Iron ore processing is indeed a technical task, and choosing the right equipment directly affects efficiency and cost. The core process is crushing, grinding, and beneficiation, with the equipment selection for the crushing stage being the most critical. It must be determined based on your ore hardness, output, and budget.

 

I. Key Points for Iron Ore Crusher Selection

 

Ore Characteristics: High-hardness, highly abrasive magnetite requires a combination of a heavy-duty jaw crusher and a cone crusher, with upgraded wear-resistant components; low-hardness hematite can be selected using an impact crusher.

 

Target Particle Size and Crushing Ratio: For coarse crushing, choose a jaw crusher with a large feed opening and high crushing force; for fine crushing requiring high fineness, an ultrafine crusher or multiple crushing operations are necessary.

 

Processing Capacity Requirements:

 

Small Mines (Daily Output < 500 tons): DHKS-750×1060 Jaw Crusher + PFQ-1310 Impact Crusher.

 

Medium Mines: HPY series hydraulic cone crusher is an option.

 

Large-scale mines: Require gyratory crushers or higher-capacity cone crushers.

 

II. Crushing Process and Equipment Configuration

Typical process: Coarse crushing → Medium crushing → Fine crushing.

 

Coarse crushing: Jaw crusher (e.g., DHKS series) or gyratory crusher.

 

Medium crushing: Single-cylinder hydraulic cone crusher.

 

Fine crushing: Multi-cylinder hydraulic cone crusher.

 

Screening: Vibrating screen for particle size classification; particles smaller than 10mm can be directly dry-separated; 10-40mm require fine crushing; particles larger than 40mm require back crushing.

 

Example of complete equipment: A 100-150t/h production line requires a raw material silo, iron remover, vibrating screen, cone crusher, vibrating feeder, jaw crusher, etc.

 

 

III. Equipment Maintenance

 

Regular inspection: Check bearing temperature weekly (stop immediately if it exceeds 70℃).

 

Lubrication management: Add approximately 1kg of special grease per ton of material.

 

Replacement of Wear Parts: High-hardness ores require shorter maintenance cycles for components such as hammers and liners.

 

IV. Market Equipment Reference

 

Horizontal Rod Mill: Suitable for medium and fine crushing, prices range from tens of thousands to hundreds of thousands of US dollars.

 

Metal Ore Processing Cone Crusher: Suitable for medium and fine crushing, prices range from tens of thousands to hundreds of thousands of US dollars.

 

V. Selection Guidelines

 

Matching Ore Hardness: Avoid using an impact crusher alone for high-hardness ores, as this can lead to frequent hammer replacements.

 

Considering Material Moisture Content: When the moisture content exceeds 15%, a sand washing machine needs to be added before the jaw crusher.

 

Balancing Investment and Cost: Although cone crushers have a high initial investment, long-term use can reduce overall costs.

 

VI. Summary

The key to iron ore crusher selection lies in equipment matching, process optimization, and cost control. It is recommended to conduct ore analysis first, then select equipment based on output and budget, and consult professional manufacturers if necessary.