Ore dressing plant generally adopts three phase crushing process to crush ore: coarse-crushing, medium-crushing and fine-crushing. The most commonly used ore crushers or minetal crushers are jaw crusher, hammer crusher, impact crusher and cone crusher. 2.1m or 2.2m gyratory crusher is often used in coarse crushing (primary crushing), while 2.1m or 2.2m standard cone crusher for medium crushing, and 2.1m or 2.2m short-head type cone crusher for fine crushing. Through the coarse crushing, the size of ore is less than 1m, and after medium crushing and fine crushing, the size becomes less than 12mm. The product with suitable size will be transferred to the final product pile while product with unsuitable size will be transferred to the crusher for re-crushing. This forms a closed cycle. These mineral crusher must be your ideal choice.

The ore mill grinds the materials into fine powder by means of knocking and abrasion between the medium (steel balls, steel bars, gravel) and ore. The purpose is to dissemble the ore and achieve the proper size for the next ore processing. Ore grinding can be divided into grinding with media and without (self-grinding). It can also be divided into dry grinding and wet grinding. If the minerals with the unsuitable size return to the mill for re-grinding, it is called closed-circuit grinding. If the minerals is not returned to the mill or transferred to other mill for re-grinding, it is called open-circuit grinding. The most common ore mills in mining are ball mill, raymond mill and high pressure suspension mill. The selection of is according to customers’ requirements and the nature of the minerals.

Generally, the whole ore production line consists of jaw crusher, ball mill, classifier, magnetic separator, flotation machines, thickener, dryers and other major equipment, with feeder, bucket elevator and conveyor can be composed of a complete ore production line. This production line feature with high efficiency, low energy, high capacity, economical and so on. Big ores are fed to the jaw crusher evenly and gradually by vibrating feeder through a hopper for primary crushing. After first crush, the material will transferred to other crusher by belt conveyor for secondary crush; the crushed materials will then transferred to vibrating screen for separating. Then, the materials will be transferred into the ball mill evenly for ore grinding. After ball mill grinding, the ore fine material into the next process: classification. Because of the weight of solid particles is different, the speed of precipitate in liquid is different, according to this principle, spiral classifier can washed and classified the mixture ore. After classifying, ore particles are sent to flotation machines, depending on the mineral characteristics with different chemicals, making the needed ores and other materials to be separated.

Iron ore refers to the ore containing iron or iron compound, which is one of the most important raw materials in production of steel. There are many large-scale iron ore area which have high value of exploitation in Australia, Brazil, India, Canada, USA, Ukraine, Liberia and other countries. Main iron ores are magnetite, hematite, limonite, iron silicate ore, iron silicate mineral, etc. The most commonly used crushers in iron ore mining industry are jaw crusher, impact crusher, hammer crusher and high-efficient iron ore fine crushers, etc. In iron ore mining, customers usually choose a complete iron ore crushing production line for higher efficiency. At present, the most popular iron ore production line consists of two jaw crushers. After crushing, the material will be sent for the magnetic separation, and then into the ball mill for grinding.

It’s important to choose different crushers for different demands. In order to achieve higher production efficiency, our engineers designed a more efficient crushing and screening process:
In order to make the materials size as fine as possible before entering into ball mill, the crusher must have an excellent fine crushing capability to minish iron ore size. To achieve this crushing effect, two grades of jaw crushers and one fine crusher (high thin broken machine) are applied in the production line. Two grades of jaw crushers are coarse and fine jaw crushers which are commonly used types in crushing. Tertiary fine crushing machine is the key of the whole production line. Widely used fine crushers are hammer crusher, impact crusher, and cone crusher etc.
Hammer crushers are widely used in small quarries with small capacities. This is because in such situation, the cost and the difficult of changing and maintaining worn hammers are more acceptable to the quarry owners.However, once the quarry owners want to enhance the capacity as to above 50-60t/h by one crushing plant, hammer crushers are no longer suitable. Using hammer crusher to do a big crushing work will lead to a passive situation of high consuming cost and frequent maintenance.

Therefore, how shall we manage the iron crushing plant with high capacity?
When customer needs a capacity above 150t/h by one crusher, we’d better think about cone crusher. Cone crusher is a typical crusher adopting the principle of inter-grain laminate. It is characterized with a long life span of wear parts. Usually, the life span of the wear parts (concaves, mantles etc.) in the tertiary crushing can reach up to about three months. Long duration of wear parts saves a great cost for customers, and highly decreases the workload of maintenance.
Cone crushers are widely applied in iron ore crushing, especially in big quarry crushing. It is divided into types of spring cone crusher, multiple cylinders hydraulic cone crusher and single cylinder hydraulic cone crusher.
Spring cone crusher is more economical, but it has a bigger bulk and heavier weight. Comparing with spring cone crusher, multiple cylinders hydraulic cone crusher has great improvement in adjusting structure and iron crushing devices. However, there is no essential difference in working principles between spring cone crusher and multiple cylinders hydraulic cone crusher. Therefore, the discovery of single cylinder cone crusher is a great break through. With precise processing and manufacturing, the price of single cylinder cone crusher may be double or several times higher than spring cone crusher and multiple cylinders hydraulic cone crusher.
Of course, which type of crusher to choose in quarry and mining depends on customers’ specifications and actual situations.