The innovative gaustec^® technology from allmineral has been widely used with success in ore processing around the world for some years. Continuous R&D has resulted in further major improvements in wet high-intensity magnetic separation. With an unsurpassed throughput capacity of up to 1,400 t/h, the new gaustec-GHX is “particularly efficient and cost-effective at processing low-grade iron ore into marketable high-grade pellet feed fines” says allmineral. Increased global demand for raw materials, combined with a steady decline in the quality of the mineral raw materials in demand, has generated new interest in the development of high-intensity magnetic separators with larger capacities. The company said that many factors make the gaustec-GHX an innovative solution: numerous improvements, vastly simplified maintenance, reduced energy consumption, smaller plant layout, and greater flexibility through variable customised settings, as well as the high throughput capacity.

Although low-grade iron ore mines will benefit from the new technology, the main focus is on reclaiming low-grade iron ore tailings from ponds, with huge positive environmental and economic benefits. Based on the new gaustec-GHX technology, construction work on a processing plant designed to process iron ore tailings with a 45% Fe grade began at the Itaminas mine in Brazil at the end of 2012. The plant went into operation in mid-2013 with a feed capacity of 480 t/h and has three processing stages (rougher, cleaner and re-cleaner) in a single unit at 2.5 mm matrix gap.The quality of the pellet feed product reaches 65% Fe with an average tailings grade of 35%, approximately equivalent to a 30% plant yield. The high performance of the first gaustec-GHX led to the construction of a second plant of the same type for further downgrading the tailings to <20% Fe. The plant is scheduled for commissioning in 2014.