Magnetite Audits

Efficient operation of dense medium separation and magnetite recovery circuits is essential for the economic operation of a CPP. For example, reducing a high magnetite consumption rate from 1.2 kg/t to an accepted industry target of 0.5 kg/t ROM feed will reduce magnetite costs by ~60%. For a 10 Mt/a operation, at an assumed magnetite cost of $250/t, this represents a $1.75 M/a saving.

Using the correct magnetite grade is also important for the efficient operating of dense medium separation processes such as baths and dense medium cyclones (DMC), as the particle size distribution of the magnetite will affect medium stability. Achieving the optimum balance between medium stability and viscosity will optimise separation efficiency.
For a 10 Mt/a operation with a magnetite consumption of 1.2 kg/t ROM feed, changing to a coarser grade, at an assumed reduced cost of $10/t, will save $120,000/a.

QPS Consulting Services

QPS provides a single day audit that includes an assessment of:

• Medium stability;
• Sources of medium contamination;
• Magnetite losses over screens; and
• Magnetite losses through magnetic separators.

The subsequent report includes a detailed assessment of particular problem areas, identifies specific causes of magnetite loss and recommends changes to areas such as operating procedures and minor plant equipment modifications for a very high financial return.