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Crushing Technology: A three - stage crushing process of "coarse - medium - fine" is adopted. A gyratory crusher (1.2m/1.5m) is used for coarse crushing to ensure that the ore lump size is ≤ 1m; a standard cone crusher (2.1m/2.2m) is used for medium crushing; and a short - head cone crusher is used for fine crushing, and the final particle size is controlled within 12mm, laying the foundation for subsequent grinding.
Grinding Technology: In large - scale beneficiation plants, a three - stage grinding process is promoted, equipped with autogenous mills (5.5m×1.8m) and pebble mills (2.7m×3.6m), and combined with a spiral classifier for secondary treatment, which significantly improves the fineness and uniformity of the ore.
Dry Magnetic Separation: Three - stage magnetic separation (the magnetic drum intensity is 400 - 1250GS) can increase the magnetite content from 35% to 65%, and the utilization rate can reach 90%. No water is required, and dust - removal equipment is equipped to achieve environmentally friendly production.
Wet High - intensity Magnetic Separation: For weakly magnetic hematite, limonite and other "red ores", combined with a pre - magnetizer (to enhance remanence) and a demagnetizer (to eliminate interference), the separation effect is optimized, and the concentrate grade exceeds 56%.
For high - silica iron ores, the anionic reverse flotation technology uses a low - temperature - resistant cationic collector (under the working condition of 12 - 22℃), which can increase the iron recovery rate to 97% and the concentrate grade to 70%. Combined with the magnetic separation process, the "magnetic separation - reverse flotation" synergy is realized, the silicon content is greatly reduced, and the economic benefits are significantly improved.
Through an induced - roll magnetic separator (alternating magnetic field gradient separation) and reagent optimization, the efficient separation of iron from symbiotic metals such as copper and zinc is achieved. The comprehensive resource recovery rate is increased by more than 20%, avoiding the waste of resources caused by "mining the main and abandoning the auxiliary".
Designed with staggered magnetic - conducting steel sheets, the magnetic field intensity on the roll surface can be precisely controlled. Non - magnetic materials are quickly separated by gravity and centrifugal force. Paired with a pre - magnetizer (electromagnetic/permanent magnet) and a demagnetizer, the separation purity of magnetite is ensured, and the equipment energy consumption is reduced by 30%.
Aiming at the easy sludging problem of hematite and limonite, an innovative "high - intensity magnetic separation - reverse flotation" process is adopted: after pre - enrichment by high - intensity magnetic separation, deep impurity removal is carried out by reverse flotation. The concentrate grade is stably above 58%, and the metal recovery rate is increased by 15%.
Fatty Acid - based and Sulfate Reagents: After improvement, the collection ability is enhanced, and the iron recovery rate exceeds 75%.
New Anionic Collector MH - 88: Applied to high - silica ores, the selectivity is increased by 40%, and the iron content in the tailings is reduced to less than 10%.
Amine - based Reagents: The compound of dodecylamine and mixed gum solves the flotation problem of fine - grained iron ores, and the cost is reduced by 20%.
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