EPIC turnkey iron ore processing plant provides complete crushing, ball mill grinding and magnetic separation solution for magnetite and hematite. Custom process flow, 100–1000 tph capacity, overseas installation and after-sales support for global mining projects.
Iron Ore Processing Plant | EPIC Complete Mineral Beneficiation Line Solution
EPIC turnkey iron ore processing plant provides complete crushing, grinding, magnetic separation and tailings handling solution for hematite, magnetite, limonite and specularite ores. From primary gyratory / jaw crushing to final iron concentrate powder (Fe ≥ 60–65%), we supply core equipment, process design, plant layout, on-site installation guidance and operator training. Designed for 100–1000 tph hard rock iron ore projects across Africa, Central Asia, Southeast Asia and South America.
Process Flow Overview
- Primary Crushing: Raw iron ore (up to 1000–1200 mm) fed into gyratory crusher or heavy-duty jaw crusher, reduced to 0–200 mm.
- Secondary & Tertiary Crushing: Cone crusher + vibrating screen close circuit, product size 0–25 mm for ball mill feed.
- Grinding Circuit: Overflow ball mill + hydrocyclone closed circuit, grinding to 200 mesh passing 60–90% for magnetic liberation.
- Magnetic Separation: Drum magnetic separators (low-intensity for magnetite; high-intensity for hematite / limonite) produce rough concentrate and tailings.
- Cleaning & Recleaning: Multiple stage magnetic separation + dewatering cyclone to upgrade iron grade to 60–65% Fe.
- Tailings Handling: High-frequency thickener + filter press, tailings slurry pumped to dam or filtered for dry stacking.
- Final Concentrate: Iron concentrate powder conveyed to storage yard, ready for shipping or pelletizing.
Key Advantages
- Turnkey EPC Solution: From geological ore test, process flow design, equipment manufacturing, plant layout drawing to on-site installation & commissioning — single responsible supplier, no interface risk between vendors.
- Tailored Process by Ore Type: Magnetite uses low-intensity magnetic separation; hematite / limonite adopts high-intensity magnetic separation + gravity separation or reverse flotation. Process matched to your mineralogy report, not a one-size-fits-all line.
- High Recovery & Grade: Optimized ball mill cyclone classification ensures proper liberation; multi-stage magnetic separation guarantees iron recovery 65–85% and final concentrate Fe 60–65% under normal ore condition.
- Energy-Saving Design: Ball mill hydrodynamic classifier, high-efficiency magnetic separator and thickener recover water; overall power consumption optimized versus traditional open-circuit plant.
- Wear-Resistant Equipment Package: High-manganese jaw plates, cone liners, rubber-lined ball mill and ceramic / rubber-coated magnetic drums extend wear life and lower operating cost.
- Flexible Capacity Range: Standardized modules from 100 tph to 1000 tph; skid-mounted or mobile crushing section for remote mine sites, expandable in phases.
- After-Sales & Spare Parts: Oversee engineer site service, operator training, long-term supply of wear parts (liners, magnetic drums, screen mesh, filter cloth).
Typical Capacity Configuration & Reference Footprint
| Plant Capacity | Main Grinding Mill | Main Motor Power | Estimated Installed Power | Reference Plant Footprint | Applicable Ore |
|---|---|---|---|---|---|
| 100 tph | Φ2.2×4.5m Ball Mill | 185 kW | ~850 kW | ~2 500 ㎡ | Magnetite / Hematite |
| 200 tph | Φ2.4×4.5m Ball Mill | 245 kW | ~1 500 kW | ~3 800 ㎡ | Magnetite / Hematite |
| 500 tph | Φ3.2×4.5m Ball Mill ×2 | 380 kW ×2 | ~3 600 kW | ~7 500 ㎡ | Magnetite / Hematite |
| 1000 tph | Φ3.6×5.4m Ball Mill ×2 | 630 kW ×2 | ~6 800 kW | ~12 000 ㎡ | Large open-pit iron mine |
Main Equipment Package
- Crushing Section: JM1600 gyratory crusher (large capacity) or JC jaw crusher (small-medium), cone crusher, vibrating feeder, vibrating screen, belt conveyor.
