To address the challenges of high energy consumption in crushing and low grinding efficiency in magnetite processing, Fighter Corporation has introduced a comprehensive crushing and beneficiation process and equipment solution that has been successfully implemented at numerous large and medium-sized mines.
The crushing stage employs a “three-stage closed-circuit” system: run-of-mine ore undergoes primary crushing (jaw crusher), secondary crushing (single-cylinder hydraulic cone crusher), and tertiary crushing (multi-cylinder hydraulic cone crusher). Integrated with heavy-duty vibrating screens to form a closed-circuit loop, this configuration ensures the final crushed product size remains consistently below 12 mm. This setup effectively reduces the feed size for the subsequent grinding stage, laying the foundation for energy-efficient grinding.
During the pre-separation and grinding stages, dry magnetic separators are installed after primary or secondary crushing to reject large amounts of gangue early on, thereby increasing the grade of the material fed into the grinding circuit. Subsequently, ball mills perform primary and secondary grinding, supported by spiral classifiers and hydrocyclones, to ensure that over 85% of the product meets the fineness requirement of -200 mesh. The material then undergoes roughing, cleaning, and scavenging via low-intensity magnetic separators to yield high-quality iron concentrate with an iron grade exceeding 65%.
The entire system features an intelligent control setup that enables real-time monitoring and automatic adjustment of the material level in the cone crusher’s crushing chamber, achieving an equipment operating rate of over 92%. By adhering to the core philosophy of “more crushing, less grinding” and “early separation and early rejection,” the process achieves significant energy savings and consumption reduction while maintaining high recovery rates.
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