Communition Circuit Flowsheet Development for Optimum Performance of Iron Ore Processing, in the Case of Sekota, Wagehemira, Northern Ethiopia

Comminution flow sheet design is a critical process in the production of iron ore. In this study, the flow rate was fixed at 150 t/h with the Crusher specification of a Cedarapids JC24x36 jaw crusher model and a Nordberg Hp 300 S/M cone crusher. Based on the mineralogical information and ore properties provided the Agg Flow Version 460.22 software is used to conduct, a comprehensive comminution flow sheet design to achieve the desired particle size distribution. In the comminution of primary crusher stage Iron ore at top size of 42 inches or (1066.8 mm) generates 5 different ranges of materials, the first is at a size of 45 mm, the second at 10 mm, and the third is at 8 mm, between 15 and 8 mm and between 23.5 and 15 mm. The primary crusher, a Cedarapids JC2436 Model Jaw crusher, was required to reduce the feed size with closed side setting of 69.85 mm to a manageable size of end product 21 Mtph for further processing. The Nordberg Hp 300 S/M cone crusher was used as a secondary crusher with closed side setting (CSS) of 28 mm to further reduce the particle size to 26 Mtph. To complete the task several choices analyzed and as final design used 1 jaw crusher Cedarapids Jc 2436, and two cone crushers Nordberg HP 300 S/M. some screening and conveyors placed in the design to increase the reduction ratio of the equipment.