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These days, high-end manufacturing, 3D printing, additive manufacturing, and powder metallurgy are all growing at a really fast pace. For this reason, ultra-pure iron concentrate has turned into a key material that supports the whole new materials industry. Compared with ordinary iron concentrate, this product has much stricter demands for grade, impurity limits, and particle size distribution. Traditional mineral processing methods simply can’t keep up with stable running, large-scale output, and high-precision purification all at once.
With years of real-world technical experience and full‑cycle EPC capabilities, Xinhai Mining has completed the 100,000 TPY ultra-pure iron concentrate purification project. We used a combined magnetic separation and flotation process to achieve deep impurity removal and highly efficient purification. This solution provides steady, practical raw material support for high-end new materials, and it also stands out as a key benchmark project for our company in the ultra-pure iron field.
As “Made in China 2025” takes effect, new materials have become a national strategic focus. Spherical metal powder, laser cladding, high-end powder metallurgy, and similar fields are expanding quickly. These high-end applications have really high standards for raw iron materials — not only high iron grade, but also tight control over silicon, manganese, sulfur, phosphorus, and acid-insoluble impurities.
On the current market, regular iron concentrate often falls short. It’s simply not pure enough, contains too many impurities, and fails to meet particle size requirements. That’s why a stable, low-maintenance, high-precision purification line became necessary. The owner decided to upgrade an existing workshop to build exactly this kind of production line. It’s not just a factory upgrade; it’s a critical supporting project for the entire high-end new materials sector.
This project is delivered by Xinhai Mining under full-process EPC general contracting. We take care of everything from mineral processing tests, engineering design, and process planning to equipment manufacturing, installation, commissioning, worker training, and full support of electrical and installation materials. Only on-site civil construction is handled by the client.
Capacity: 500 tonnes per day, 100,000 tonnes per year of ultra-pure & high-purity iron concentrate
Raw material: Magnetite powder with TFe ≥ 65%
Products: Ultra-pure iron concentrate TFe ≥ 71.5%; High-purity iron concentrate TFe ≥ 70%
Grinding fineness: 90% passing -400 mesh
Core process: Combined magnetic separation and flotation deep purification
Operation requirement: Continuous running for at least 3 years; 3‑year overhaul cycle; one running, one standby for wearing parts
From the very beginning, this project was designed for high precision, long service life, and low maintenance costs. We aimed to build a truly reliable industrial production line that leads the domestic market.
Based on actual ore properties and final product demands, Xinhai created a full production flow: closed-circuit grinding, multi-stage magnetic separation, and reverse flotation. This combination ensures both grade and impurity targets are fully met.
Grinding & Classification System: Material goes through primary grinding, roughing magnetic separation, and cyclone classification. It then enters secondary closed-circuit grinding. We precisely control fineness to 90% passing -400 mesh, which creates ideal conditions for later purification.
Magnetic Separation & Flotation Purification: The material goes through five stages of magnetic cleaning and scavenging. It then enters desulfurization flotation and six stages of reverse flotation. This step deeply removes silica, manganese, sulfur, phosphorus, and acid-insoluble substances.
Dewatering System: Ultra-pure and high-purity products use separate dewatering lines. Each includes a magnetic thickener and ceramic filter, so moisture stays stable, and product quality stays consistent.
Tailings Dry Stack & Water Recycling: Tailings are thickened and filter-pressed for dry stacking, a much more environmentally friendly approach. Almost all process water is recycled and reused, reducing water use and lowering operating costs.
Since being put into use, the system has run smoothly and reliably. Every key performance index has reached or even gone beyond the original design requirements.
Ultra-pure iron concentrate stays steadily above 71.5% TFe; high-purity grade above 70% TFe
Ultra-pure yield ≥ 70%; high-purity yield ≥ 20% — resource usage is highly efficient
Impurities strictly controlled: AIC ≤ 0.20%, Si ≤ 0.08%, S ≤ 0.020%, P ≤ 0.015%
The system can run nonstop all year, with low maintenance costs
Renovated from an old workshop, so the investment is lower, the construction is faster, and production starts sooner
The final product can be directly used in 3D printing, additive manufacturing, laser cladding, and powder metallurgy iron concentrate production. It really does ease the pressure of high-end raw material supply.
This project is Xinhai’s very first benchmark in ultra-pure iron concentrate purification, and it marks several important breakthroughs for our team.
Real technical progress: We mastered deep purification, high-precision classification, and long‑period stable operation — challenges many companies still struggle with.
Full EPC delivery: We handle the whole process in one stop. This shortens the timeline, reduces risk, and makes it a typical model for high-purity iron ore EPC general contracting.
Effective deep purification: Magnetic separation plus reverse flotation easily meets the strict raw material standards for 3D printing and powder metallurgy.
Stable long-term design: Equipment is properly matched, key parts have backups, and the whole system is built for consistent, low-cost running.
Smart old-plant renovation: We made full use of existing buildings to cut investment and speed up commissioning.
The 100,000 TPY ultra-pure iron concentrate project is a major milestone for Xinhai Mining. It shows our shift from standard mineral processing toward high-purity mineral deep processing and high-end new material support. With our proven ultra-pure iron concentrate purification technology, high-standard equipment, and full EPC capabilities, we deliver efficient, stable, and large-scale production.
In the future, we will keep focusing on high-precision mineral purification. We plan to offer more professional, cost-effective EPC solutions for new energy, additive manufacturing, powder metallurgy, and other growing industries. Through steady technical innovation, we will keep supporting the healthy development of high-end manufacturing around the world.
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