Designing of the Grinding and Classification Systems for Increasing the Concentrate Iron Grade in 4th Production Plant at Golgohar Mining and Industrial Company

"The concentration of the fourth production line at Golgohar includes 66% iron with Blaine number of 500 cm2/g. For pelletizing process, the feed iron grade should be greater than 68% with minimum Blaine number of 1800 cm2/g. In this study, the low intensity magnetic Separators, particularly the feed particle size distribution of LIMS were considered. The feed particle size distribution of the separators was optimized to prepare an appropriate concentrate (as mill pelletizing feed). The samples were performed from the LIMS feed and after grinding, four d80 (64, 103, 132, and 15 3µm) were prepared. Then, laboratory magnetic separation experiments were conducted on these samples. The best results obtained using d80 of 132µm. In this particle fraction, the iron grade and Blaine number were 70.3% and 1571 cm2/g, respectively. Therefore, it seems necessary to include a grinding and classification systems before LIMS stage. According to the presence of a high amount of -132 µm particles in the initial feed, an inverse closed circuit was selected. The hydrocyclone was designed in three units as the classification system with 62 cm (diameter), 22 cm (overflow outlet) and 11 cm (apex diameter). By simulation of hydrocyclone with USIMPAC software, the size distribution of underflow was determined. Based on these results, a ball mill with dimensions of 6.7 m (length) and 5 m (diameter) was designed as grinding system.INTRODUCTIONGole-Gohar iron ore concentration plant No.4 (Polycom Plant) in Gole-Gohar Industrial and Mining Complex was installed to increase production capacity as well as treating the circulating load from AG and SAG mills of the main concentration plant of the complex. The load from the mine is crushed using jaw and cone crushers. The crushed ore is then combined with the circulated load and the combination is then grounded using HPGR and ball mills respectively.After comminution, there is a magnetic separation plant which includes a medium intensity magnetic separator (MIMS) followed by three low intensity magnetic separators (LIMS). Final concentrate dewatering is done using three belt filters. After the primary magnetic separation, the ore is upgraded to 62% Fe content and final concentrate which is the product of LIMS has 66% Fe content."