Applications

500 TPH Iron Ore Beneficiation Plant Case

    Iron ore beneficiation is a critical process that separates valuable iron minerals from gangue minerals and enriches iron content through a series of physical and chemical methods. This process aims to obtain high-grade iron concentrate and purify iron-bearing ores for subsequent smelting. Based on the specific project requirements and on-site conditions of the South African client, Sentai customized and delivered a 500 TPH iron ore beneficiation plant, perfectly adapting to the local iron ore characteristics and mining environment.​

Customized Solutions​

    Tailored to the South African client’s ore properties (hematite as the main mineral, with a small amount of associated gangue) and capacity requirements, Sentai designed the beneficiation process as follows:​

    Crushing Stage: Firstly, the vibrating feeder uniformly conveys raw iron ore to the jaw crusher for primary crushing, reducing large ore lumps into small particles. If the particle size does not meet the subsequent grinding requirements, the material is sent to the cone crusher for secondary fine crushing, ensuring a uniform crushed product size of 10-20mm.​

    Grinding Stage: The crushed material is classified and screened by a vibrating screen. Qualified particles are fed into the ball mill for fine grinding, reducing the ore to below 75μm (80% passing 200 mesh) to fully dissociate iron minerals from gangue.​

    Magnetic Separation Stage: Utilizing the magnetic difference between iron minerals and gangue, Sentai’s high-efficiency wet permanent magnetic drum separator is adopted for precise sorting. This equipment effectively enriches iron minerals, increasing the iron concentrate grade to over 65%.​

    Tailings Treatment Stage: After obtaining iron concentrate through magnetic separation, the tailings generated during the beneficiation process are harmlessly treated by tailings processing equipment (including thickening, dewatering, and drying units). The dried tailings can be reused for road base filling and other applications, fully complying with South Africa’s environmental protection regulations.​

Client Feedback​

    The 500 TPH iron ore beneficiation plant provided by Sentai features advanced, complete, and energy-efficient equipment. While reducing project construction and operational costs, it has achieved steady production capacity improvement, fully meeting the client’s expected goals. The client highly recognizes the professionalism of the solution, praising not only the high quality and stable performance of the equipment but also Sentai’s profound professional expertise and responsible attitude in scheme design, equipment installation and commissioning, and subsequent technical support. Based on this successful cooperation, the client has clearly expressed a strong willingness for further collaboration, hoping to continue working together on future new project expansion, equipment upgrading and transformation to achieve mutual benefit and win-win results.