Iron Ore Beneficiation Operations and Technical Optimization

Beneficiation operations form the core process of iron ore processing. Process monitoring and control constitute a vital component of beneficiation automation, requiring management of numerous parameters with diverse and complex characteristics. In this process, iron ore undergoes classification via classifiers and collection via collectors to produce iron concentrate. Practical production primarily employs gravity separation, magnetic separation, and flotation techniques. For special iron ore types like hematite and magnetite, multiple processes can be combined to enhance separation rationality and efficiency. As iron ore particle size decreases, viscous drag forces in water flow become the dominant factor affecting separation. The industry effectively improves the separation of fine-grained iron ore by intensifying separation forces like gravity and magnetism, and by utilizing static separation environments.

Specifically, in gravity separation, the SLon centrifugal concentrator significantly boosts iron recovery by amplifying centrifugal force to counteract viscous drag interference. The Reflux Classifier creates a static separation environment through narrow-spaced inclined channels, minimizing fine gangue entrainment. At Brazil's Itabira iron ore mine, it achieved a concentrate iron grade of 65.6% with a recovery rate of 72.9%. Magnetic separation technology focuses on developing high-intensity magnetic field equipment. The ZH-type flat ring high-intensity magnetic separator and SLon-5000 vertical ring pulsating high-gradient magnetic separator deliver magnetic fields of 1.8–1.9 T. Simultaneously, the washing magnetic separator effectively addresses the challenge of fine magnetic agglomerate entrainment through the combined action of magnetic and gravitational fields, thereby enhancing concentrate grade.