Flowsheet Design of Pilot Beneficiation Plant for Melka Arba Iron and Some Essential Minerals in Ethiopia Using METSIM

Ethiopia possesses abundant mineral resources, including coal, iron, lithium, niobium, chromium, gold, and tantalum, yet faces challenges in efficiently utilizing these for economic development. A lack of dedicated pilot-scale beneficiation simulation flowsheets has hindered research and optimization of extraction techniques. This study proposes a common pilot beneficiation plant flowsheet using METSIM software, tested through simulation of Melka Arba iron ore magnetic separation. Equipment selection was guided by mineralogical analysis and literature review to suit Ethiopian ores, integrating industry-standard crushers, mills, and separation methods (magnetic, gravity, flotation) to streamline operations and reduce redundancy. METSIM simulations demonstrated nearly 86% magnetite recovery, validating magnetic separation’s effectiveness. Mass balance confirmed successful separation of magnetite from gangue minerals. These results provide a solid foundation for process optimization, enhancing recovery, efficiency, and economic viability. The proposed pilot design offers a scalable framework to modernize Ethiopia’s mineral processing industry and address the lack of standardized beneficiation approaches.