With an unparalleled depth of knowledge in fine minerals the world’s largest producers rely on us as their ‘go to’ partner to beneficiate Iron Ore fines for new and existing projects.
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We know that not all Iron Ore deposits are the same and changing commodities prices are placing higher demands on producers to ‘sweat the assets’ through process improvements, and increase revenues by converting tailings. That’s why understanding your project objectives and opportunities is our first step in developing solutions that transform your ores into valuable commodities. This holds true for all projects that we are involved in and forms the basis for our ongoing work in developing and delivering innovative and cost effective process solutions across the project lifecycle that transform your ore bodies into valuable commodities.
To be confident in investing in a project, you need to know that the separation process will work on start-up and throughout the life of the operation. We give you certainty by testing representative samples and analysing the results beyond basic calculations to deliver innovative and cost effective process flowsheets that maximise the grade and recovery of valuable minerals including Magnetite, Hematite and Goethite.
Customers value our 75 years’ experience in metallurgical testing, whether performed in our extensive metallurgical test laboratory in Australia or, under our direction, in partner test laboratories in the USA, South Africa, Brasil and India.
We routinely test samples as small as 100 grams for characterisation and specific gravity fractionation, through to larger samples up to 2000 kg for bench and pilot scale testing and flowsheet development. We also have the capability to create multi-stage pilot scale circuits to treat bulk samples (80-100 tonnes) for process testing and circuit optimisation and our test equipment includes the latest gravity, electrostatic and magnetic equipment.
High grade concentrates and high recovery of iron ore can be achieved using effective feed preparation systems (typically controlled crushing, screening, milling, classification and slimes removal) in combination with cost effective, efficient metallurgical separation.
Hard rock hematite deposits often require a combination of milling, screening and on occasion, fine classification to prepare a finely sized (-1.0mm), liberated feed for beneficiation by gravity separation. This is typically followed by re-grinding of the tailings to liberate more hematite for further iron unit recovery by magnetic separation.
WHIMS are also often employed to recover fine hematite from spiral circuit tailings. The inclusion of medium intensity magnetic drum separation (MIMS) in combination with jigging may be considered for the beneficiation of the 6-1mm fraction of some friable ore bodies.
The following diagram demonstrates some typical flowsheet designs for Iron Ore beneficiation of hard rock and friable ores.
Having developed an effective and optimised flowsheet, you need a plant that safely and effectively applies this flowsheet to the ore body to extract high grade iron ore whilst delivering high availability, with low capital and low operational expenditure.
Our teams understand these challenges and bring a depth of knowledge underpinned by a deep metallurgical understanding and extensive operational knowledge from regular access to processing plants.
Combined with our multi-disciplined expertise and proprietary 3D design tools, we deliver plant designs beyond standard engineering outcomes that extract optimum value from your ore bodies.
Engaged by Iron Ore producer Arrium in Australia, we delivered two complete beneficiation plants to transform variable, low grade tailings stockpiles into high grade Iron Ore product.
When purchasing new equipment, we understand that you need to ensure the equipment maximises grades and recovery whilst having low operational costs and adhering to tight capex budgets.
For this reason our equipment is designed and manufactured using the latest technologies and is fully tested in processing operations to ensure maximum performance. This means that when we release new process equipment you can be assured that it will be fit for purpose and cost effective.
A good example is the engineering we completed for ArcelorMittal’s projects in Canada and Africa. The specific ore required our teams to design a High Capacity wash water spiral which becames the HC33.
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As a world leader in process solutions we have delivered some of the largest and most complex projects including design of the world’s largest wet concentrating plant at the ArcelorMittal project, and the design and supply of two tailings treatment beneficiation plants for Arrium in Australia.
With teams located in major mining regions worldwide, we can work with you to supply Iron Ore beneficiation solutions across all stages of the project lifecycle.