Iron Ore Beneficiation Plant: Process and Equipments

Isiphetho:Le ndatshana inikeza umbono obanzi ngama-iron ore beneficiation plants, ibhekisisa izici ze-ore, izindlela zokwenza, ukuhamba kwenqubo, imishini ethintwayo, nezinto ezihambisana nemvelo.

I-iron ore beneficiation iyinqubo ebalulekile emkhakheni wokusansimbi nezimayini, enqwenela ukuthuthukisa ikhwalithi ye-iron ore ngokukhipha izinto ezilukhuni nokwandisa umkhiqizo wensimbi. Inqubo yokuthuthukiswa iguqula i-iron ore eluhlaza ibe yindawo efanelekayo yokusebenza ekwenzeni insimbi nasemkhakheni wezicelo zezimboni. Ngenkathi isidingo se-iron ore esisezingeni eliphezulu sikhula futhi kubhujiswa izinsiza ezicebile, izitshalo zokuthuthukiswa seziyisixazululo esingenakuphikiswa sokusebenzisa kahle izinsiza nokusebenza okumisiwe kwezokumbiwa.

Le ndatshana ihlinzeka ngombono ophumelelayo weiplanti yokuthuthukiswa kwe-iron ore, ifaka phakathi izici zensimbi, izindlela zokuthuthukiswa, ukuhamba kwezinqubo, amadivayisi abamba iqhaza, nezinto ezithinta imvelo.

Izici ze-Iron Ore

Iron ores zingamatshe nezinsiza ezivela kuzo okungukuthi insimbi eyinsimbi ingatholakala ngemali. Izinhlobo ezivamile ze-iron ore zimi kanje:

• Hematite:Uhlobo lwe-ore oluphezulu olufaka cishe u-70% wensimbi.
• Magnetite:Uqukethe cishe u-72% wensimbi futhi unombono wokuthakazelisa.
• Limonite:Contains 55-60% iron.
• Siderite:Contains about 48% iron.

The quality of iron ore is primarily determined by its iron content and the presence of impurities such as silica, alumina, phosphorus, sulfur, and other gangue minerals. Beneficiation aims to increase iron content and reduce impurities.

Advantages of Iron Ore Beneficiation

• Increase iron content:To produce high-grade concentrate suitable for steel production.
• Remove impurities:Reduce silica, alumina, phosphorus, sulfur, and other unwanted materials.
• Ngcono izakhiwo zomzimba:Thuthukisa usayizi wezinhlayiya nomumo ukuze kwenziwe kube lula ukuphatha nokucubungula.
• Phucula izinqubo eziphathelene:Facilitate efficient pelletizing, sintering, and smelting.

Inqubo Yokuthuthukisa I-Ore ye-Iron

Inqubo yokuthuthukisa i-ore yensimbi ivamise ukuhlanganisa izigaba eziningi:Ukuphanga → Ukwakha → Ukuhlukanisa → Ukugxila → Ukuwasha → Ukuphuma kwepellet noma Sintering

1. Ukuphanga i-Ore ye-iron

Izigaba zokuqala ekuthuthukiseni i-ore ye-iron ukuchoboza nokugaya, okunciphisa usayizi we-ore ye-iron raw ukuze kukhulule izimayini ezithwele insimbi emgqeni wezinto ezizungezile.

Primary Crushing:I-iron ore ithunyelwa ngezimoto noma ama-conveyor ukusuka endaweni yokumba iye emhlanganweni wokuthuthukiswa. Ukudla okufanele kuqinisekisa ukuhamba okuqhubekayo. I-iron ore enkulu iphanswa ngosayizi nge-jaw noma ama-gyratory crushers ibe ngu-150 mm, ukuze kube lula ukuhamba nokucubungula okwengeziwe.

Secondary Crushing:Ukunciphisa usayizi okwengeziwe kube cishe ku-20-50 mm kufinyelelwa nge-cone crushers. Ama-vibrating screens ahlukanisa ama-particles e-iron ore ngosayizi, athumele impahla yokugaya noma ezinye izinqubo.

