportation ...................................................................26 Iron Ore Prices .....................................................................................................27 Iron Ore Drilling & Blasting .......................................................................................................... 27 Iron Ore Drilling ...................................................................................................27 Iron Ore Blasting ..................................................................................................28 Iron Crushing and Screening ....................................................................................................... 28

Engineering Department

Iron Ore

Bonab Steel Complex

Iron Ore Crushing ................................................................................................28 Iron Ore Screening ...............................................................................................30 Iron Ore Grinding............................................................................................................................. 31 Iron Ore Grinding Process ....................................................................................31 Iron Ore Grinding Mills.........................................................................................32 Iron Ore Beneficiation .................................................................................................................... 33 Methods of Iron Ore Beneficiation ........................................................................33 Iron Ore Beneficiation ..........................................................................................34 Agglomeration of Iron Ore ........................................................................................................... 35 Overview of Agglomeration ..................................................................................35 Sintering and Pelletising.......................................................................................36 Iron Ore Pelletizing Technology ...........................................................................37 Iron Ore Pelletizing Equipment.............................................................................37 Iron Slag Recycling .......................................................................................................................... 38 Overview of Slag Recycling ...................................................................................38 Slag Recycling and Management ..........................................................................39 Waste Rock and Ore Piles .....................................................................................39 Tailings Impoundments .......................................................................................40 Mine Pits and Underground Workings ..................................................................40 Iron Ore Drilling Plant ..........................................................................................40 Iron Ore Blasting Plant .........................................................................................42 Iron Ore Crushing & Screening Plant ......................................................................................... 43 Primary Crusher ...................................................................................................43 Secondary Crusher ...............................................................................................44 Tertiary Crusher ...................................................................................................45 Vibrating Screen ..................................................................................................46 Iron Ore Grinding Mills .................................................................................................................. 46 Iron Ore Grinding Mill ..........................................................................................46

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Iron Ore

Bonab Steel Complex

MTM Trapezium Grinding Mill ..............................................................................46 MTW Trapezium Grinding Mill ..............................................................................47 MXB Coarse Powder Mill .......................................................................................47 Raymond Mill .......................................................................................................48 SCM Series Super Thin Mill ...................................................................................48 Ball Mill ................................................................................................................48 Vertical Roller Mill ................................................................................................49 Iron Ore Beneficiation Plant .......................................................................................................... 49 Beneficiation Plant In Milling Process....................................................................49 Beneficiation Plant In Magnetic Separation ...........................................................50

Engineering Department

Iron Ore

Bonab Steel Complex

What is Iron Ore?

Iron ores are rocks and minerals most of whose deposites are found in sedimentary rocks. They formed from chemical reactions that combined iron and oxygen in marine and fresh waters. The ores are usually rich in iron oxides and vary in color from dark grey, bright yellow, deep purple, to rusty red.

The most important minerals in these iron ore deposits are magnetite (Fe 3O4), hematite (Fe2O3), goethite (FeO(OH)), limonite (FeO(OH).n(H2O)), ilmenite(FeTiO3) , siderite (FeCO3) and Pyrite (FeS2). These iron ores have been mined to produce almost every iron and steel object that we use today from paper clips to automobiles to the steel beams in skyscrapers.

What is Iron Ore used for?

Most of the iron ore that is mined is used for making steel. Raw iron by itself is not as strong and hard as needed for construction and other purposes. Most of the iron produced is then used to make steel. Steel is used to make automobiles, locomotives, ships, beams used in buildings, furniture, paper clips, tools, reinforcing rods for concrete, bicycles, and thousands of other items.

Engineering Department

Iron Ore

Bonab Steel Complex

While the other uses for iron ore and iron are only a very small amount of the consumption, they provide excellent examples of the ingenuity and the multitude of uses that man can create from our natural resources.

Uses of Special Iron

Powdered iron is mainly used in metallurgy products, magnets, high-frequency cores, auto parts, catalyst. Black iron oxide is often used as pigment, in polishing compounds, metallurgy, medicine, magnetic inks, in ferrites for electronics industry. Iron blue can be used in paints, printing inks, plastics, cosmetics (eye shadow), artist colors, laundry blue, paper dyeing, fertilizer ingredient, baked enamel finishes for autos and appliances, industrial finishes. Radioactive iron (iron 59) is applied in medicine, tracer element in biochemical and metallurgical research.

Industrial Applications of Iron Ore

Some types of iron ores according the variety of ores have some special uses / applications in Industry. Micaceous iron ore is generally soft and unctuous. It is used in the manufacture of welding rods (electrodes) and used as a coating material in the preparation of welding rods. Magnetite is used for the preparation of heavy media in coal-washing plants. It has got distinct advantage over sand as magnetite particles adhering to coal can easily be separated by teh magnetic separator. Bog iron ore is used as purifying and desulphurising material of producer gas and municipal gases. The ore is filled in purifying tank through which gases are passed and purified.

Engineering Department

Iron Ore

Bonab Steel Complex

Spathic ore is used for the production of hydrogen by steam iron contact process. The ore to be used must have a spongy structure in order to present the maximum surface contact. Generally ore of light yellow color is preferred. It should not sinter together when subjected to the high temperature of 1000C. The ore is calcined before use to make it suitable for reduction and oxidation cycles. For the production of hydrogen, the calcined ore is first reduced at 700-1000C by use of water gas or producer gas. Steam is then passed over it. The ore gets oxidized and the hydrogen is liberated from the steam. The oxidized ore is then subjected to the reduction cycle by passing water gas which makes the ore suitable for reuse. The arrangement for the process of oxidation and reduction cycle is made automatic in the plant to get the supply of commercial hydrogen which is utilised for the hydrogenation of vegetable oils. Hydrogenation effects hardening of the oils.

Iron Ore Business

Iron Ore Business is a wide concept of iron ore related business including iron ore prices, iron ore production, iron ore pricing, iron ore run escape, iron ore etf, iron ore plants, iron ore quarry machinery, iron ore wholesale, etc.

How is Iron Ore Processed?

The iron ores are often processed by following stages : Ore Reduction (maybe called Ore mining and crushing ) process, Ore Grinding Process, Iron Ore Beneficiation, Iron Sintering and Pelletizing, Iron Slag Recycling process. These steps are in normal iron ore production line designs. The process of iron ore reduction is to make the large blocks of iron ore rocks small enough for the next ore grinding process, when large blocks are transfered from mines or quarries of iron ores. For usual condition, ore reduction contains primary crushing, secondary crushing and fine crushing

Engineering Department

Iron Ore

Bonab Steel Complex

process. After that , iron ores are usually smaller than 12 mm which is ready for the grinding mill machines. Then the primary grinding and fine grinding process are done before iron ore beneficiation. There are many methods in Iron Ore Beneficiation such as ore washing, gravity separation, flotation and magnetic separation. For magnetite iron ore, smelting and magnetic separation are often chosen as suitable methods of magnetite beneficiation. For hematite iron ore, washing and flotation are nomal methods of hematite beneficiation. For other iron ores , there are also specific methods of beneficiation according to the mixture of the iron ore minerals.

