The ore beneficiation plant production flowsheet outlines the sequence of processes used to separate valuable minerals from the ore. Below is a generalized flowsheet for a typical beneficiation plant, which can be adapted based on the type of ore (e.g., iron, copper, gold, phosphate, etc.) and its characteristics.
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1. Crushing & Screening
– Primary Crushing (Jaw/Gyratory Crusher): Reduces large ore chunks to smaller fragments (~150–250 mm).
– Secondary/Tertiary Crushing (Cone Crusher): Further reduces size to ~10–30 mm.
– Screening: Classifies crushed ore into size fractions for efficient downstream processing.
2. Grinding
– Ball Mill/Rod Mill: Reduces ore to fine particles (~75–150 µm) for liberation of minerals.
– Classification (Hydrocyclone/Screen): Separates fine particles (slurry) from coarse material (returned for regrinding).
3. Beneficiation (Mineral Separation)
Depending on the ore type, one or more of these methods are used:
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# a. Gravity Separation (For heavy minerals like gold, tin, iro.jpg)
– Spiral Concentrators
– Jigging Machines
– Shaking Tables
# b. Magnetic Separation (For iron ore, magnetite)
– Low-Intensity Magnetic Separators (LIMS)
– High-Intensity Magnetic Separators (HIMS)
# c. Froth Flotation (For sulfides like copper, lead-zinc)
– Rougher Flotation → Scavenger Flotation → Cleaner Flotation
– Reagents: Collectors, Frothers, Depressants
# d. Leaching & Adsorption (For gold/silver)
– Cyanide/Thiosulfate Leaching → Carbon Adsorption (CIP/CIL)
# e. Electrostatic Separation (For heavy mineral sands)
4. Dewatering & Tailings Management
– Thickener: Concentrates slurry by removing water.
– Filter Press/Vacuum Disc Filter: Further dewatering to produce a dry concentrate.
– Tailings Storage Facility (TSF): Safe disposal of waste material.
5. Product Handling
– Dried concentrate is transported for smelting or further processing.
– Waste rock and tail