2. Grinding

Ngemuva kokuphahlazeka, imishini yokugaya (efana nemishini yokugaya ye-bola noma ye-rod) iyanciphisa Usayizi we-iron ore particle kube uthuli oluthile, ngokuvamile ithinta u-80% odlula ku-200 mesh (cishe ama-microns angama-75). Lokhu kugaya okuphezulu kuqinisekisa ukuthi izimayini zensimbi ku-iron ore zikhululiwe ngokwanele kumagange ukuze kube nokuhlukaniswa okulandelayo.

Ukuphahlazeka nokugaya okusebenza kahle kwe-iron ore kubalulekile ngoba ukugaya kakhulu kungakhiqiza amaphuzu amaningi kakhulu, okwenza kube nzima izinqubo ezizayo futhi kukhuphule ukusetshenziswa kwamandla.

3. Ukuhlola nokuhlukanisa

Ngemuva kokuncipha kosayizi, ingxube yensimbi yensimbi ihlolwa futhi ihlukaniswe ukuze ihlukanise amaphuzu ngokususelwa kusayizi nobukhulu.

• Ukuhlola:Izixubho eziyimishini noma izixubho ezivundlile zihlukanisa amaphuzu amakhulu kwi-fines ekudleni kwensimbi. Lesi sinyathelo siqinisekisa ukuthi kuphela izinto zensimbi ezikahle ziya phambili esigabeni esilandelayo, kuthuthukisa ukusebenza kahle kokucubungula.
• Ukuhlukanisa:Izihlungi zamanzimanjolo noma abahlukanisi be-spiral bahlukanisa amaphuzu esimbi ngokwemithamo nobukhulu ngendlela ye-slurry. Le nhlobo yokuhlukanisa iyasiza ekukhombiseni izigaba ezahlukene zosayizi emisebenzini efanele yokubuyisela.

Proper screening and classification optimize the feed for iron ore concentration processes, improving recovery rates and product quality.

4. Concentration of Iron Ore

Concentration is the core beneficiation stage where valuable iron minerals are separated from the waste gangue in the iron ore.

• Gravity Separation:Utilizes differences in specific gravity between iron minerals and gangue within the iron ore.
• Magnetic Separation:Employs magnetic fields to isolate magnetic iron minerals in the iron ore.
• Flotation:Iyasebenzisa izinto zokusebenza zamakhemikhali nezikhukhula zomoya ukuze ihlukanise imayini yensimbi engathandwa amanzi ezivunguvungwini ezincane.

Ukukhetha indlela yokugxila kuncike kuhlobo lwezinsimbi, usayizi wezinhlayiya, kanye ne-mineralogy.

5. Ukukhuhla

Ngemuva kokugxila, i-iron ore concentrate ekhiqizwa containing inani elikhulu lamanzi, okungakufanele ukususa ukuze kube lula ukuphathwa, ukuthuthwa, nokucubungula okwengeziwe.

• Ukukhulisa:Abakhulisi be-gravity bagxila i-iron ore slurry ngokuhluza ama-solids, sephula umswakama.
• Filtration:Izihlungi ze-vacuum noma zok pressure zinciphisa umswakama engxenyeni yokuxuba ushukela wensimbi ziye ezingeni elamukelekayo, imvamisa ngaphansi kuka-10%.

Ukukhishwa okuphumelelayo komswakama engxenyeni yokuxuba ushukela wensimbi kunciphisa izindleko zokoma futhi kuvinjeze ukuwohloka kwemathiriyeli ngesikhathi sokugcina nokuhamba.

6. Ukuhlinzekwa kwemigodi noma Sintering

Isigaba sokugcina silungiselela ingxube ye-iron ore ukuze isetshenziswe ekwenziweni kwesithako sensimbi.

• Ukuhlinzekwa kwemigodi:Ingxube ye-iron ore ethambile ibhujiswe ibe ama-pellet amajiyile asebenzisa ama-binders njenge-bentonite. Ama-pellet wensimbi anobukhulu obufanayo, amandla athuthukile, nokuhamba, okwenza afanele ukudliwa kwe-blast furnace.
• Sintering:Ukugxila kwezinye izinsimbi kuzixube nezimpahla zokugaya nezinsimbi ezicabangelekile bese kuphuthwa ukuze kukhiqizwe isinter, okuyinto engaphezu kwegte elivulekile efanelekile ukusetshenziswa emlilweni omkhulu.