Distribution in the world

Iron-rich rocks are common worldwide, but ore-grade commercial mining operations are dominated by the countries listed in the next paragraph. The major constraint to economics for iron ore deposits is not necessarily the grade or size of the deposits, because it is not particularly hard to geologically prove enough tonnage of the rocks exist. According to the yearly production of iron ore, China, Australia, Brazil, India, Russia, Ukraine, South Africa, Iran, Canada, United States, Kazakhstan, Sweden, Venezuela, Mauritania are the main iron ore production countries.

Classified Iron Ore By Minerals

According to the composition of minerals ,Iron ores are classified into magnetite, hematite, goethite, limonite, siderite, ilmenite, pyrite, etc. Magnetite , Hardness: 5.5-6.5 , color: iron black ore black, special: strong magnetic.

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Iron Ore

Bonab Steel Complex

As it is with magnetite ore, there are several types including Titanomagnetite (Fe xTiyO4) , Vanadium magnetite (FeV2O4 / FeVO4 / V2O5) V-Ti magnetite (mixture of both of above), Cr magnetite (mixed with Cr2O3), Magnesium Magnetite (mixed with MgO).

By Harmful Impurities
By harmful impurities (S, P, Cu, Pb, Zn, V, Ti, Co, Ni, Sn, F, As) ratio of content, iron ores can be divided into high-sulfur iron ore, low sulfur iron ore, high phosphorus iron Ore, low phosphorus iron ore and so on. Harmful impurities are often the minerals that we remove from iron ore in the ore production. Sometimes for removing these impurities , some special physical or chemical methods of beneficiation are chosen to filter them.

By Grades
Iron ore is typically classified as High grade (+65% Fe), Medium grade (+62 65% Fe) and Low grade (62% Fe). Typically, the Integrated Steel Plants(ISPs) use medium/High grade Iron Ore whereas the Sponge Iron plants require only High Grade iron ore, preferably, with +67% Fe.

By Ore Structure
According to the structure, iron ores can be divided into disseminated ore , stock work disseminated ores, striped ores, banded ore , dense massive ore, breccia ore, the oolite and bean-shaped, kidneyshaped, honeycomb, powdery, earthy ores.

By Special Form
(i) Lumpy/Fine Ore: Iron Ore is traded in lumps (i.e. sized ore) or in fines. Production/availability of lumps is limited by virtue of the natural occurrence and also because of generation of lot of fines during crushing of large lumps present in the run-of mines (ROM).

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Bonab Steel Complex

(ii) Natural pellet: It is a term coined by producers in some Asian counties, to designate sized iron ore used directly in Sponge Iron production. (iii) Blue Dust: Blue Dust is the name given to naturally occurring, extremely friable, high grade Hematite Iron Ore powder.

By Gangue Mineral
According to the gangue mineral, iron ores can be divided into quartz-based minerals, amphibole type, type of pyroxene, plagioclase type, Seri cite chlorite type, skarn, actinolite type, serpentine type, type and ankerite Jasper-based iron ore. According to the investment of world minerals, the main iron ores are distributed in the following countries: Brazil, Australia, Russia, Ukraine, China, India, Venezuela, Canada, Sweden, USA, Iran, Mauritania, South Africa, Mexico, etc.

Magnetite Mining Knowledge

Physical Properties: Cleavage: Parting on {Ill}, very good. Fracture: Uneven. Tenacity: Brittle. Hardness == 5.5-6.5 VHN == 681-792 (100 g load). D(meas.) == 5.175 D(calc.) == 5.20 Strongly magnetic.

Occurrence: A common accessory mineral in igneous and metamorphic rocks, in which magmatic segregation or contact metamorphism may produce economic deposits. Extensive deposits in sedimentary banded iron formations; a biogenic product; important detrital deposits.

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Iron Ore

Bonab Steel Complex

Distribution: Many localities, even for fine crystals. In Sweden, at Falun, Kiruna, Vastanfors, and elsewhere. At Arendal, Norway. From Zlatoust and Magnitogorsk, Ural Mountains, Russia. In the Zillertal, Tirol, Austria. From Traversella, Piedmont, Italy. In Switzerland, at Binntal and Rimpfischwang, Valais, and elsewhere. In the Gardiner complex, beyond the head of Kangerdlugssuaq Fjord, Greenland. From Bancroft, Ontario, Canada. In the USA, around Lake Sanford, Essex Co., and in the Tilly Foster mine, Brewster, Putnam Co., New York; at Magnet Cove, Hot Springs Co., Arkansas; in the Iron Springs district, Iron Co., Utah. From the Cerro del Mercado, Durango, Mexico. At Itabira, Minas Gerais, Brazil.

Magnetite Mining
Magnetite is mined using underground mining. It is found in: Austria, Switzerland, South Africa, and the United States [Franklin, New Jersey, Utah, Arkansas, Vermont].

Magnetite Beneficiation
Solution One One kind of wet and dry combined magnetite beneficiation process method, mainly for three magnetic ore processing, and then by wet magnetic material, magnetic field strength of the selected 400 ~

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Iron Ore

Bonab Steel Complex

1200GS, magnetic roller speed of 60 ~ 320 rev / min, the wet material obtained by the dehydration products of iron ore, usually iron ore at 35% by this method after magnetic separation of iron ore iron content of up to 68 ~ 70%, the joint process method, ore than 90% utilization, process in less water consumption, save water, reduce costs, reduce pollution, magnetic separation of dust from the dust trapping device will not cause air pollution, this method is a high production efficiency, product quality, and pollution-free technology with creative methods.

Magnetite Processing Flow Diagram

Hematite Hematite Mining Knowledge

Physical Properties: Fracture: Uneven to subconchoidal. Tenacity: Brittle; elastic in thin laminate. Hardness = 56 . VHN = 10001100 (100 g load). D(meas.) = 5.26 D(calc.) = 5.255.

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Iron Ore

Bonab Steel Complex

Occurrence: An accessory mineral in felsic igneous rocks, a late-stage sublimate in volcanic rocks, and in high-temperature hydrothermal veins. A product of contact metamorphism and in metamorphosed banded iron formations. A common cement in sedimentary rocks and a major constituent in oolitic iron formations. Abundant on weathered iron-bearing minerals. Association: Ilmenite, rutile, magnetite (metamorphic and igneous); goethite, siderite, lepidocrocite (sedimentary).

