1. Crushing / Washing / Screening Section.
This process is aimed at breaking ore down from 40cm to < 5mm, liberating and scrubbing the Andalusite crystals to get rid of impurities. The end result is that only 30% of the original mass remains, indicating 70% is pumped to the slimes dam.
2. DMS (Dense Media Separation).
Separation with the aid of cyclones and a medium consisting of Ferrosilica and water is effected, leading to a 97% pure product. The control of light impurities is essential in this part of the process. AR prides itself as a leading authority in this regard.
The material is gently dried in a rotary kiln. The discharge temperature is of the outmost importance, in order not to damage the magnets in the next production step.
4. Magnetic separation: Fe2O3
The 97%, dried product is passed over a series of perm roll magnets where magnetic impurities are removed and where the Fe2O3 content is managed to well below 1%. At this time the product will be 99% pure – implying very low impurities. AR is a world leader in this regard with less than 0.3% contained impurities.
5. Storage, packaging and dispatch.
Final product is stored in bins, bunkers and/or bags in well-protected, rain-proof sheds. Several thousand tons can be stored as inventory at any given time. Dispatches are all in containers or trucks directly from the mine or from a warehouse at the port in the case of bags.