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<p>This study develops an adaptable pilot-scale beneficiation flowsheet for Ethiopian iron ores using METSIM modeling. After developing the adaptable pilot-scale beneficiation flowsheet, it was validated using the Melka Arba titaniferous magnetite deposit (48–52% Fe, 16–19% TiO<sub>2</sub>). The flowsheet features a refined three-stage comminution circuit (jaw crusher → cone crusher → ball mill/hydrocyclone, P80 200&#xa0;μm) ahead of magnetic separation. This results in 86% magnetite recovery (4.472 t/h from 5.2 t/h feed), 78.33% iron recovery, and 49.95% Fe concentrate grade. Magnetic separation is more effective than gravity/flotation for this ore composition. Accurate P80 200&#xa0;μm (± 25&#xa0;μm) grinding control to minimize slime losses and maximize liberation; regrinding or secondary magnetic separation to increase grade above 65% Fe; 10 t/h physical pilot validation prior to scale-up; parallel gravity/flotation adaptations for ores such as manganese, copper, and gold; and real-time PSD monitoring with automated reduction ratios (jaw 4.75, cone 3.79, and ball 7.1). These steps lower scale-up risks by 30–50% and streamline low-risk mineral processing for Ethiopia’s sector modernization.</p>

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Flowsheet design of pilot beneficiation plant for Melka Arba iron and some essential minerals in Ethiopia using METSIM

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年7月5日

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  • Asmamaw Mulugeta,
  • Mulugeta Sisay,
  • Ijara Tesfaye

摘要

This study develops an adaptable pilot-scale beneficiation flowsheet for Ethiopian iron ores using METSIM modeling. After developing the adaptable pilot-scale beneficiation flowsheet, it was validated using the Melka Arba titaniferous magnetite deposit (48–52% Fe, 16–19% TiO2). The flowsheet features a refined three-stage comminution circuit (jaw crusher → cone crusher → ball mill/hydrocyclone, P80 200 μm) ahead of magnetic separation. This results in 86% magnetite recovery (4.472 t/h from 5.2 t/h feed), 78.33% iron recovery, and 49.95% Fe concentrate grade. Magnetic separation is more effective than gravity/flotation for this ore composition. Accurate P80 200 μm (± 25 μm) grinding control to minimize slime losses and maximize liberation; regrinding or secondary magnetic separation to increase grade above 65% Fe; 10 t/h physical pilot validation prior to scale-up; parallel gravity/flotation adaptations for ores such as manganese, copper, and gold; and real-time PSD monitoring with automated reduction ratios (jaw 4.75, cone 3.79, and ball 7.1). These steps lower scale-up risks by 30–50% and streamline low-risk mineral processing for Ethiopia’s sector modernization.