Distribution: Widespread. Exceptional crystals from Switzerland, as at Fibbia, St. Gotthard, Uri; Binntal, Valais; Cavradi, Tavetsch, Graubunden; and many other places. At Ocna de Fier (Moravicza; Vasko), Romania. From Rio Marina, Elba, Italy. At Cleator Moor, Cumbria, England. From Kragerand Hiassen, Norway. In Brazil, large crystals from Mesa Redonda and Congonhas do Campo, Minas Gerais; at Itabira and in the Brumado mine, Bahia; at Miguel Burnier, Ouro Preto. From the Kuruman district, Cape Province, South Africa. At Nador, Algeria. In the USA, in the Thomas Range, Juab Co., Utah, and near Quartzsite, La Paz Co., Arizona.

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Iron Ore

Bonab Steel Complex

Hematite Mining
Hematite is mined using underground mining. It is mined in England, Mexico, Australia, Canada, and Brazil.

Hematite Beneficiation
Currently beneficiation of hematite ores is conducted using either direct flotation (hematite flotation) or indirect flotation (quartz flotation) techniques depending upon the nature of the available ore bodies. In direct flotation, iron bearing mineral, mostly hematite, is floated using oleate as collector leaving siliceous gangue, usually quartz, in the tailings. Kick et al. were among the first to investigate the utility of various collectors in hematite flotation from quartz. In their extensive study, they concluded that fatty acids and their soaps are superior collectors for hematite flotation and among these, sodium oleate is the best collector. Rietz , Kihlstedt and Kivalo et al. have demonstrated the successful use of tall oil in hematite flotation. Solution One: Magnetic Separation was first step for the hematite processing. Then Gravity Separation was processed as the second step. Solution Two: Magnetic Separation ---> Flotation Process Solution Three: Gravity Separation ----> Magnetic Separation ---> Flotation Process Related Knowledge: Magnetic Separation - Gravity Separation - Flotation Process

Simple Tips:

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Iron Ore

Bonab Steel Complex

For the crystallization of dense red - magnetite-quartzite, the re-election method widely used coarsegrained disseminated ore sorting, high intensity magnetic separation or flotation for sorting of fine ore. For the red clay - magnetite ore, the main use of washing or dry magnetic separation

Siderite Siderite Mining Knowledge

Physical Properties: Cleavage: Perfect on {1011}. Fracture: Uneven to conchoidal. Tenacity: Brittle. Hardness = 3.754.25 D(meas.) = 3.96(1) D(calc.) = 3.932

Occurrence: A common component of bedded sedimentary iron ores and metamorphic iron formations; in hydrothermal metallic veins; rarely in granite and nepheline syenite pegmatite; in carbonatites; authigenic, and in concretions. Association: Quartz, barite, fluorite, pyrite Distribution: Many noted localities worldwide, including: in Germany, from Freiberg and Neudorf, Harz Mountains, and in the Siegerland district, Westphalia. In Austria, on the Erzberg, near Eisenerz, Styria, and Huttenberg-Lolling, Carinthia. From Allevard, Is`ere, France. In England, from many mines in Cornwall, as at the Great Onslow Consols mine, St. Breward, Wheal Maudlin, Lanlivrey, Dolcoath mine, Camborne; from the Virtuous Lady mine, Tavistock, Devon. At Panasqueira, Portugal. From Ivigtut, Greenland. Very large crystals at Mont Saint-Hilaire, Quebec, Canada. In the USA, from Bisbee, Cochise Co., and in the Antler mine, Mohave Co., Arizona; at Leadville, Lake Co., Colorado. From Mosojllacta, Colavi, Bolivia, large crystals. In Brazil, in the Morro Velho gold mine, Nova Lima, Minas Gerais, and at Pedreira Ataleia, Governador Valadares.

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Iron Ore

Bonab Steel Complex

Siderite Mining
Siderite is mined surface or underground Many noted localities worldwide, including: in Germany, from Freiberg and Neudorf, Harz Mountains, and in the Siegerland district, Westphalia. In Austria, on the Erzberg, near Eisenerz, Styria, and Huttenberg-Lolling, Carinthia. From Allevard, Isere, France. In England, from many mines in Cornwall, as at the Great Onslow Consols mine, St. Breward, Wheal Maudlin, Lanlivrey, Dolcoath mine, Camborne; from the Virtuous Lady mine, Tavistock, Devon. At Panasqueira, Portugal. From Ivigtut, Greenland. Very large crystals at Mont Saint-Hilaire, Quebec, Canada. In the USA, from Bisbee, Cochise Co., and in the Antler mine, Mohave Co., Arizona; at Leadville, Lake Co., Colorado. From Mosojllacta, Colavi, Bolivia, large crystals. In Brazil, in the Morro Velho gold mine, Nova Lima, Minas Geris, and at Pereira Italia, Governador Valadares

Siderite Beneficiation
One kind of siderite ore dressing process includes the following steps: The first step is the particle size less than 10mm, less than 15% moisture Ling iron ore mine with a blending capacity of 0-8 weight percent of coal into the kiln; Ling iron ore mine in the same kiln

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Iron Ore

Bonab Steel Complex

drying within dry, magnetization, arsenic removal, desulfurization process, rotary speed of 0.8-1.5 rev / min; rotary kiln calcination zone temperature is 800-50 , drying zone temperature of 350-0 ; The second step is processed by the steps of baking a mine water cooling; cooling equipment classification by the classifier, return sand separation with magnetic pulley, pump the overflow was concentrated to a weak magnetic separator equipment wet magnetic separation, magnetic part of the final product of iron ore. Of low iron, high-grade brown iron ore mine arsenic for sulfur impurities in coal blending, drying, roasting, magnetic and off arsenic and sulfur impurities in the body to complete the same kiln, process simplification, baking grade ore by water quenching after magnetic separation, after magnetic separation to get high-speed rail grade, low-arsenic and sulfur impurities in magnetite powder; widely used in the weak magnetic iron-containing minerals beneficiation of ores and waste. Common siderite mineral processing equipment, including crusher, ball mill, spiral classifier, high gradient magnetic separator and magnetic separator and other equipment, machinery manufacturing Co., Ltd. Zhengzhou Huachang professional siderite mineral processing equipment manufacturers, welcomed the new old users to visit our factory inspection siderite and siderite ore beneficiation process, we will be the most perfect diamond iron ore beneficiation process to work for you, siderite ore

Pyrite Pyrite Mining Knowledge

Physical Properties: Fracture: Conchoidal to uneven. Tenacity: Brittle. Hardness = 66.5 VHN = 1505 1520 (100 g load). D(meas.) = 5.018 D(calc.) = 5.013 Paramagnetic; a semiconductor.

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Iron Ore

Bonab Steel Complex

Occurrence: Formed under a wide variety of conditions. In hydrothermal veins as very large bodies, as magmatic segregations, as an accessory mineral in igneous rocks, in pegmatite; in contact metamorphic deposits, also in metamorphic rocks; as diagenetic replacements in sedimentary rocks. Association: Pyrrhotite, marcasite, galena, sphalerite, arsenopyrite, chalcopyrite, many other sulfides and sulfosalts, hematite, fluorite, quartz, barite, calcite.

