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1. Process Overview
Manganese ore is a weakly magnetic mineral. The strong magnetic-medium magnetic combined process is the core technology. Through multi-stage magnetic separation and classification, efficient enrichment of manganese ore can be achieved. The customized solution of Zoomjo can increase the manganese grade by 4%-10%, and the concentrate recovery rate can reach 85%-95%. It is suitable for low-grade manganese ore (15%-25%) and complex embedded ore bodies.
2. Core process flow
1. Crushing pretreatment
Coarse crushing: jaw crusher processes raw ore to 100-200mm, with a processing capacity of 5000t/d; Fine crushing: CNC sand machine accurately controls particles to 0-30mm, reducing over-crushing and reducing energy consumption by 20%.
2. Strong magnetic roughing (primary enrichment)
Equipment: high gradient magnetic separator (magnetic field strength 1.2-1.5T);
Technical highlights:
Quickly discard 60%-70% of gangue, and increase the manganese grade of coarse concentrate to 25%-30%;
The tailings are directly discharged into the concentrator to reduce ineffective circulation.
3. Grading optimization (granularity control)
Spiral classifier:
The bottom flow (coarse particle size) enters the medium magnetic separation, and the overflow (fine particle size) is concentrated and reused;
Classification efficiency>85%, accurately separating +0.1mm and -0.1mm particles.
4. Medium magnetic separation (deep purification)
Equipment: Permanent magnetic cylinder medium magnetic machine (magnetic field strength 0.6-0.8T);
Technical highlights:
Secondary separation removes residual quartz and clay, and the manganese grade of the concentrate reaches 35%-40%;
The manganese loss rate of tailings is less than 5%, and the resource utilization rate is maximized.
5. Concentration and dehydration (closed loop)
Concentration system:
High-efficiency thickener sedimentation, bottom flow concentration>60%, overflow return water rate≥90%;
Dry tailings discharge:
Combined process of dewatering screen + filter press, tailings moisture content < 15%, can be directly stored or made into building materials.
3. Technical advantages and benefits
Taste Leap:
The manganese grade of the raw ore is 18% → the grade of the concentrate is 38%-45%, and the purification rate exceeds 100%;
Compared with the traditional single magnetic separation, the recovery rate is increased by 10%-15%.
Energy saving and consumption reduction:
CNC sand machine + closed-circuit grading system, energy consumption per ton of ore is reduced by 25%;
Power consumption of strong magnetic machine is less than 3kW·h/t, and operating cost is leading in the industry.
Green production:
Tailings dry discharge technology reduces storage capacity pressure, and water recycling saves 30% of water resources;
dust closed collection system, PM2.5 in the working area<15μg>
4. Production Example: A Low-Grade Manganese Mine Project in Guangxi (3000t/d)
Ore characteristics:
Manganese grade 19.5%, fine embedded particle size (-0.074mm accounting for 65%), containing quartz and clay.
Process design:
Strong magnetic roughing: tailing rate 65%, coarse concentrate grade 28.3%;
Medium magnetic concentrating: concentrate grade increased to 42.7%, recovery rate 89.4%.
