With the continuous advancement of industrial technology, the global mineral resources, especially high-quality iron ore resources, are decreasing day by day, which puts higher requirements on the development of existing iron ore resources. In this context, the optimization of iron ore beneficiation production line equipment has become particularly important, which is not only related to improving production efficiency, but also directly affects the utilization rate of ore. Through the continuous improvement and optimization of the beneficiation process, not only can limited resources be used more efficiently, but also energy consumption and environmental impact in the production process can be reduced. This article will introduce the equipment and process flow of the iron ore beneficiation production line in detail, focusing on how to improve production performance through the optimization of equipment and process.
Use the table of contents below to navigate through the guide:
01Introduction to iron ore beneficiation production line equipment
The commonly used crushing process is a three-stage crushing process of coarse crushing, medium crushing and fine crushing:
1. Coarse crushing equipment: generally use a 1.2m or 1.5m gyratory crusher to crush the ore to a size of no more than 1m.
2. Medium crushing equipment: use a 2.1m or 2.2m standard cone crusher to further crush the ore.
3. Fine crushing equipment: use a 2.1m or 2.2m short-head cone crusher to finally crush and screen the ore into products with a particle size of less than 12mm.
Common processes in beneficiation plants
The process flow of iron ore grinding production line is mainly divided into one-stage grinding and two-stage grinding. In recent years, some beneficiation plants have introduced a new process of fine screening and re-grinding, changing the two-stage grinding to three-stage grinding. The specific process is as follows:
1. One-stage grinding process: it is suitable for small and medium-sized beneficiation plants, using one-time grinding to complete the ore crushing.
2. Two-stage grinding process: Most ore dressing plants adopt this process, grinding in two stages to improve the accuracy and efficiency of grinding.
3. Three-stage grinding process: Some ore dressing plants use the new process of fine screening and re-grinding to change the two-stage grinding to three-stage grinding, further improving the fineness and grade of the ore.
Commonly used grinding equipment includes:
- Ball mill: maximum size is 3.6m×6m
- Rod mill: maximum size is 3.2m×4.5m
- Autogenous mill: maximum size is 5.5m×1.8m
- Pebble mill: size is 2.7m×3.6m
The classification after grinding usually uses a spiral classifier, but some ore dressing plants use a hydrocyclone to replace the secondary spiral classifier to achieve the purpose of improving the classification efficiency.
02Iron ore beneficiation line separation technology
1. Magnetite beneficiation
Due to the strong magnetism of magnetite, it is easy to grind and sort. Domestic magnetic separation plants generally adopt stage grinding and multi-stage grinding processes:
- Coarse-grained magnetite: one-stage grinding is adopted.
- Fine-grained and ultra-fine-grained magnetite: two-stage or three-stage grinding is adopted.
By promoting the new technology of fine screening and re-grinding, the grade of magnetite concentrate has increased from 62% to about 66%, meeting the 65% concentrate grade requirement proposed by the Ministry of Metallurgical Industry.
2. Weakly magnetic iron ore beneficiation
Weakly magnetic iron ore includes hematite, limonite, specularite, etc. This type of ore has low grade, fine grain size, complex mineral composition, and is difficult to sort. The process of roasting magnetic separation, wet strong magnetic separation, weak magnetic flotation and gravity separation has been continuously improved, which has continuously improved the concentrate grade and metal recovery rate.
03Equipment optimization strategy for iron ore beneficiation line
In order to further improve the efficiency and effect of mineral processing production line, the following optimization strategies can be adopted:
1. Equipment upgrade: Introduce advanced crushing, grinding and grading equipment to improve production capacity and ore processing effect.
2. Process optimization: According to the characteristics of the ore, flexibly adjust the process flow and adopt more efficient separation technology, such as fine screening and re-grinding technology.
3. Automation and intelligence: Use automatic control and intelligent management system to realize real-time monitoring and optimization scheduling of mineral processing process, and improve the operation efficiency and stability of production line.
4. Environmental protection measures: Strengthen the use of environmental protection equipment and the treatment of wastewater, waste gas and waste residue, reduce environmental pollution, and enhance the sustainable development capacity of mineral processing plant.
Through the above optimization measures, the efficiency and product quality of iron ore beneficiation line can be greatly improved, bringing greater economic and social benefits to enterprises.
The optimization of iron ore beneficiation production line equipment is a systematic project, which requires comprehensive consideration of various factors such as equipment, process and management. Through equipment upgrades, process optimization, automation and intelligent management, and environmental protection measures, the performance of the beneficiation production line can be effectively improved, and the goals of high efficiency, low consumption and environmental protection can be achieved, thereby promoting the sustainable development of the beneficiation industry.
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