Distribution: The most abundant and widespread sulfide. Only a few localities for large or fine crystals can be mentioned. From Rio Marina, on Elba, and at Traversella, Piedmont, Italy. From Ambasaguas and Navajun, Logrono Province, Spain, sculptural groups of crystals. At Aktchitao, Kazakhstan. In the USA, in the Ibex mine, Leadville, Lake Co., Colorado; in Illinois, as "suns" at Sparta, Randolph Co.; very large crystals from the Santo Nino mine, near Duquesne, Santa Cruz Co., Arizona. In Pennsylvania, at the French Creek mines, Chester Co., and in the Carleton talc mine, Chester, Windsor Co., Vermont. From Butte, Silver Bow Co., Montana; at the Spruce claim, King Co., Washington; as "bars" from the Buick mine, Bixby, Iron Co., Missouri. In Peru, from many districts, with exceptional crystals from the Quiruvilca mine, La Libertad, and Huanzala, Huanaco.

Pyrite Mining
Pyrite is mined with underground mining. It can be dangerous to mine pyrite. If it combines with oxygen and water, it becomes sulfuric acid, and sinks into the ground. Then it travels into aquifers, rivers, and streams and kills everything in it. After they get the pyrite ore out of the ground, it is

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Bonab Steel Complex

heated. This takes the iron and sulfur out of it. It is mined all over the world. The most pyrite comes from the United States, Italy, Russia, Sweden, and Peru.

Pyrite Beneficiation
Solution One Raw Pyrite Ores ---> Raw Ores Crushing Screening Process ---> Raw Ores Grinding Process ---> Ore Washing---> Ore Magnetic Separation ---> Flotation Process --> Recycling Process Solution Two Raw Pyrite Ores ---> Raw Ores Crushing Screening Process ---> Grinding Process ---> Ore Washing ---> Ore Flotation ---> Recycling Process

Limonite Limonite Mining Knowledge

Physical Properties:Lustre: Earthy; Colour: Light brown to brown, may be yellowish-brown; Streak: Yellowish brown to red; Hardness (Mohs): 4 - 5.5; Comment: Massive may be very soft.

Occurrence:A very common material in the oxidized zones of iron-bearing deposits, it is produced by the decomposition of many iron minerals, particularly pyrite, with water being retained in varying amounts. Association: Magnetite, hematite, siderite, pyrite.

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Iron Ore

Bonab Steel Complex

Distribution: Gold bearing limonite gossans were productively mined in the Shasta County, California mining district. Similar deposits were mined near Rio Tinto in Spain and Mount Morgan in Australia. In the Dahlonega gold belt in Lumpkin County, Georgia gold was mined from limonite rich lateritic or saprolite soil. The gold of the primary veins was concentrated into the limonites of the deeply weathered rocks. In another example the deeply weathered iron formations of Brazil served to concentrate gold with the limonite of the resulting soils.

Limonite Mining
Limonite is mined with surface mining or underground mining.

Limonite Beneficiation

Solution One Limonite Raw Ores ---> Ore Crushing Screening ---> Weak Magnetic Separation ---> Gravity Separation ---> Flotation Process Solution Two Limonite Raw Ores ---> Ore Crushing Screening ---> Strong magnetic Separation ---> Roasting

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Iron Ore

Bonab Steel Complex

Other Solutions There are some other solutions with the conbination of magnetic separation and other separation processes. If you are insterested in the Limonite Processsing Beneficiation Solutions, please contact with Online Agent!!

Goethite Goethite Mining Knowledge

Physical Properties: Cleavage: {010}, perfect; {100}, less perfect. Fracture: Uneven. Tenacity: Brittle. Hardness = 55.5 VHN = 667 (100 g load). D(meas.) = 4.28(1) D(calc.) = 4.18

Occurrence: A common weathering product derived from numerous iron-bearing minerals in oxygenated environments; an important component of ore in weathered iron deposits. Also a primary precipitate in hydrothermal, marine, and bog environments upon oxidation of reduced iron-bearing waters. Association: Lepidocrocite, hematite, pyrite, siderite, pyrolusite, manganite, many other iron and manganese-bearing species. Distribution: Widespread; some localities for good crystals include: from Siegen, North RhineWestphalia, and near Giessen, Hesse, Germany. At Prbram, Czech Republic. Exceptional crystals from the Restormel mine, Lanlivery; the Botallack mine, St. Just; and elsewhere in Cornwall, England. From Chaillac, Indre-et-Loire, France. In the USA, from the Pikes Peak district and Florissant, El Paso Co., Colorado; an ore mineral in the Lake Superior district, as at the Jackson mine, Negaunee, and the Superior mine, Marquette, Marquette Co., Michigan.

Goethite Mining
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Bonab Steel Complex

Goethite is mined with underground mining.

Goethite Beneficiation
The precipitation of goethite iron removal technology developed by the Belgian Laoshan Barron factory Vieille Montagne and industrialization, known as the VM method. Successfully precipitated goethite key is to maintain a low concentration of Fe3 + in the solution Mainly Processes Goethite Raw Ores ---> Crushing Screening Process ---> Grinding Milling Process ---> Washing ---

Ilmenite Mining Knowledge

Physical Properties: Fracture: Conchoidal to subconchoidal. Tenacity: Brittle. Hardness = 56 VHN = 566698 (100 g load). D(meas.) = 4.72 D(calc.) = 4.789 Weakly magnetic.

Occurrence: A common accessory mineral disseminated in igneous rocks, such as granites, gabbros, and kimberlites; in granite pegmatites, carbonatites, and high-grade metamorphic rocks; may attain economic concentration in layered mafic intrusions and in "black sand" placer deposits. Association: Magnetite, hematite, rutile, ulvospinel, pyrrhotite, apatite Distribution: Widespread; well-crystallized from numerous localities. In the Vishnevy-Il'men Mountains, Southern Ural Mountains, Russia, large crystals; from the Lovozero massif, Kola Peninsula. In Norway, at Tellnes and Snarum; large crystals from Kragerand Arendal. From Binntal, Valais, Switzerland. At St. Cristophe, Bourg d'Oisans, Is`ere, France. In the USA, at Quincy, Norfolk Co., Massachusetts; from Litchfield, Litchfield Co., Connecticut; large crystals from the Lake Sanford area, Essex Co., New York. At Allard Lake, Quebec; Bancroft, Ontario; and elsewhere in Canada. From Arkaroola Bore, Flinders Ranges, and near Bimbowrie, South Australia.

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Ilmenite Mining
Ilmenite is mined with underground mining. The ilmenite mining process is similar to normal metal ore mining process. With the help of mining equipment such as drilling blasting equipment, the ilmenite is mined from underground. Then trucks transport the raw blasted ores into the crushing screening site.