- Grinding Section: Overflow ball mill, hydrocyclone cluster, slurry pump.
- Separation Section: Permanent magnetic drum separator (CTB series), high-gradient magnetic separator (for hematite), optional flotation machine for reverse flotation.
- Dewatering Section: High-frequency thickener, disc vacuum filter or filter press, concentrate conveyor.
- Auxiliary: Slurry pumps, piping, steel structure, electrical control cabinet, PLC monitoring system.
Applicable Ores & Typical Projects
- ✅ Suitable Iron Ores
- Magnetite (Fe₃O₄) — low-intensity magnetic separation, high recovery
- Hematite (Fe₂O₃) — high-intensity magnetic separation or roasting-magnetic process
- Limonite, specularite, siderite — gravity + magnetic + flotation combined process
- Weak-magnetic mixed iron ore with sulfide gangue
- Typical Projects
- Greenfield open-pit iron ore processing plant (100–1000 tph)
- Existing iron concentrator capacity expansion or flow-sheet upgrade
- Iron ore fines beneficiation plant for pelletizing feed
- Mobile crushing + stationary grinding-magnetic separation combined line for remote mine
- ⚠️ Note: Final process flow, equipment model and power data are confirmed after receiving your ore sample mineralogy report (Fe grade, mineral composition, liberation size, hardness).
FAQ
What information do you need to design an iron ore processing plant?
Please provide: (1) ore type and run-of-mine Fe grade; (2) hourly or daily capacity; (3) max feed size; (4) target concentrate Fe grade and recovery; (5) on-site power supply condition; (6) local climate and elevation. If available, send us the ore mineralogy report, and our metallurgical engineer will design the process flow and equipment list.
What final iron concentrate grade can your plant achieve?
For magnetite ore, final concentrate Fe can reach 65–66% with recovery 75–85%. For hematite, after high-intensity magnetic separation or magnetic-flotation combined process, concentrate Fe typically reaches 60–62%. Actual result depends on ore liberation size and gangue mineral composition.
Do you supply the whole plant or only individual equipment?
We supply both: standalone core equipment (ball mill, jaw crusher, magnetic separator, thickener) and turnkey EPC package including process design, manufacturing, shipping, on-site installation guidance and commissioning. Most overseas clients choose the turnkey package for shorter commissioning time and single-point responsibility.
How long does it take to deliver and commission a 200 tph plant?
Equipment manufacturing takes about 60–90 days after down payment. On-site installation and commissioning normally take 30–45 days, depending on site civil work readiness and client’s local labor availability. Our engineer will guide installation remotely or on-site.
Can you handle hematite or weak-magnetic iron ore?
Yes. Magnetite uses low-intensity permanent magnetic drums. For hematite, limonite and specularite, we provide high-intensity magnetic separation, gravity separation (spiral chute / shaking table) or reverse flotation combined process. Pilot test on your ore sample is recommended before final flow-sheet confirmation.
What about tailings disposal and water recovery?
We design a closed water system: thickener recycles process water back to the plant, tailings slurry is pumped to tailings dam or dewatered by filter press for dry stacking. This reduces fresh water consumption and meets environmental requirements for overseas mining projects.
What after-sales service and spare parts do you provide?
We supply foundation drawings, P&ID, operation & maintenance manual, overseas engineer on-site guidance, operator training, and long-term wear parts: ball mill liners, steel balls, jaw plates, cone liners, magnetic drum plates, screen mesh, filter cloth and pump spares.
Get In Touch
Send us your ore type, daily capacity and target concentrate grade. Our metallurgical engineer will design the process flow, list main equipment with power and footprint, and provide a preliminary proposal for your iron ore project.
