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The metal ore crushing plant, as illustrated in the ilmenite beneficiation flow chart, operates through a meticulously designed sequence of comminution and separation stages. The process begins with ​​primary crushing​​, where raw run-of-mine (ROM) ore is consistently fed by a vibrating grizzly feeder into a ​​PE (Primary Efficiency) Jaw Crusher​​. This initial stage reduces large, coarse ore lumps to a manageable size.

The output from the jaw crusher is then conveyed to a ​​secondary crushing​​ stage, typically performed by a ​​Cone Crusher​​. This equipment further reduces the ore particle size, ensuring it is prepared optimally for the subsequent grinding circuit.

Following secondary crushing, the crushed material is directed onto a ​​Vibrating Screen​​ (or a multi-deck screen series) for ​​particle size classification​​. The oversize material (which does not meet the target size specification) is recirculated back to the cone crusher for further reduction in a closed-loop system. The correctly sized, or “screen undersize,” product is discharged and transported to a ​​small-size ore bin​​, which acts as a regulated surge capacity hopper, ensuring a steady and continuous feed for the downstream grinding mills.

From the ore bin, the material is fed via a belt feeder or conveyor into ​​Ball Mills​​ for the ​​grinding​​ (or tertiary crushing) phase. Here, the ore is pulverized with steel balls to liberate the valuable mineral grains (ilmenite) from the worthless gangue material, creating a slurry.

The subsequent processes include:

• ​Classification:​​ The ground slurry is fed into hydrocyclones or spiral classifiers, which separate particles based on size and density. The coarse particles are returned to the ball mill for further grinding (forming a closed grinding circuit), while the fine slurry proceeds.
• Desliming:​​ This critical step removes ultra-fine clay and silt particles (slimes) that can interfere with the efficiency of the downstream magnetic separation. This is often also achieved using hydrocyclones.
• ​Magnetic Separation:​​ The deslimed slurry is processed through a ​​High-Gradient Magnetic Separator (HGMS)​​. Ilmenite is a ferromagnetic mineral, and the HGMS powerfully attracts and separates it from the non-magnetic gangue minerals, producing a magnetic concentrate.
• ​​Concentration and Filtration:​​ The magnetic concentrate may undergo additional cleaning steps and is then thickened to increase solids density. Finally, it is dewatered using ​​Disc Filters​​ or a similar filtration system to create a damp filter cake, which is the final ilmenite concentrate product ready for transport or further processing.

Throughout this process, the non-magnetic ​​tailings​​ from the magnetic separator are channeled to a tailings storage facility (TSF) for responsible, environmentally sound disposal, often involving water recovery and recycling.