Ilmenite Beneficiation

The ilmenite beneficiation is mainly to separate the titanium from the titanium-iron oxide mineral. The titanium is of high value for its industrial use. Titanium can be alloyed with iron, aluminum, vanadium, molybdenum, among other elements, to produce strong lightweight alloys for aerospace (jet engines, missiles, and spacecraft), military, industrial process (chemicals and petro-chemicals, desalination plants, pulp, and paper), automotive, agri-food, medical prostheses, orthopedic implants, dental and

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Iron Ore

Bonab Steel Complex

endodontic instruments and files, dental implants, sporting goods, jewelry, mobile phones, and other applications. Solution One Raw ilmenite ores ---> crushing screening process ---> grinding process ---> flotation ---> Roasting Process ---> Recycling Solution Two Raw ilmenite ores ---> crushing screening process ---> grinding process ---> ore washing ---> magnetic separation ---> Flotation Process ---> Electrostatic Separation ---> Recycling

Production
The only source of primary iron is iron ore, used directly, as lump ore, or converted to briquettes, concentrates, pellets, or sinter. At some blast furnace operations, ferrous scrap may constitute as much as 7% of the blast furnace feedstock. Scrap is extensively used in steelmaking in electric arc furnaces and in iron and steel foundries, but scrap availability can be an issue in any given year. In general, large price increases for lump and fine iron ores and iron ore pellets through mid- 2009 were commensurate with price increases in the alternativescrap. The ratio of scrap to iron ore import prices has greatly increased since the end of 2009, causing the relative attractiveness of scrap compared to iron ore to decrease to levels of 2008. The ratio of scrap to iron ore price still remains markedly below levels seen between 2003 and 2007.

Iron Ore Industry Overview of Iron Ore Industry

Iron Ore Industry is a concept that contains iron ore mining, quarrying, crushing, grinding, iron ore beneficiation, ore reduction, iron ore transporting, trading, primary production, iron ore prices, iron

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ore production plant, wholesale , iron ore shipping, ore slag recycling, pollution solution, iron ore specific solution, etc.

Iron Ore Mining

Mine Production (2009): 2356t Major Countries: China, Brazil, Australia Major Companies: Vale (formerly CVRD), BHP Billiton, Rio Tinto Key Uses: Steel industry Main process: Drilling, Blasting, Excavation

Iron Ore Crushing & Screening

In earlier mechanized opencast mines, processing involved was crushing to required size and separation of various products by dry screening. With the increasing emphasis on cleaner product, wet screening has come in vogue in place of dry screening. Small capacity crushers have now given place to large capacity crushers with improved reduction ratio. From Jaw crushers, mine operations have switched over to gyratory and cone crushers where closely sized materials are required. Since steel plants are switching over to sinter, iron ore fines are now finding market and full recovery of these fines, classifiers, hydro cyclones and filters are increasingly used. For obtaining iron ore concentrates from low grade ore various processing routes of gravity separation, flotation and magnetic separations are in practice through out the world and India too.

Iron Ore Haulage and Transportation

At global level, high horse power (2400hp) and large capacity dumpers up to 350T have already been in service. In advanced countries, trolley assisted dumpers of 120 T and unto 170 T are in use in view of the spiraling fuel costs, faster cycle and better productivity.

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Iron Ore Prices

Iron Ore Trading especially iron ore price is a world trading issue for all the iron consumption countries. Iron Ore prices are expected to rise during the 2010 through 2011 period. Expected price increases are anticipated to range between 10% up to 60%, in some cases, as new contracts for iron ore delivery are negotiated. This is good news for all iron ore miners, as it will continue their growth period forward.

Iron Ore Drilling & Blasting

Iron Ore Drilling
Many drillers adopt their chosen method of both hole-making and hole clearing and become experts over time. Long and successful careers are had by working within the method of drilling/hole clearing chosen. These drillers identify themselves by their chosen methods: "cable tool driller" "mud rotary driller" "environmental/geotechnical driller."

Mechanical hole making methods: Cable tool: For a cable tool drill to operate the drill string must have these four components: drilling cable swivel socket - drill stem - drill bit Auger drilling: Often used for site investigation, environmental and geotechnical drilling and sampling, auger drilling can be an efficient drilling method.

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Rotary Drilling: Rotary drilling uses a shape, rotating drill bit to dig down through the Earth's crust. Much like a common hand held drill, the spinning of the drill bit allows for penetration of even the hardest rock. The idea of using a rotary drill bit is not new.

Iron Ore Blasting

Using a platform, the shot firers charged the holes with explosives and electronic detonators then initiated the blast. The bottom row of holes would be the first part of the sequence to be detonated; this was to ensure there was sufficient clearance at the face for the remaining rock to fall as a pile, and not to project outward of the tunnel.

Iron Crushing and Screening Iron Ore Crushing

Iron Ore Crushing Process is main to crush / break large blocks of iron ore into small blocks. When large blocks are transported from iron ore mines , the crushing process is ready for rocks crushing. This process is the main part of crushing and breaking the big iron ore ores into small bits with iron ore crushing plant. According to the investigation, most of iron ore mines choose to buy Jaw Crusher to carry on the coarse crushing, and buy Cone Crusher to complete the secondary breaking or medium crushing , crushing the medium rock into bits.

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Normal Process of Iron Ore Crushing. If you want to see specific iron ore process , welcome to visit specific iron ore part. Primary Crushing: What primary crushing process considers is always suitable capacity and fine crushing ratio. Jaw Crusher is popular used as primary crusher in primary crushing process for jaw crusher is large capacity , easy maintenance, cheap price, easy spare parts. Primary crushing is usually completed by a jaw crusher consisting of a heavy metal plate which moves backwards and forwards against a fixed plate (these are the "jaws"). The moving plate is kept in motion and given its crushing energy by a large flywheel. The crusher is wider at the top than at the bottom. Rock from the quarry face is fed into the top of the crusher and crushed rock falls out of the bottom of the jaws. The size of the crushed stone which passes through the jaws is partly governed by the gap set at the bottom of the jaws, though larger size rocks can pass through if the rock being crushed is slabby or elongate in shape. Large scale gyratory crushers can also be used. Secondary Crushing: Secondary crushing process is often to make iron ores be smaller and fine shape. Impact Crusher or Gyratory crusher is usually selected as secondary iron ore crusher. Then the blocks of iron ore continues to be small. These operate on the principle of a steel mantle mounted on an eccentric bearing and vertical shaft assembly. Rotation of the eccentric assembly makes the mantle gyrate within a static outer concave. There is a gap between the mantle and the concave. The shape of the gap is tapered towards the base. As the mantle gyrates inside the concave, the gap between it and the concave at any one point opens

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and closes on each gyration, this produces the required crushing action. Stone is fed in at the top and crushed product falls out from the bottom of the cone.

Tertiary Crushing: Tertiary crushing is to crush and pulverize the iron ores small enough (usually 10mm-250mm). So Tertiary crusher must be (hydraulic / CS /spring) cone crusher or high pressure grinding roller mill , both of which can crush or pulverize small iron ores into smaller enough for the iron ore grinding process.

