Limonite, an iron ore consisting of hydrated iron(III) oxide-hydroxide (FeO(OH)·nH₂O), is typically processed to extract iron or improve its grade for industrial use. The dressing (beneficiation) equipment for limonite depends on its physical and chemical properties, such as low magnetism, high water content, and fine dissemination. Here are the key types of equipment used in limonite processing:
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1. Crushing & Grinding Equipment
– Jaw Crusher / Cone Crusher: For primary and secondary crushing.
– Ball Mill / Rod Mill: For fine grinding to liberate iron minerals from gangue.
2. Classification & Washing Equipment
– Spiral Classifier / Hydrocyclone: Separates particles by size and density.
– Log Washer / Scrubber: Removes clay and impurities adhering to limonite.
3. Gravity Separation Equipment (For coarse-grained limonite)
– Jigging Machine (Jig Separator): Effective for high-density iron mineral separation.
– Shaking Table: Recovers fine limonite particles via differential settling.
– Spiral Chute: Separates minerals based on density differences in slurry.
4. Magnetic Separation Equipment (For weakly magnetic limonite)
– High-Gradient Magnetic Separator (HGMS): Enhances recovery of weakly magnetic limonite after roasting or reduction treatment.
5. Roasting & Reduction Equipment (To enhance magnetism)
– Rotary Kiln / Shaft Furnace: Converts limonite into magnetite (Fe₃O₄) via reduction roasting, making it responsive to magnetic separation.
6. Flotation Equipment (For fine-grained or refractory limonite)
– Flotation Machine: Uses collectors (fatty acids, sulfonates) to separate limonite from silica/alumina gangue after reverse flotation or direct flotation processes.
7. Dewatering Equipment
– Thickener: Concentrates slurry before filtration.
– Filter Press / Vacuum Disc Filter: Removes moisture from the final concentrate.
Typical Limonite Beneficiation Flow:
1. Crushing → 2. Grinding → 3. Washing/Scrubbing → 4a. Gravity Separation
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