Lezi zinqubo zandisa ukusebenza kokuhlanganiswa kwezinsimbi futhi kuthuthukisa ukusebenza kweziko.

Izindlela Ezivamile Zokuhlukanisa Izinsimbi Zensimbi

1. Ukuhlukaniswa Ngomoya

Ukuhlukaniswa komoya kusebenzisa umehluko ekunciphiseni phakathi kwezimayini zensimbi nezinsimbi eziphumelelayo ngaphakathi kwe-insimbi ukuze kufinyelelwe ekuhlukanisweni.

Isimiso:Izinsimbi ezinzima (imagneite, hematite) ngaphakathi kwe-insimbi ziyezithola ngokushesha kunalezi zinsimbi ezlight ezifakwe uma zihlushwa ngamandla omoya esimweni eshibhile.

Izinto ezisetshenziswayo:

• Jigs:Sebenzisa amanzi apholileka ukuze uhlukanise ama-particles e-iron ore ngokomthamo.
Shaking Tables: Sebenzisa ukuwushaya nokuhamba kwamanzi ukuhlukanisa ama-particles e-iron ore ngokuya ngenhloso ethile.
• Spiral Concentrators:Sebenzisa umthelela wezinga lokuhluka kanye namandla e-centrifugal emanzini ashisayo ukuhlukanisa izimuncagazi ze-iron ore.
• Izicelo:Kusebenza kahle kumaparticles amakhulu e-iron ore nasezimbongolweleni ezineqile ukwehluka kwesisindo, njenge-magnetite ne-hematite ezinekhono elikhulu lokukhululwa. Ukuhlukaniswa kwezinga lokuhluka kuvamise ukusetshenziswa njengesinyathelo sokuqala ekuthuthukisweni kwe-iron ore ngaphambi kokusebenza kwe-magnetic noma i-flotation.

2. Ukuhlukaniswa Kwamajikijolo

Separation ye-magnetic ivamise kakhulu ukusebenzisa ukuze uthuthukise i-magnetite iron ore, futhi, ukuya kweminye imiphumela, ye-hematite iron ore.

Isimiso:Abahlukanisi be-magnetic basebenzisa izinkambu ze-magnetic ukuheha imithombo ye-magnetic ye-iron emgqeni we-iron ore, bebekela ngaphandle ama-gangue angama-magnetic.

Izinhlobo Zabahluzi be-Magnetic:

• Low-Intensity Magnetic Separators (LIMS):Kufanele i-magnetite iron ore enamandla kakhulu. High-Intensity Magnetic Separators (HIMS): Isetshenziswa emithonjeni ye-iron ore enokuphazamiseka okuncane njenge-hematite kanye nezinto ezincane.
• Wet and Dry Magnetic Separators:Abahlukanisi abomisi procese umphumela we-iron ore, bethuthukisa ukusebenza kokuhlukaniswa; abahlukanisi abomisiwe basebenza ngezinto ze-iron ore ezomile.
• Izicelo:Iziqhamo zesikhumba se-magnetite zisebenzisa kakhulu ukuhlukaniswa kwe-magnetic ukuze zithole ukusiza okuphezulu kwe-iron ore concentrate. Isekela futhi ngemuva kokugaya ukuze ibuyise ama-mineral e-iron ku-iron ore.

3. Ukukhuhla kwe-Iron Ore

Ukukhuhla kuwubuchwepheshe bokusiza bokwakha obusetshenziswa ikakhulukazi ukuze amaqoqo e-iron ore ahlanzekile namagile lapho ukuhlukaniswa kwe-magnetic kungasebenzi.

Isimiso:In flotation, reagents such as collectors and frothers are added to an iron ore slurry. Hydrophobic iron ore minerals attach to air bubbles and rise to the surface, forming a froth layer that is skimmed off, while hydrophilic gangue sinks.

