The Iron Knob ore beneficiation plant in South Australia processes high-grade iron ore into premium sand and aggregate products. The crushing and sand-making line integrates advanced equipment to optimize particle shape, gradation, and yield.
1. Primary Jaw Crusher
– Model: JC120
– Feed Size: ≤800mm
– Capacity: 200–400 t/h
– Power: 110 kW
2. Secondary Cone Crusher
– Model: HPC300
– Closed Side Setting (CSS): 20–50mm
– Capacity: 150–350 t/h
3. Tertiary VSI Crusher (Sand Maker)
– Model: VSI-1140
– Max Feed Size: 50mm
– Output: 60–140 t/h (0–5mm sand)
4. Vibrating Screen
– Deck Layers: 3
– Mesh Sizes: 5mm, 10mm, 20mm
1. Coarse Crushing: Ore is reduced to ≤200mm by the jaw crusher.
2. Intermediate Screening: Oversized material is recirculated to the cone crusher.
3. Fine Shaping: VSI crusher produces cubical sand with <5% flakiness.
Q1: How is dust controlled?
A1: Wet suppression systems and bag filters are installed at transfer points.
Q2: What’s the final product application?
A2: Sand for concrete (0–5mm), aggregates for road base (10–20mm).
Whyalla Steelworks Expansion (2023) – Supplied 500,000 tons of iron-rich sand for slag conditioning using the same configuration, achieving <3% moisture content via dewatering screens.
