Magnetite Processing with Cyclone Mill Bypass to Cut Energy and Water
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Solution Overview
Problem
Processing magnetite iron ore is not cost-effective due to high energy and water consumption, and lower grade hematite deposits are reducing its desirability and pricing on the international market.
Innovation Solution
Utilizing a two-stage high pressure grinding roller (HPGR) process with dry magnetic separation and air classification to crush and separate magnetite, minimizing energy consumption and water usage, and incorporating a product upgrade circuit to enhance iron content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by stationary object
If conventional magnetite processing methods are used, then iron concentrate can be produced, but energy consumption is excessively high making the process not cost-effective
Solution Approach 1:
The patent changes the physical and chemical parameters of the processing system by introducing high pressure (HPGR) and low temperature roasting conditions. This transforms the conventional high-energy ball milling process into a lower-energy process that achieves similar or better liberation results through pressure-induced micro-fracturing and controlled thermal treatment at moderate temperatures.
Solution Approach 2:
The patent replaces the conventional mechanical ball milling system with a high pressure grinding roller system followed by magnetic separation. This substitution eliminates the need for extensive mechanical grinding by using pressure-induced fracture mechanisms and enhances separation efficiency through advanced magnetic separation technology, thereby reducing overall energy consumption.
2Quantity of substance
If conventional magnetite processing methods are used, then iron concentrate can be produced, but water consumption is excessively high making the process not cost-effective
Solution Approach 1:
The patent extracts and eliminates the wet processing stage from the conventional flow sheet by implementing a dry processing route. This removes the need for water-intensive operations such as slurry preparation, hydrocyclone classification, and filter press dewatering, thereby dramatically reducing water consumption while maintaining processing efficiency.
3Manufacturing precision
If hematite iron ore is processed, then iron concentrate can be produced, but the grade is declining reducing market desirability and pricing
Solution Approach 1:
The patent applies preliminary low temperature roasting treatment to the hematite ore before magnetic separation. This pre-treatment step transforms the mineralogical structure and enhances the magnetic properties of iron-bearing minerals, enabling more effective separation and production of high-grade concentrate that meets international market specifications despite declining ore grades.
4Use of energy by stationary object
If high pressure grinding roller is used to crush magnetite, then energy consumption is reduced, but particle size reduction efficiency must be maintained
Solution Approach 1:
The patent employs dynamic high pressure grinding rollers that apply varying pressure cycles to the ore feed. This dynamic loading-unloading mechanism creates repeated stress cycles that progressively fracture particles into fine sizes without requiring excessive energy input, maintaining particle size reduction efficiency while minimizing energy consumption compared to static crushing systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves a cost-effective processing of magnetite with reduced energy and water consumption, increasing the iron content to at least 67% by weight and minimizing silica content, thereby improving market desirability and pricing.
Implementation Method 1
using a high pressure grinding roller (HPGR) to crush the magnetite
Implementation Method 2
using a dry magnetic separation unit (DMS) unit to discard non-magnetic materials
Implementation Method 3
passing the particles through an air classifier which separates fines which are fed to a bag house from coarse particles
Data Source
Figure 1
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AI summary
An apparatus for processing magnetite iron ore, including an upstream cyclone and a mill for grinding particles, wherein the upstream cyclone is arranged to operate as a splitter by diverting material in an overflow of the upstream cyclone to bypass the mill and by feeding material in an underflow of the upstream cyclone to the mill.