Introduction and Application of Limonite magnetic separator
The limonite ore beneficiation process includes limonite ore crushing, magnetic separation and flotation. This passages tells you how to produce iron ore concentrate and the limonite beneficiation equipments.
Limonite crushing and grinding
Very low grade limonite iron ore in large lumps need to crush and grind, in order to be sized into required dimension. The common crushing machines used in iron ore beneficiation plant are jaw crusher as primary crusher, cone crusher or fine jaw crusher as secondary crusher. The iron ore materials of required size after screening then pass to the flotation process. Wet ball mill is used to grind limonite ore in powder, of which 70% is 0.076mm is size.
The common iron ore crushers are jaw crusher (for primary crushing), cone crusher or fine jaw crusher (for secondary crushing). Materials in large lumps are reduced by crushers into small particles and then separated by vibrating screen. Large ones return to crushing process, while small ones pass to milling step.
High intensity magnetic separation
Limonite ore after classifier passes to high intensity magnetic separator. High iron content (+47.69%) limonite ore is moved to thickener and low iron content one to high intensity magnetic scavenger separation. the middlings are mixed with rough middlings for thickening process, while the rest ones are discharged as tailings.
First thickening, classification and grinding
After first thickening, low iron content (-47.25%) limonite ore is moved to ball mill to be grinded into finer powder (90% < 0.067mm). The fine ore powder is mixed with middlings after first thickening for second thickening process.
Second thickening
The second thickening is conducted for further upgrading of limonite iron ore. The product with iron content lower than 40.08% returns to scavenging, and the one higher than 49.04% passes to reverse flotation.
Reverse flotation
Reverse flotation includes rough flotation and clean flotation, through which Limonite iron ore would be greatly upgraded. The iron concentrate obtained is of 56.73% in content. The middlings return to magnetic flotation, forming a close-circle process.

Features of Limonite magnetic separator
1. Widely used: to complete more than 30 mineral processing of iron needs; 
2. Operation is simple: one person can complete the entire magnetic separation process; 
3. Save costs: low energy consumption and saving over the past more than 45% magnetic separation equipment; 
4. Poor in iron, broken or crushed by the thick rough after the election, remove rock and other waste rock, improve quality, reduce the load on the next process.