Iron Ore Screening

Iron ore screening process is to select different size of iron ore particles to send them to primary crusher / secondary crusher / tertiary crusher. What is used most for iron ore screening is vibrating screen. Each stage of crushing produces progressively smaller sized stones. In order to produce a usable endproduct, the crushed rock has to be screened into various size categories. Crushed and screened rock is called aggregate. Screening is carried out at various stages in the crushing process. Screens are

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basically box frames into which sheets of screen meshes of the required apertures are inserted, clamped and tensioned. Screens are usually "multi-deck", i.e., two or more screen meshes are stacked vertically within the screen frame. The whole screen is coupled to its support frame by springs or resilient rubber mountings. Screens are made to vibrate by a rotating transverse shaft. The shaft is machined to be unbalanced, and when driven by an electric motor by v-belts, the required vibratory motion to agitate the aggregate is imparted. Screen decks are mounted at an angle so that the aggregate moves down them. Aggregate is fed onto the high end of the top deck and the vibration causes the aggregate to jiggle down the screen until it either drops through a mesh aperture or falls off the end of a deck. The aggregate is then sorted or 'screened' according to the mesh sizes fitted, from large aperture mesh at the top, to small aperture mesh at the bottom. The vibrating screen is a kind of sieving equipment of international advanced level, developed by our company on the basis of carrying on the advantages of traditional screens and absorbing the outstanding technology from US. It is widely used for grading and screening materials in the following fields: minerals, quarry, building materials, water conservancy and hydropower, transportation, chemical industry, smelting and so on.

To cope up with the need of higher production of iron ore, blasting materials are also being developed / manufactured at the same pace.

Iron Ore Grinding Iron Ore Grinding Process

Iron Ore Grinding Process is the process to grinding or pulverize iron ore particle into iron ore powder or even smaller. If you want to see specific iron ore process , welcome to visit specific iron ore pages. Normal grinding process for Iron Ore:

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Primary Grinding: Primary grinding process is optional when it is used in many mineral powder grinding process. When it goes to iron ore primary grinding , Raymond mill / rod mill / ball mill are all suitable primary grinding mill for iron ore grinding.

Secondary Grinding: Secondary grinding process is really the fine grinding process to refine the iron ore powder . For iron ore secondary grinding, ball mill / scm supper powder mill / vertical roller mill (large scale) are all suitable for iron ore powder production.

Iron Ore Grinding Mills

As what i said above, iron ore grinding mills are fine powder making machines. Ball mill for iron ore is widely used in all over world. Raymond mill / rod mill is newly star grinding powder mill. SCM super powder mill is easy to refine particles for fine thin powder. Vertical mill is large scale powder making machines.

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Iron Ore Beneficiation Methods of Iron Ore Beneficiation

Washing: Sometimes washing can be called a beneficiation process. In washing process, sand washer can wash the powder for the next stage. Gravity Concentration/Beneficiation: Gravity concentration is used to suspend and transport lighter gangue (nonmetallic or no valuable rock) away from the heavier valuable mineral. This separation process is based primarily on differences in the specific gravities of the materials and the size of the particles being separated. Values may be removed along with the gangue material (tailings) despite differences in density if the particle sizes vary. Gravity beneficiation (concentration) is a flow of processes including pre-process , gravity beneficiation, pro-process. Pre-process of G-B is processes containing crushing and grinding , washing and desshanghai, screening or hydraulic classification. Gravity Process is the main process of G-B including several gravity units. Pro-process is to complete the processed of concentrate dehydration, tailing transmission and storage.

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Magnetic Separation : Magnetic separation is most commonly used to separate natural magnetic iron ore (magnetite) from a variety of less-magnetic or nonmagnetic material. It is a mineral dressing method based on the differences between magnetic minerals, realize uneven magnetic separation. Typically, magnetic separation involves three stages of separation: cobbling, cleaning/roughing, and finishing. There are many different magnetic separation plants such as permanent magnetic separation, electronic magnetic separation, weak magnetic separators, medium magnetic separators, strong magnetic separators, etc. Flotation: Flotation is a technique where particles of one mineral or group of minerals are made to adhere preferentially to air bubbles in the presence of a chemical reagent. This is achieved by using chemical reagents that preferentially react with the desired mineral. Several factors are important to the success of flotation activities. These include uniformity of particle size, use of reagents compatible with the mineral, and water conditions that will not interfere with the attachment of the reagents to the mineral or air bubbles. Pre-process preparation is necessary such as crushing and grinding, washing. Then flotation individual stages are : 1. pulp adjustment and flotation reagents to join ; 2. stir companion and caused a lot of bubbles ; 3. bubble mineralization ; 4. mineralized foam layer formation and blow out . Flotation process is a more complex mineral processing process, and its influencing factors can be divided into not adjustment factors (undressed ore properties and the production water quality) and adjustable factors (flotation process, grinding fineness and pulp density, pulp ph value, flotation reagents system).

Iron Ore Beneficiation

Iron ore is upgraded to a higher iron content through concentration. Iron ore is being beneficiated all round the world to meet the quality requirement of Iron and Steel industries. However, each source of Iron ore has its own peculiar mineralogical characteristics and requires the specific beneficiation and metallurgical treatment to get the best product out of it. The choice of the beneficiation treatment

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depends on the nature of the gangue present and its association with the ore structure. Several techniques such as washing, jigging, magnetic separation, advanced gravity separation and flotation are being employed to enhance the quality of the Iron ore.

For hematite: Due to the high density of hematite relative to silicates, beneficiation usually involves a combination of crushing and milling as well as heavy liquid separation. This is achieved by passing the finely crushed ore over a bath of solution containing bentonite or other agent which increases the density of the solution. When the density of the solution is properly calibrated, the hematite will sink and the silicate mineral fragments will float and can be removed. For magnetite: (Here we refers to the process of Qidashan Iron Mine of China, which is low grade of magnetite.) Design 1: Stage Crushing, Stage Ore Grinding, Gravity Concentration, Magnetic Separation, Anionic reverse flotation ; Design 2: Stage Crushing, Stage Ore Grinding, Gravity Concentration, Magnetic Separation, Acid are flotation. For ilmenite: (Referring to low grade ilmenite mines in China) Design 1 (old design) : Strong magnetic separation, Gravity Concentration, the flotation. Design 2 : Primary cast tail, selection, middlings wave bed grinding reelection again.

Agglomeration of Iron Ore

Overview of Agglomeration
After concentration activities, agglomeration is used to combine the resulting fine particles into durable clusters. The iron concentrate is balled in drums and heated to create a hardened

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agglomerate. Agglomerates may be in the form of pellets, sinter, briquettes, or nodules. The purpose of agglomerating iron ore is to improve the permeability of blast furnace feed leading to faster gassolid contact in the furnace . Agglomerating the ore prior to being sent to blast furnaces reduces the amount of coke consumed in the furnace by increasing the reduction rate.

