Saudi Arabian Iron Ore Beneficiation Plant Project

The project undertaken involves processing low-grade magnetite ore with high silica and low sulfur and phosphorus content, and a high content of iron silicate and iron carbonate. The ore structure is mainly banded, and the texture is mainly granular metamorphic. The Saudi Arabian low-grade magnetite ore is characterized by fine-grained, unevenly distributed magnetite. The average particle size of the iron minerals is 44.95 μm, and the average particle size of the gangue minerals is 71.20 μm. Based on the ore characteristics, Xinhai engineers proposed a beneficiation process: staged grinding and single-stage magnetic separation. Staged grinding and separation allow for the early rejection of some low-grade tailings, reducing the processing volume of subsequent grinding and separation operations. When the ore is ground to a particle size where the -0.074mm fraction accounts for 55% to 65%, tailings with a grade below 10% and a yield of over 40% can be discarded. The raw ore mainly contains magnetic minerals, with a small amount of iron silicate and iron carbonate, and very little hematite and limonite. Therefore, a single-stage magnetic separation process was considered. The full magnetic separation process has the advantages of a simple process, low operating costs, high iron recovery rate, and reliable technology. The staged grinding and single-stage magnetic separation process achieved satisfactory results in processing the Saudi Arabian iron ore.