Cradle to Gate
Identity ID
d8cd64e4-47fc-4b15-8c2e-9ede680fd7a4
Materials
Associated ID
7387b0a8-d45d-4024-b9c8-e108314e9411
Included activities starts
Included activities ends
Description
This dataset represents the life cycle inventory (cradle-to-gate) of magnetite processing in Hunan using a process flow of multi-stage crushing, strong magnetic separation, two-stage ball milling, and multi-stage magnetic separation to produce iron concentrate. It covers all activities associated with iron concentrate beneficiation production, but excludes direct and indirect greenhouse gas emissions from the production of crushing equipment, magnetic separation equipment, personnel transportation, and daily office operations during the beneficiation process. The dataset was compiled from multiple data sources based on national standards such as the 'Manual of Production and Emission Coefficients for the Iron Ore Mining and Processing Industry (0810)', 'Emission standard of pollutants for mining and mineral procressing industry (GB 28661-2012)', 'Cleaning production standard Iron ore mining and mineral processing industry', and 'The norm of the energy consumption per unit product of iron ore dressing(GB31337-2014)'. It represents the average production level of multi-stage crushing - high-intensity magnetic separation - two-stage ball milling - multi-stage magnetic separation processing of magnetite in Hunan.
Activity Description
This dataset describes the magnetite ore processing technology in Hunan Province, involving multiple stages of crushing, high-intensity magnetic separation, secondary ball milling, and multiple magnetic separation to produce iron concentrate. The process steps are as follows:
1.1 Primary Crushing
Equipment: Jaw crushers or gyratory crushers are typically used. Jaw crushers are suitable for coarse crushing of large-sized ore, characterized by high crushing ratio and strong processing capacity.
Particle Size Requirement: The ore should be crushed to a particle size of 10–30 mm to ensure the subsequent high-intensity magnetic separation process can be effectively carried out.
2. 3. High-Intensity Magnetic Separation
Equipment: High-intensity magnetic separators, typically wet-type devices, are used. This method is suitable for recovering highly magnetic iron minerals, such as magnetite.
Operation: The ore slurry is fed into the high-intensity magnetic separator, where magnetic minerals are captured and separated by the magnetic field, while non-magnetic impurities are discharged with the slurry. The magnetic iron minerals are recovered and sent to subsequent processing stages.
4. Secondary Crushing
Equipment: Cone crushers or impact crushers are commonly used. The required particle size after crushing at this stage is relatively fine, typically 5–10 mm.
Process Characteristics: Further crushing helps liberate residual iron minerals within the ore, enhancing the efficiency of subsequent magnetic separation and grinding operations. Magnetic Separation
Equipment: Wet medium-intensity magnetic separators are typically used, suitable for separating minerals with medium to low magnetism.
Operation: During the magnetic separation process, magnetic minerals are attracted and held on the magnetic drum, while non-magnetic minerals are discharged. The iron minerals obtained from magnetic separation are sent to the subsequent grinding stage, while non-magnetic residues are discarded as tailings.
5. Secondary Ball Milling
Equipment: Ball mills are used for secondary grinding. The first-stage ball milling grinds the ore to 0. A particle size of around 0.074 mm, followed by secondary ball milling to further reduce the particle size. Operation method: The secondary grinding stage employs spiral classifiers or hydrocyclones for classification; the slurry meeting the required particle size proceeds to the subsequent magnetic separation process, while coarse particles that do not meet the specifications are returned to the ball mill for re-grinding. Concentrate Magnetic Separation
Equipment: High-efficiency wet magnetic separators are used for purifying the concentrate. The magnetic field strength of the magnetic separation equipment can be adjusted according to the grade of iron minerals.
Operation: After secondary ball milling, the ore slurry undergoes magnetic separation, in which magnetic minerals are attracted and separated to form high-grade iron concentrate. The tailings are discharged to a tailings pond or treated as waste rock.
Process Description
In this dataset, the iron ore concentrate has a grade of 61%, belongs to transition metals, and is the primary product of the mineral beneficiation process. Typically in powder form, iron ore concentrate is widely used in downstream processing at sintering and pelletizing plants, serving as a key raw material for steel production.
Time period
2022
2026
Geography
China,Hunan
Geography comment
Forming Hunan's average data through merging data from multiple sources
Macroeconomic value
Business-as-Usual
Data validation
Yes
Technology
Current Technology
Technology comment
The multi-stage crushing-high intensity magnetic separation-two-stage ball milling-multi-stage magnetic separation process effectively separates iron minerals from iron ore by removing impurities through repeated crushing, high intensity magnetic separation, ball milling, and multi-stage magnetic separation, thereby enhancing the grade of the final iron concentrate. This process is suitable for the extraction of minerals such as magnetite, particularly for ore deposits with high iron content but complex ore structures.