Sintering and Pelletising

Two types of agglomerated products are commonly produced/used in the industry namely Sinter and Pellet. Accordingly the processes are known as Sintering and Pelletising respectively.

Sinter : Sinter is a clinker like aggregate which is normally produced from relatively coarser fine iron ore (normally 3mm) mixed with coke breeze (-3mm), limestone dolomite fines (-3mm) and other metallurgical return wastes from the plant. Sinter is a much preferred input/raw material in blast furnaces. It improves BF operation and productivity and reduces coke consumption in blast furnace. Presently, more than 70% hot metal in the world (in India 50%) is produced through the sinter. Pellet: Pellets are normally produced in the form of globules from very fine iron ore (normally 100 mesh) and mostly used for production of Sponge Iron in gas based plants, though they are also used in blast furnaces in some countries in place of sized iron ore.

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Iron Ore Pelletizing Technology

Today, however, pellets account for more than 97 percent of all agglomeration products Pelletizing operations produce a "green" (moist and unfired) pellet or ball, which is then hardened through heat treatment. These pellets are normally relatively large (3/8 to 1/2 inch) and usually contain at least 60 percent iron. Pellets must be strong enough to withstand abrasion during handling, transport, and high temperature treatment within the furnace. It is also important for the material to be amenable to relatively rapid reduction (removal of oxygen) in the blast furnace. Bentonite is often added as a binder to form green pellets prior to agglomeration .

In addition to iron, pellet constituents can include silica, alumina, magnesia, manganese, phosphorus, and sulfur. Additives such as limestone or dolomite may also be added to the concentrate in a process Mining Industry Profile: Iron known as "fluxing," prior to balling to improve blast furnace recovery (Weiss 1985). In the past, these constituents were added in the blast furnace. However, the development of fluxed pellets, which incorporate the flux in the pellet material, has been shown to increase furnace efficiency.

Iron Ore Pelletizing Equipment

The first step in pelletizing iron concentrates is forming the pellets. This is usually accomplished in a series of balling drums or discs. The pellets are formed by the rotating of the drums, which act to roll the iron concentrate into balls. One of three different systems may then be used to produce hardened pellets:

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Travelling GrateIs used to produce pellets from magnetite concentrates obtained from taconite ores. Green pellets are fed to a travelling grate, dried, and preheated. The pellets then proceed to the ignition section of the grate where nearly all the magnetite is oxidized to hematite. An updraft of air is then used to cool the pellets.

Shaft FurnaceGreen pellets are distributed across the top of a furnace by a moving conveyor belt, then pass vertically down the length of the furnace. In the furnace, the pellets are dried and heated to 2400 F. The bottom 2/3 of the furnace is used to cool the pellets using an upward-rising air stream. The pellets are discharged from the bottom of the system through a chunkbreaker. Grate KilnCombines the grate technique with a rotary kiln. No fuel material is incorporated into or applied to the pellets in this process. The pellets are dried and preheated on a travelling grate before being hardened by high-temperature heating in the kiln. The heated gas discharge from the kiln is recycled for drying and preheating. Agglomeration generates byproducts in the form of particulates and gases, including compounds such as carbon dioxide, sulfur compounds, chlorides, and fluorides that are driven off during the production process. These are usually treated using cyclones, electrostatic precipitators (wet and dry), and scrubbing equipment. These treatment technologies generate either a wet or a dry effluent, which contains valuable iron units and is commonly recycled back into the operation

Iron Slag Recycling

Overview of Slag Recycling
As is noted in the previous section, a variety of wastes and other materials are generated and managed by iron mining operations.

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Some, such as waste rock and tailings, are generally considered to be wastes and are managed as such, typically in on-site management units. Even these materials, however, may be used for various purposes in lieu of disposal. Some quantities of waste rock and tailings, for example, may be used as construction or foundation materials at times during a mine's life. Many other materials that are generated and/or used at mine sites may only occasionally or periodically be managed as wastes. These include mine water removed from underground workings or open pits, which can be recirculate for on-site use but also can be discharged to surface waters.

Slag Recycling and Management

Waste Rock and Ore Piles
Overburden and waste rock removed from the mine are stored or disposed of in unlined piles onsite. These piles may also be referred to as mine rock dumps or mine dumps. As appropriate, topsoil may be segregated from overburden and mine development rock, and stored for later use in reclamation and revegetation. Ore is stored in piles at the mine or mill before beneficiation.

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Tailings Impoundments

Bonab Steel Complex

Tailings are the discarded material resulting from the concentration of ore during beneficiation operations. Tailings are characterized by fine particle size and varying mineralogical and chemical composition . The disposal of tailings requires a permanent site with adequate capacity for the life of the mine. Tailings ponds or impoundments are created to dispose of these wastes. Literature consulted for this report suggests that only impoundments are used in the iron ore industry.

Mine Pits and Underground Workings

In addition to wastes generated during active operations, pits and underground workings may be allowed to fill with water when the mine closes or stops operation, since the need for dewatering is over.

Drilling & Blasting Plant

Iron Ore Drilling Plant
There are different requirements relating to drilling equipment, drilling tools and drilling applications depending on the type of bench blasting operation. In open-pit mining and quarrying, the emphasis is normally on longterm performance and hole quality, whereas a general contractor or drilling contractor operating in a variety of conditions is likely to pay more attention to the flexibility and terrain-handling features of the equipment. But for all equipment users, economy, reliability, ergonomics and ease of use are of vital importance.

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In planning the blasting pattern, careful consideration must be given to the type and size of loading equipment. In wheel loader operations the rock pile should preferably be long and shallow with blasting planned to produce a loose pile. Front-shovel characteristics on the other hand are best supported by higher, peaked rock piles. This can be achieved with a V-type initiation pattern. Surface drilling top-hammer unit for open-pit mining, quarrying and large construction projects eg Tamrock Ranger 500, 600 and 700. Features: powerful hydraulic rock drill, turning superstructure, large reach, good terrain handling, ergonomic operator controls, FOPS/ROPS cabin with joystick controls for drilling, rod cassette and tramming. Hole diameter range: 64115mm

Surface drilling top-hammer unit for construction projects and quarrying eg Tamrock Pantera 800, 900, 1100 and 1500. Features: powerful hydraulic rock drill, zoom boom, sturdy construction, ergonomic operator controls, high production capacity, FOPS/ROPS cabin with joystick controls for drilling, rod cassette and tramming. Hole diameter range: 76152mm

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Iron Ore Blasting Plant

Drill and blast at the designated slope lines according to the blasting plan. Perform presplitting to obtain smooth faces in the rock and shale formations. Perform the presplitting before blasting and excavating the interior portion of the specified cross section at any location. The Department may allow blasting for fall benches and haul roads prior to presplitting when blasting is a sufficient distance from the final slope and results are satisfactory to the Engineer. Use the types of explosives and blasting accessories necessary to obtain the required results. Free blast holes of obstructions for their entire depth. Place charges without caving the blast hole walls. Stem the upper portion of all blast holes with dry sand or other granular material passing the 3/8-inch sieve. Dry drill cuttings are acceptable for stemming when blasts are more than 800 feet from the nearest dwelling.

