Iron Ore Beneficiation Plants
Retro-fit wet processing that unlocks medium-grade ores, lifts Fe value by 3–4 points and cuts your cost of steel production.
Iron ore beneficiation washes and screens mined ore before it reaches the furnace, removing silica, alumina and clay. CFlo's wet processing plants deliver a 3–4 percentage point increase in Fe value, cut coke consumption by up to 6%, and recover calibrated lump ore down to 2 mm, even through the monsoon.
Small quality gains, large cost impact
Even a modest improvement in raw material quality has a significant impact on final product quality and the cost of steel production. CFlo iron ore processing plants retro-fit to your existing Raw Material Handling (RMH) system, washing mined ore before it is fed to the furnace and delivering measurable efficiencies across the operation.
Clean Calibrated Lump Ore (CLO) for efficient kilns
Accurate wet screening unlocks the true value of medium-grade iron ores, reducing reliance on purchased high-grade ore and cutting raw material costs. CFlo's calibration systems deliver:
- 3–4 percentage point increase in Fe value
- Significant reductions in silica, alumina and clay
- Improved metallisation, resulting in higher productivity
Less silica, less coke
Silica and impurities demand extremely high temperatures to burn off: the more silica in the raw material, the more energy consumed producing the ore oxide. CFlo's wet screening technology is extremely efficient at removing minus 60 micron material, and with it significant levels of silica, alumina and clay. Perfectly calibrated clean ore reduces coke consumption by up to 6%.
Maximum recovery, all year round
CFlo wet screening efficiently recovers material down to minus 2 mm at highest efficiency throughout the year, including the monsoon season, where traditional dry screens fail. That means:
- Recovery of 2–20 mm calibrated iron ore, considerably improving overall economics
- Processed minus 2 mm recovered as a by-product suitable for sinter feed or pelletising
Longer campaign life, delivered by Oremax
Fine particles and alumina in the feed end up as accretions on kiln walls, so lower alumina means far less kiln cleaning and maintenance. Clients report up to 30% increase in campaign life and higher kiln productivity, plus reductions in phosphorus content of 0.005% and more. Wet screening also cuts dust accumulation in the dust cleaning system.
The platform is Oremax, CFlo's modular wet processing range for iron ore beneficiation, a Next-Gen 'Super' System: Super modular for retro-fit into existing RMH systems, Super smart process control that holds calibration quality while reducing water and power, Super easy app-guided installation and service. It runs in the field at SAIL's Kiriburu Iron Ore Mine, Jai Balaji Jyoti Steel and Pacific Industries, each documented in a case study.
See it in action
Frequently asked questions
What does iron ore beneficiation actually improve?
Washing and wet screening remove silica, alumina, clay and minus 60 micron fines before ore reaches the furnace. CFlo plants deliver a 3–4 percentage point increase in Fe value, improved metallisation and up to 0.005%+ reduction in phosphorus, letting you run medium-grade ores instead of buying only high-grade.
How much coke does calibrated iron ore save?
Up to 6%. Silica and impurities require extremely high temperatures to burn off, so every point of silica in the feed consumes energy. By removing minus 60 micron material, and with it significant silica, alumina and clay, wet screening cuts the coke consumed per tonne of production.
Can a beneficiation plant be added to my existing plant?
Yes. CFlo iron ore processing plants are designed to retro-fit to your existing Raw Material Handling (RMH) system, processing mined ore before it is fed to the furnace. The modular Oremax range keeps installation fast and the footprint compatible with an operating site.
Does wet screening work during the monsoon?
Yes, and that is a key advantage. CFlo wet screening recovers material down to minus 2 mm at highest efficiency all year round, including monsoon season, where traditional dry screens fail on wet, sticky feed. That protects recovery of 2–20 mm calibrated lump ore through the wettest months.
What happens to the minus 2 mm fraction?
It is recovered as a saleable by-product suitable for sinter feed or for pelletising, rather than being lost as waste. Combined with recovery of the 2–20 mm calibrated lump, this considerably improves the overall economics of the beneficiation circuit.
How does cleaner ore extend kiln campaign life?
Fine particles and alumina in the feed form accretions on kiln walls, forcing cleaning shutdowns. Lower alumina feed means considerably less kiln cleaning and maintenance: clients report up to 30% longer campaign life and higher kiln productivity, plus less dust accumulation in the dust cleaning system.
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