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<p>Continuous coarse particle gangue rejection from an ultra-lean magnetite ore holds much potential to significantly reduce the energy consumption and processing costs. To enhance the HPGR comminution efficiency and gangue rejection performance, a comparative study was conducted between two different circuits. The base circuit employed an HPGR integrated with dry magnetic separation in closed-loop operation. The alternative circuit incorporated an HPGR coupled with a 3&#xa0;mm aperture dry screening prior to magnetic separation. Industrial-scale sampling campaigns conducted in an ultra-lean magnetite comminution plant (base circuit) revealed that the primary cause of the high HPGR recycling load (151.95%) was the recirculation of the − 25 + 10&#xa0;mm particle size fraction (characterized by coarse size and insufficient mineral liberation) from the HPGR comminution product, through the dry magnetic separation middlings stream back to the HPGR. Laboratory-scale comparative study revealed that the alternative circuit exhibited significant improvements in gangue rejection performance. Specifically, the HPGR recycling load decreased from 139.46% to 97.6%, and gangue rejection increased from 40.01% to 44.54%. Moreover, a reduction of 17.48% in specific HPGR energy demand and a 25.06% decrease in subsequent ball mill grinding energy requirements were achieved compared to the base circuit. The alternative gangue rejection circuit reduces production costs through lower energy consumption, enabling the development of ultra-lean magnetite ore resources that were previously uneconomical due to low grade.</p>

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Optimization of Early Gangue Rejection from an Ultra-Lean Magnetite Ore Using High Pressure Grinding Rolls (HPGR) and Dry Magnetic Separator: A Case Study

  • 期刊论文

  • 发表日期：

    2026年6月1日

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  • Bo Wei,
  • Zhitao Yuan,
  • Quan Feng,
  • Qiang Zhang,
  • Qingyou Meng,
  • Lixia Li,
  • Xinyang Xu,
  • Bern Klein,
  • Chengtie Wang

摘要

Continuous coarse particle gangue rejection from an ultra-lean magnetite ore holds much potential to significantly reduce the energy consumption and processing costs. To enhance the HPGR comminution efficiency and gangue rejection performance, a comparative study was conducted between two different circuits. The base circuit employed an HPGR integrated with dry magnetic separation in closed-loop operation. The alternative circuit incorporated an HPGR coupled with a 3 mm aperture dry screening prior to magnetic separation. Industrial-scale sampling campaigns conducted in an ultra-lean magnetite comminution plant (base circuit) revealed that the primary cause of the high HPGR recycling load (151.95%) was the recirculation of the − 25 + 10 mm particle size fraction (characterized by coarse size and insufficient mineral liberation) from the HPGR comminution product, through the dry magnetic separation middlings stream back to the HPGR. Laboratory-scale comparative study revealed that the alternative circuit exhibited significant improvements in gangue rejection performance. Specifically, the HPGR recycling load decreased from 139.46% to 97.6%, and gangue rejection increased from 40.01% to 44.54%. Moreover, a reduction of 17.48% in specific HPGR energy demand and a 25.06% decrease in subsequent ball mill grinding energy requirements were achieved compared to the base circuit. The alternative gangue rejection circuit reduces production costs through lower energy consumption, enabling the development of ultra-lean magnetite ore resources that were previously uneconomical due to low grade.