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Iron Ore Crushing & Screening Plant

Iron Ore Crushing Plant

Iron Ore Crushing can be completed in three or four steps, primary crushing (first step), secondary crushing(second step), tertiary crushing (third step) and, in some iron ore quarries, a quaternary crushing (fourth step). Crushed rocks of iton ores , or product, is transported along the process line on conveyor belts or down chutes. The crusher plant is fed by a chute and vibrating feeder. The base of the feeder is made of steel "grizzly" bars and it is here that the first screening operation is actually done. Fine material and dust produced by the blast, along with any remaining subsoil or weathered rock from the top of the quarry face, drops through the bars onto a separate conveyor belt and onto a stockpile. This screened material is called scalpings and is used as rock fill.

Primary Crusher
Primary Crusher is crusher that is used in primary crushing process ie jaw crusher.

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Jaw crusher used high strength steel, forming a casting, with wear, compression, and long life. Mainly for crushing large, medium and small stones and the corresponding objects.

Secondary Crusher
Secondary Crusher is crusher that is used in primary crushing process ie gyratory or cone crusher , impact crusher.

Impact crusher used for the broken side not exceeding 500mm, the compressive strength of not more than 360Mpa a variety of materials. Granite, limestone, gravel, which are better applicability.

Cone crusher is the crusher to produce the best performance for a variety of crushing process: from the special crushing to the crushing, breaking from the fixed to mobile crusher station.

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Tertiary Crusher

Bonab Steel Complex

Tertiary Crusher is crusher that is used in tertiary crushing process usually referring to cone crusher, VSI Crusher (Vertical Shaft Impact Crusher) or HPGR (High Pressure Grinding Roll).

This series cone crusher is widely used in metallurgical industry, construction industry, and the phosphate industry, is suitable for crushing hard and medium hard ore, such as copper ore, limestone, granite...

Vsi crusher used for highway, railway, high-rise construction, municipal, hydroelectric dam construction, concrete mixing plant, provide high-quality sand and gravel aggregate.

The HPGR - grinding is achieved by an advanced type of grinding roll. Particles are broken by compression in a packed particle bed, and not by direct nipping of the particles between the 2 rolls.

Iron Ore Screening Plant

Screening is carried out at various stages in the crushing process. Screens are basically box frames into which sheets of screen meshes of the required apertures are inserted, clamped and tensioned.

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Screens are usually "multi-deck", i.e., two or more screen meshes are stacked vertically within the screen frame. The whole screen is coupled to its support frame by springs or resilient rubber mountings. Screens are made to vibrate by a rotating transverse shaft. The shaft is machined to be unbalanced, and when driven by an electric motor by v-belts, the required vibratory motion to agitate the aggregate is imparted.

Vibrating Screen

Vibrating screens of this series are mainly composed of screen box, screen mesh, vibrator, damping spring device, base, etc. The vibrator is on the side panel of the screen box and can be driven by the generator through joint or belt to rotate and produce centrifugal inertial force to make the screen box vib.

Iron Ore Grinding Mills

Iron Ore Grinding Mill
As a leading global manufacturer of crushing and milling equipment, we offer advanced, rational solutions for any size-reduction requirements, including quarry, aggregate, grinding production and complete plant plan. We also supply individual crushers and mills as well as spare parts of them.

MTM Trapezium Grinding Mill

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MTM trapezium grinding mill are designed to crush and grind stones and non-metallic products such as kaolin, gypsum into powder. It adopts the ladder-shapper roller and ring improving crushing eddiciency and produce a typical product size of 1.6 mm to 0.038 mm when operating in open circuit and in closed circuit with a screen or other sizing device.

MTW Trapezium Grinding Mill

MTW european trapezium grinding machine is mainly applied to the powder processing of mineral products in industries of metallurgy, construction, chemistry, and mining etc. The grinding mill machine can produce powder from non-flammable and non-explosive mineral materialssuch as barite, limestone, quartz, calcite, granite, porcelain clay, basalt, gypsum etc.

MXB Coarse Powder Mill

MXB coarse powder grinding mill is used for pre-processing of various crushable non-flammable and non-explosive brittle materials with Mohs under 9. MXB coarse powder grinder machine is widely applied in quartz sand, silica sand, foundry sand, fine sand and other sand abrasive industry. It is also applied in industries of mining, construction, metallurgic, road building and water

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Raymond Mill

Bonab Steel Complex

In the Raymond grinding plant, the stuff for grinding is loaded into the grinding chamber of the main frame evenly and continuously. The stuff is grinded when roller rolls. The rough powder will be put back to grinder for regrinding. The fine powder flows into the product cyclone collector together with airflow and is expelled from the powder output pipe as product.

SCM Series Super Thin Mill

On the basis of more than 15 years' production experience of Shibang company, we absorb technology advantages from the same field abroad and domestic, organizing elite powder processing experts to investigate, research, try again and again; finally, we develop this high-efficiency and low-cost SCM Series Super Thin Grinding Mill.

Ball Mill

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Ball mills are used primary for single stage fine grinding, regrinding, and as the second stage in two stage grinding circuits. According to the need of customers, ball mill can be either wet or dry designs. These mills are sized from 2 t/h to 30 TPH for wet grinding and from 0.5 t/h to 30 TPH for dry grinding. Ball mills have been designed in standard sizes of the final products between 0.074 mm and 0.4 mm in diameter.

Vertical Roller Mill

The high-efficiency, energy-saving LM Series vertical mill can simultaneously handle pulverizing, drying, sizing and air jet transport. This series vertical mill has the high grinding efficiency, meaning a 50% reduction in per-unit power consumption over ball mills. The particle size adjustments of this vertical mill are simple, with minimal noise and vibration.

Iron Ore Beneficiation Plant

SBM supplies all the equipments needed in beneficiation. SBM beneficiation plant is necessary in the mineral beneficiation or ore beneficiation. SBM ore beneficiation plant includes magnetic separators and gravity separators. SBM magnetic separator includes magnetic ore separator and common magnetic separator and gravity separator includes shaking table and jigger machine. SBM have other mineral beneficiation plants like stone crusher, grinding mill, vibrating screen and sand washing machine. If you want any beneficiation plant, SBM will supply your demand with best service and best quality.

Beneficiation Plant In Milling Process

Hydro cyclone

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Beneficiation Plant In Magnetic Separation

Cobber / Magnetic separator

Cleaners / Scavengers

Finishers

Rotary drum separator

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Magnetic pulley

Roll separator

Cross belt separator

Ring-type separator

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