In the mining industry, efficient and stable crushing processes are key to improving resource utilization and reducing costs. Today, we present a successful case study of hematite mining and crushing, demonstrating how refined equipment configuration and scientific process design achieve seamless integration from raw ore to high-quality finished products.

More Iron Ore Crushing Solutions

Project Background

Faced with a mountain rich in hematite, how can it be efficiently and economically transformed into the iron concentrate needed by the market? This project aims for an annual processing capacity of hundreds of thousands of tons, designing and implementing a high-efficiency crushing and processing system specifically optimized for the hardness and yield requirements of iron ore.

Core Equipment Configuration

Primary Crushing Pioneer: Utilizing a PE1200x1500 deep-cavity jaw crusher as the first stage of the crushing process, its powerful crushing capacity and deep-cavity design easily handle the initial crushing of large pieces of hematite, ensuring that the material particle size is controlled between 150mm and 300mm, laying a solid foundation for subsequent processing.

Two powerful precision crushers: Two HPT400 hydraulic cone crushers work in tandem to further process the material after primary crushing. Through hydraulic adjustment and an automatic control system, the output particle size is precisely controlled, further improving crushing efficiency and finished product quality.

Shaping and Sand Making Tools: Subsequently, two 5X1145 sand making and shaping machines are put into operation to finely shape the material, removing excess edges and corners, and enhancing the market value of the product.

High-Efficiency Screening and Conveying: A GZD1500×6000 vibrating feeder, three YZS2160 circular vibrating screens, and a series of supporting conveyors construct a highly efficient and smooth material conveying and screening system, ensuring seamless connection between each stage, reducing waiting time, and improving overall efficiency.

Process Flow:

After blasting, the hematite ore is transported to the production line by dump trucks. First, the vibrating feeder feeds the stone into the jaw crusher at a uniform speed for primary crushing. Subsequently, the crushed material is precisely distributed by a vibrating feeder to two hydraulic cone crushers for secondary crushing, ensuring that every particle of ore receives thorough refinement. The crushed material is then rigorously screened by a circular vibrating screen; large, unqualified particles are automatically returned to the cone crusher for further crushing until the predetermined particle size is achieved. Finally, the qualified material enters a sand making and shaping machine for final processing, is then graded by a circular vibrating screen, and smoothly conveyed to the finished product area via a belt conveyor.

Customer Feedback

"This production line truly achieves a perfect combination of high efficiency and energy saving. It not only fully considers the high hardness of hematite but also significantly improves crushing efficiency while ensuring output, greatly reducing our operating costs. Both the equipment performance and the overall design demonstrate a very high level of professionalism, making it a classic example in our hematite processing field," said a representative of a mining company.

The successful implementation of this case not only provides valuable experience for mining companies but also sets a new benchmark for efficient crushing and processing in the entire industry.