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This large-scale iron ore processing plant is custom-designed for a client based in South America. Hematite is the dominant mineral resource in the local mining area. The iron grade of run-of-mine ore is only 55%, with clay content peaking at 10%. Such clay contaminants greatly reduce the market value of finished iron ore products.
Two standard iron ore feedstocks are required by the regional steel industry: sinter feed ranging 1–10 mm and blast furnace lump ore sized 10–30 mm and 10–40 mm. Washing and desliming upgrading is mandatory to lift the iron grade above 58%.
The project site follows IEC electrical standards. Local environmental policies enforce closed-circuit wastewater circulation, which calls for a complete slurry recovery system. The plant is scheduled to operate three shifts around the clock, with an annual ore processing capacity of 4 million tons.
Production Capacity: 500 tons per hour; equipment availability rate 90%, overall plant utilization rate ≥85%, annual raw ore processing capacity 4 million tons.
Raw Material: Hematite run-of-mine ore, maximum feed size 800 mm, bulk density 2.4 t/m³, moisture content 5%.
Production Targets: Two finished products to be separated, including 1–10 mm sinter feed and 10–30/40 mm blast furnace lump ore. Fine slimes smaller than 1 mm will be diverted for separate treatment, and the iron grade of final products shall exceed 58%.
Key Supporting: Full-process closed water circulation system to drastically cut fresh water consumption; designed for three-shift continuous operation with extra capacity reserved for peak production demand.
Project Scope: Process design, complete equipment supply, civil & steel structure works, PLC electrical automation system, on-site installation and commissioning guidance, and two-year full operational spare parts supply.
Large hematite lumps are delivered into the system. Surge bins and belt conveyors work together to maintain steady, uniform material feeding.
Rotary scrubbers mechanically strip clay coatings off ore surfaces to remove slime impurities effectively.
Scrubbed ore undergoes grading to separate materials of different particle sizes in the first stage.
Hydrocyclones carry out precise separation of fine sand and slime, independently diverting ultra-fine material below 1 mm.
Magnetic separators are deployed to further eliminate harmful impurities in ore, raising iron grade to over 58%.
Two target products are sorted out: 1–10 mm sinter feed and 10–30/40 mm blast furnace lump ore.
Thickeners settle slurry waste, cooperating with slurry pumps to build closed water circulation and lower fresh water make-up volume.
Equipped with belt transfer lines, finished product storage silos and central transfer stations.
Dust extraction equipment is arranged across the whole production line to meet local environmental emission limits.
A central control platform consisting of PLC, HMI and SCADA supports full-process remote monitoring and safety interlock protection for all equipment.
Steel access platforms and walkways, high and low voltage power distribution facilities, plus a complete package of spare parts for two years of operation and maintenance.
Our company has the ability to supply complete sets of equipment, process design, and tailings water circulation system for large-scale iron ore washing lines.
We can provide standardized budget plans for iron ore projects with a capacity of tens of millions of tons, covering the entire process of crushing, screening, scrubbing, magnetic separation, tailings thickening and pressure filtration, and supporting EPC general contracting services for the whole plant.
