Project Overview
• Project Name: Hematite Ore Processing with Tin Recovery
• Location: TBD, Laos
• Feed Capacity: 500 tonnes per day (tpd)
• Ore Grade:
o Iron (Fe): 50%
o Tin (SnO₂): 500 ppm
• Target Products:
o Iron Concentrate: >62% Fe
o Tin Concentrate: >72% Sn
1. Key Highlights
• Main Focus: Processing hematite ore to produce a high-grade iron concentrate and recover valuable tin from tailings using gravity and electrostatic separation.
• Efficient Recovery: Process designed to achieve:
o Iron recovery: 80–85%, producing Fe concentrate with >62% Fe.
o Tin recovery: 70–75%, yielding Sn concentrate with >72% Sn.
• Technologies: No flotation is involved. Tin is recovered using gravity separation followed by electrostatic separation for final concentrate upgrade.
2. Process Flow Summary
Step-by-Step Process:
1. Crushing & Grinding:
o Purpose: Liberate hematite and cassiterite (SnO₂).
o Equipment: Jaw crusher, cone crusher, ball mill.
o Grind Size: 80% passing 150 µm.
o Output: Ore ready for separation with 50% Fe and ~500 ppm Sn.
2. Magnetic Separation (Iron Recovery):
o Equipment: Wet High-Intensity Magnetic Separator (WHIMS).
o Purpose: Recover iron (hematite) and produce concentrate with >62% Fe.
o Recovery: 80–85% Fe from ore.
3. Gravity Separation (Tin Recovery):
o Equipment: Shaking tables for initial tin concentration.
o Purpose: Recover tin-rich concentrate (~30% Sn) from tailings.
o Recovery: 60–65% of tin.
4. Electrostatic Separation (Tin Upgrade):
o Equipment: Electrostatic separator.
o Purpose: Upgrade tin concentrate to >72% Sn.
o Recovery: Additional 10–15% of Sn from gravity concentrate.
3. Equipment Specifications
| Equipment | Type | Key Specs |
Primary Crusher | Jaw Crusher | 160 kW motor, output size <150 mm |
Secondary Crusher | Cone Crusher | 132 kW motor, output size <25 mm |
Grinding Mill | Ball Mill | 800 kW motor, 80% passing 150 µm |
| Magnetic Tramp Iron Separator | WHIMS / HGMS | 10,000–15,000 Gauss, 0.15 mm feed |
Tin Separator (Gravity) | Shaking Table | Feed <1 mm, 60–65% tin recovery |
Tin Separator (Electrostatic) | Electrostatic Separator | 20–40 kV, tin concentrate upgrade to >72% Sn |
4. Material Balance & Estimated Recovery
| Stage | Total Fe (%) | Sn (ppm) | Recovery (%) | Comments |
ROM | 50% | 500 | 100 | Run-of-mine ore |
Magnetic Separation | 62-65% | -50 | Fe: 80-85% | Iron concentrate |
Tailings (to Tin Recovery) | <15% | 300 | Sn: 60-65% | Tin recovered via shaking tables. |
Electrostatic Separation | <5% | >72% | Sn: 10-15% | Final tin concentrate upgrade to >72% Sn. |
Final Products | 62-65% | >72% | Fe: 80-85%, Sn: 70-75% | Target product grades achieved |
5. Capital and Operating Costs
• CAPEX:
o Crushing & Grinding: $4–6 million.
o Magnetic & Gravity Separation: $5–7 million.
o Electrostatic Separator: $1.5–2 million.
o Total Estimated CAPEX: $10–15 million.
• OPEX:
o Estimated $20–25 per tonne of ore processed.
o Power consumption, consumables (grinding media, maintenance), labor costs are key contributors.
6. Risks & Opportunities
• Risks:
o Ore Grade Variability: Variability in iron and tin grades could impact recovery efficiency. Mitigated by ore sorting and real-time monitoring.
o Tin Recovery Challenge: Fine particle cassiterite recovery through gravity and electrostatic methods must be optimized through pilot testing.
• Opportunities:
o Increased Tin Price: Tin prices are highly favorable in current markets, with the potential for increased revenue from tin concentrates.
o Sustainable Processing: No flotation used, and electrostatic separation requires minimal water, reducing environmental impacts.
7. Environmental Considerations
• Tailings: Proper tailings management required. Non-toxic tailings will contain residual iron and gangue minerals.
• Water Use: Minimal water requirements, especially in electrostatic separation, allowing for efficient recycling and reduced freshwater consumption.
• Permitting: Environmental permits for tailings disposal and water use will be critical.
8. Revenue & Economic Analysis
• Iron Concentrate Revenue:
o Price: $90–120/tonne (depending on Fe market).
o Total Iron Production: ~250 tpd.
• Tin Concentrate Revenue:
o Price: $25,000–30,000/tonne of Sn.
o Tin Concentrate Production: ~0.35 tpd.
• Payback Period: Estimated 4–5 years, depending on metal prices, recovery rates, and operating costs.
9. Next Steps
• Pilot Testing: Finalize tin recovery efficiency through pilot tests of the electrostatic separator.
• Engineering Design: Prepare a detailed plant design with equipment sizing.
• Environmental Studies: Conduct impact assessments for permitting and approval.