Izinto ezisetshenziswayo:

• Imishini Yokuhlanza Ngemishini:Inikezela ngokuqhumisa nokuphefumula ukuze kuthuthukiswe ukuhlanganiswa kwezinsalela zamabhamuza emanzini ensimbi.
• Izikhungo Zokuhlola Ngemikhondo:Zinikeza ukubuyiselwa okuphezulu nokukhethwa ngekheshi eliphansi ekukhanyeni kwensimbi.
• Izicelo:Ukukhanya kubalulekile ikakhulukazi kumaminerali e-hematite nase-siderite ane-ukuhluka okuphansi nezinga eliphezulu le-silica. Kuvumela ukususwa kwe-silica ne-alumina impurities, kuthuthukisa ikhwalithi yokuhlulela insimbi.

4. Ukuhlinzwa Nokugaya

Ukuhlinzwa nokugaya kahle kwe-iron ore kuyizidingo ezisemqoka zokulethwa kwezimpahla eziphumelelayo.

Imishini Yokuhlinzwa:

• Ama-Jaw Crusher:Abasikazi bokuqala abaphatha ama-lump amakhulu e-iron ore.
• Ama-Cone Crushers: Abasikazi besekondari bokunciphisa kahle i-iron ore.
• Abasikazi Be-Gyratory:Basetshenziselwa izenzakalo ezinkulu ze-iron ore zokuhlinzwa kokuqala.

Imishini Yokugaya:

• Amabhola Amamili:Izingcezu zomjikelezo ezine-midiyamu yokugaya ezinciphisa i-iron ore ibe ubuthakathaka.
• Amarodi Amamili:Sebenzisa amarodi njengemidiya yokugaya, efanele ukuhlinzwa okukhulu kwe-iron ore.
• Vertical Roller Mills:Imishini yokugaya efaneleka kahle yokugcina esebenziswe kwezinye izitshalo zentsimbi zanamuhla.

Key Considerations:

• Ukugwema ukugaya kakhulu insimbi ukuze kuncishiswe ukukhiqizwa kwezingxenye ezincane kakhulu, ezithuthukisa ukuhlukaniswa.
• Ukugcina usayizi ofanele wokugaya ukuze kuthuthukiswe ukukhululwa nokubuyiselwa kweminerali yensimbi.

Environmental Considerations

Izitshalo zokuhlunga insimbi kufanele zibheke imiphumela yemvelo:

• Tailings Management:Ukulahla ngokuphepha kanye nokubuyiselwa okungenzeka kwe-tailing.
• Water Usage:Ukubuyiselwa nokwelashwa kwamanzi okwenziwayo.
• Ukunciphisa Uthuli:Ukunciphisa ukukhishwa kwephunga ngesikhathi sokuphahlazeka nokuphatha.
• Ukusebenza Kwamandla:Ukuhlela imishini nezinqubo zokunciphisa ukusetshenziswa kwamandla.

Ukuthuthuka Kwamva Nokuqhubekela Phambili

• Ukuzijwayeza Nokulawula:Ukusetshenziswa kwemisakazo, i-AI, nokufunda kwemishini ukuze kuthuthukiswe izinqubo.
• Ukuthuthukiswa Kwangaphandle:Ukunciphisa ukusetshenziswa kwamanzi ngokusebenzisa ukuhlelwa kwe-magnetic okumsulwa noma kokusebenza nge-electrostatic.
• Ukuphathwa Kwamathokheni:Ukusebenzisa amatshe okukhishwa ezindaweni zokwakha noma ezinye izicelo.
• Ukugaya Okusebenzayo Ngamandla: High-pressure grinding rolls (HPGR) and stirred mills.

Ukucutshungulwa kwe-iron ore kuyingxenye eyinkimbinkimbi, eyizigaba eziningi ehilela ukuwisa, ukugaya, ukuhlukanisa, ukuqinisekisa, ukususa amanzi, nokuhlanganisa. Isigaba ngasinye sidinga amathuluzi ahlukeneyo nezindlela eziklanyelwe izici ze-mineralogy kanye nezici zomzimba ze-ore. Ukuqhuba phambili kwezobuchwepheshe bokusebenza kuqhubeka nokwenza ngcono izinga lokubuyiselwa, ikhwalithi yomkhiqizo, nokuhlaliswa kwemvelo, kuqinisekisa ukusetshenziswa kahle kwemithombo ye-iron ore ukuze kulungiswe isidingo se-steel emhlabeni jikelele.