Magnesite (MgCO3), the naturally occurring carbonate of magnesium (Mg) is one of the key natural sources for the production of magnesia (MgO) and subsequently fused magnesia. Magnesite occurs in two distinct physical forms: macro crystalline and cryptocrystalline. Cryptocrystalline magnesite is generally of a higher purity than macro crystalline ore, but tends to occur in smaller deposits than the macro crystalline form. Therefore ,magnesite ore process flow is needed.
Magnesite Processing Flow
Beginning with open cast mining of Magnesite (MgCo3), the process of transformation into the best of basic refractories follow the stages of preparation and processing as shown in Chart which presents a typical process flow diagram.
The selected grade of Magnesite is sized by primary crushing, screening and washing before being fed into the High Temperature Rotary Kilns (50-100 TPD capacity). The DBM (Dead Burnt Magnesite) obtained is further sized to the desired standards.
The meticulously formulated compositions are pressed into a variety of shapes and sizes in an array of presses including high capacity hydraulic presses.
The bricks are dried and fired in state-of-art High Temperature Tunnel kiln from where they are sent for finishing, testing/inspection and packing before being forwarded to a wide range of customers across the country.
Magnesite Processing Machine
Depending on hardness of material, different types of crushing and grinding equipment are used.(Mineral Grinding Plant For Sale) The improved machinery now available is: Higher width jaw crushers（jaw crusher price）; Rock-on Rock crushers, which obviate the use of conventional Gyratory-Cone-Crushers（cone crusher for sale） and Roll Crushers and are a better choice.
In case of relatively softer materials, impact mills and vibro-grinding mills provide the required range of particle sizes.
All refractory materials need to be free from metallic iron introduced during the comminuting operations. The new rare earth magnetic separators provide excellent alternatives, both in terms of productivity and energy consumed, compared to Induced Electro Magnetic Separators.
Mixers are the most essential piece of equipment in the manufacture of refractories-shaped or unshaped. The new generation high intensity mixers, though require higher power to operate, take less time to make a better mix.
Conventional Counter current mixers would have taken 40-45 minutes to produce the consistency now possible in 10 minutes on these high intensity mixers.
Presses are the major consumers of power in ceramic & refractory industry. Several developments have taken place in this area. In refractory industry, hydraulic presses are essential to achieve higher quality consistency and productivity. Though friction screw presses are the choice, when capital is scarce it is advisable to go for hydraulic presses. For small volume high precision refractories, specialized vibro-pneumatic presses may be a better alternative to conserve energy and capital. Iso-static presses are also finding increasing application in the production of sophisticated concast (CC) refractories like sub- merged nozzles and shrouds and also in the production of industrial ceramics. The bricks are flat and uniform with iso-static presses and the presses are also compact.
Kilns and Dryers are the major consumers of energy (thermal energy) in ceramics & refractory industry. The industry has seen the most energy inefficient down draft kiln to the modern kilns tunnel/ shuttle and roller kilns. For high volumes, Tunnel kilns are very efficient and for low volumes, shuttle kilns with high velocity burners may be preferred.
The major losses in kilns occur because of:
• Insulation loss;
• Exhaust loss; and through
• Intermittent operation.
The suggestions for energy conservation are as follows:
• Insulate the furnace with proper insulating material such as ceramic fiber, hot face insulating refractory.
• Proper combustion control system is essential to optimize fuel consumption.
• Waste heat recovery system, typically the gases from the cooling zone area
are sent to heating zone.
Magnesite Processing Machine Manufacturer
Shanghai Zenith is a professional magnesite processing machine manufacturer. We can supply all kinds magnesite processing machine, magnesite crusher, magnesite grinding mill and design magnesite processing plant according to the requirements of customers. Our magnesite processing machine have exported to South Africa, USA, Australia, Russia, Canada, Egypt, Nubia, Peru, Indonesia, Brazil, Nigeria, Papua New Guinea, Kenya, Zimbabwe, Zambia, Oman, Ghana, Mexico, Philippines, Zimbabwe, Argentina, Guinea, etc.