Title Ore Beneficiation Plant 2 - Class Notes ✅

7. Magnetic Separation  A High-Gradient Magnetic Separator (HGMS) or similar magnetic equipment removes any remaining iron from the tailings stream and upgrades the concentrate by attracting magnetic iron (magnetite, hematite) and leaving non-magnetic waste behind.  These separators are mechanical systems with high-strength magnets and coils, not electrical systems.[1] 8. Dewatering and Product Handling  The final iron concentrate is dewatered using vibrating (dewatering) screens to remove excess water.  Dewatered product is sized—plus 150 microns and minus 3 mm fractions become the sinter feed or go to pelletization. 9. Downstream Use  The plant produces high-grade iron ore concentrate suitable for use in sinter plants, pellet plants, or direct shipping, upgrading low-grade ore to higher grade. 10. System Automation and Control  The plant is typically divided into models or modules (Model 1, Model 2, etc.), each operating with a series of cyclones (for example, 64 cyclones per module) for classification. Each cyclone separates lighter and heavier particles based on density using pressure (often around 1.1 bar).  Cyclones and classifiers can be monitored via distributed control systems, with feedback loops to adjust pressure, feed rate, and wash water for optimal separation.[1] Key Terms Defined:  Silo: Buffer storage, maintains steady flow.  Belt Feeder: Mechanical device to regulate material flow from storage.  Wet Screen: Uses water spray to help size separation and wash ore.  Classifier/Linear Screen: Separates finely sized particles (primary and secondary stages).  Scrubber: Removes clays/impurities through agitation.  Spiral Separator: Gravity-based separation for mineral density differences.  Cyclone: Uses centrifugal force/pressure for fine particle classification.  HGMS (High-Gradient Magnetic Separator): Extracts magnetic iron minerals from the ore.  Dewatering Screens: Vibratory screens to remove water from final product. Relevant Process Flow Overview (condensed and clarified as per actual industry practice): 1. Ore blending and storage (RMHS)