Project Overview
WSHT Mining Group delivered a comprehensive iron ore processing facility for a major mining operation in the Inchiri region of Mauritania. The plant processes approximately 10 million tonnes per year of hematite iron ore to produce 6.5 million tonnes annually of high-grade concentrate for export to European and Asian steelmakers.
Process Design
The Beneficiation process uses conventional crushing, grinding and magnetic separation to upgrade low-grade hematite ore to saleable concentrate:
Crushing Circuit (Three-Stage):
- Primary jaw crusher reducing feed to -200mm
- Secondary cone crushers achieving -50mm
- Tertiary cone crushers producing -12mm product
- Pre-screening at each stage to remove fines
Grinding Circuit:
- Semi-autogenous (SAG) mill 8.5m × 4.0m
- Ball mills 5.5m × 8.5m in closed circuit with hydrocyclones
- Grind size: 80% passing 75 microns
- Recycle crushing for pebble material
Magnetic Separation:
- Low-intensity magnetic separators (LIMS) for coarse rejection
- High-gradient magnetic separators (HGMS) for fine recovery
- Tailings magnetic separation for iron recovery
- Final concentrate thickening and filtration
Iron Ore Beneficiation Plant — Mauritania
Key Equipment
- Primary Jaw Crusher PE-1200×1500
- Secondary Cone Crushers PYB-2200 (2 units)
- Tertiary Cone Crushers PYD-2200 (2 units)
- SAG Mill 8.5m × 4.0m (4.5 MW)
- Ball Mills 5.5m × 8.5m (3.6 MW each, 4 units)
- Hydrocyclone clusters (6 units)
- LIMS magnetic separators (8 units)
- HGMS magnetic separators (4 units)
- Concentrate thickener (45m diameter)
- Pressure filters (4 units)
Performance Results
- Throughput: 10.5 Mtpa (design 10 Mtpa)
- Concentrate Grade: 65.2% Fe (design 65%)
- Iron Recovery: 78% overall
- Concentrate Moisture: 8.5% (filter cake)
- Plant Availability: 93%
Project Execution Highlights
Local Content: The project achieved 40% local content as required by Mauritanian law, with extensive training programs for local workers and engineers.
Logistics: Project equipment was shipped via the deep-water port of Nouadhibou, with 95% of equipment arriving on schedule despite global supply chain challenges.
Commissioning: The plant achieved first concentrate production within 22 months of contract award, with commercial production declared within 26 months.
Since commissioning, the plant has consistently exceeded design throughput and has become a model operation for iron ore processing in West Africa.
