Magnetite Crushing Production Line
Magnetite crushing production line needs to be customized according to ore characteristics and production goals. The core is to achieve efficient crushing, energy saving and consumption reduction, and environmentally friendly production through a reasonable combination of equipment.
Magnetite characteristics and core requirements for crushing
High hardness + strong magnetism: Mohs hardness 5.5-6.5, easy to wear equipment and adsorb metal impurities during crushing.
Iron grade improvement requirements: multi-stage crushing (≤15mm) is required to create dissociation conditions for subsequent grinding and selection.
Mud content influence: clay is easy to block the crushing chamber, and the wet process needs to wash the ore in advance.
Typical magnetite crushing production line configuration
1. Process flow (dry/wet method optional)
Dry method (applicable to low moisture content ore)
Ore bin → vibrating feeder → jaw crusher (coarse crushing) → iron remover → cone crusher (medium crushing) → high pressure roller mill (fine crushing) → circular vibrating screen (closed loop) → qualified material (≤12mm)
Wet method (high mud content ore)
Ore washer → jaw crusher → drum screen (+ hydrocyclone) → cone crusher → wet screening → ball mill feeding
2. Special design points
Magnetic protection: The conveyor belt uses non-magnetic rollers to avoid iron filings mixing.
Wear-resistant solution: The cone crusher lining uses a rubber + magnetic lining composite type (life expectancy increased by 40%).
Pre-selection and waste disposal: After medium crushing, add a dry magnetic separator (magnetic field strength ≥ 2000 Gauss) to discard 10%-15% of waste rock in advance.
Production line optimization strategy
Energy saving and consumption reduction
High-pressure roller mill replaces traditional cone crusher for fine crushing, reducing energy consumption by 30% (micro cracks are generated after rolling, which is conducive to subsequent grinding and selection).
Use variable frequency vibrating screen to adjust the amplitude according to the hardness of the ore (saving 15% electricity).
Improve iron recovery rate
Stage crushing + stage selection: Set up a magnetic separator after coarse crushing and before medium crushing to discard waste in time.
Particle size control: 80% of the final crushed product passes through the 12mm sieve hole (too coarse affects the efficiency of the mill, too fine increases energy consumption).
Automated control
Online particle size analyzer (such as MLA system) monitors the particle size of the crushed product in real time and automatically adjusts the discharge port of the cone crusher.
PLC centralized control: Equipment interlocking start and stop, automatic reverse operation to troubleshoot when blocked.
Classic case
Process flow:
Three-stage one closed circuit (jaw crusher + cone crusher + high-pressure roller mill) + dry magnetic separation pre-waste disposal
Configuration list:
- Coarse crushing: JC1200 jaw crusher (discharge ≤180mm)
- Medium crushing: HST315 single-cylinder cone crusher (discharge port 25mm)
- Fine crushing: GM1400 high-pressure roller mill (roller gap 8mm)
- Magnetic separation: CTB1230 drum magnetic separator (3 units in series)
Effect:
After crushing, the Fe grade of the ore is increased to 45%, and the waste rock disposal rate is 18%;
The power consumption per ton of ore is only 9.8kWh (about 14kWh for traditional process).
