Multi-Stage Suspension Roasting for Refractory Iron Ore
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Solution Overview
Problem
Conventional mineral processing technologies face challenges in effectively treating refractory iron ore due to its fine grain size, complex mineral composition, and low iron content, leading to inefficient industrial development and utilization, with issues of over-firing or under-burning during magnetizing roasting.
Innovation Solution
A multi-stage suspension magnetizing roasting-magnetic separation system that includes a series of reactors and separators, with controlled temperature and gas flow to achieve piecewise magnetization, allowing for advanced separation of materials with different reducing degrees and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If single-stage magnetizing roasting is used, then the process is simple, but the product quality is inconsistent with over-firing or under-burning
Solution Approach 1:
The patent divides the single-stage magnetizing roasting process into multiple stages (first-stage and second-stage suspension magnetizing roasting), with each stage having specific temperature ranges and duration parameters. This segmentation allows different parts of the roasting process to be optimized independently, preventing over-firing or under-burning and ensuring consistent product quality across batches.
2Adaptability or versatility
If multiple roasting products with different qualities are required, then product versatility is improved, but the cooling and separation process becomes more complex
Solution Approach 1:
The patent performs preliminary classification during the magnetizing roasting process itself by controlling temperature and time parameters in different stages to produce magnetic products with different reduction degrees directly. This preliminary action eliminates the need for complex post-roasting cooling and separation operations, as the products are already differentiated by quality when exiting the roaster.
Solution Approach 2:
The patent applies different temperature ranges, holding times, and atmospheric conditions to different stages of the roasting process, creating local quality variations in the final product. The first-stage produces magnetic products with one reduction degree while the second-stage produces magnetic products with another reduction degree, allowing versatile product output from a single integrated system.
3Quantity of substance
If refractory iron ore with fine grain size and complex composition is processed, then resource utilization is improved, but conventional mineral processing technology fails to achieve ideal indicators
Solution Approach 1:
The patent transforms the processing approach for refractory iron ore by changing key parameters: using suspension roasting instead of conventional solid-state roasting, controlling specific temperature ranges (450-700°C for first-stage, 700-1000°C for second-stage), and regulating atmospheric conditions. These parameter changes enable effective processing of fine-grained, complex-composition ores that conventional methods cannot handle, achieving ideal technical and economic indicators.
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
This system effectively prevents over-firing and under-burning, improves reduction and separation indices, and enhances technical and economic outcomes for refractory iron ore processing.
Implementation Method 1
suspension preheater connected to the gas burner through the gas inlet, and control the material temperature at 600-1300℃
Implementation Method 2
first-stage suspension oxidizer, control the material temperature at 800-1200℃ and stay for 10-60min, control the air excess to ensure an oxidizing atmosphere
Implementation Method 3
first-stage suspension reductor, control the material temperature at 450-700℃ and stay for 5-25min, control the reducing atmosphere
Implementation Method 4
magnetizing roasting-magnetic separation technology
Implementation Method 5
first-stage electromagnetic dry magnetic separator
Implementation Method 6
magnetizing roasting-magnetic separation technology
Implementation Method 7
first-stage X-ray fluorescence online grade analyzer
Implementation Method 8
first-stage X-ray fluorescence online grade analyzer
Implementation Method 9
cyclone separator
Implementation Method 10
dust remover
Data Source
AI summary
The invention discloses a multi-stage suspension magnetizing roasting-magnetic separation system and method for refractory iron ore, which belongs to the field of mineral processing technology. This system comprises multistage suspension preheater, multistage suspension oxidizer, multistage suspension redactor, on-line grade analyzer, ore-like splitter, magnetic separator, dust remover, roots blower and other components and connection modes. The refractory iron ore treated by the present method can be produced to homogeneous magnetite or maghemite accurately, and through magnetic separation, on-line grade analyzer detection and ore-like splitter, the concentrate powder which reach the set grade can be obtained, and the unqualified ore powder enters the next stage of oxidation-reduction-magnetic separation-split treatment. Through the present system and method, products with different roasting quality can be obtained, and can avoid the phenomenon of over burning or under burning occurring in the past process and equipment.