In nature, there are many types of iron minerals. The minerals with primary industrial value are Magnetite, Hematite, and Pseudo-hematite, followed by Siderite and Limonite. As the foundation of the steel industry, natural iron ore must undergo a series of rigorous processes—such as crushing, grinding, magnetic separation, flotation, and gravity separation—to produce high-grade iron concentrate.

Because iron ore generally possesses physical characteristics of high hardness and strong abrasiveness, the efficiency of the crushing stage directly affects the feed particle size for the Ball Mill as well as the overall operational costs of the processing plant.

300 TPH Iron Ore Crushing Flowsheet Design: Three-Stage Process

or a capacity of 300 tons per hour (TPH), ZME recommends the classic Three-Stage Crushing (Primary, Secondary, Tertiary) + Closed-Circuit process. This flowsheet maximizes the application of the “More Crushing, Less Grinding” principle to optimize downstream processing efficiency.

• Stage One: Primary Crushing (Coarse Crushing) Raw material is evenly fed by a ZSW Series Vibrating Feeder into the Jaw Crusher. The primary task of this stage is to rapidly reduce the size of large run-of-mine ore boulders, preparing the material for secondary crushing.
• Stage Two: Medium & Fine Crushing (Cone Crusher) The coarsely crushed ore is transferred via belt conveyor to a Primary Cone Crusher or Secondary Cone Crusher. The Cone Crusher utilizes the laminated crushing principle, which is highly ideal for handling hard materials like iron ore, significantly reducing spare parts wear.
• Stage Three: Screening Classification & Closed Circuit The crushed material is screened using a Vibrating Screen.
  • Undersize Material: Ore that meets the size specifications (typically the ideal feed size for the Ball Mill) is sent to the final product stockpile.
  • Oversize Material: Ore that fails to meet the required size specification is recirculated from the vibrating screen back into the Fine Cone Crusher for re-processing, forming a closed circuit.

Core Equipment Configuration List for 300 TPH Iron Ore Production Line

No.	Equipment	Model	Process Stage	Qty	Power	Function
1	Vibrating Grizzly Feeder	ZSW490×110	Feeding	1 Unit	15–22 kW	It feeds raw ore evenly and continuously into the jaw crusher. The grizzly bars screen out fine material (<100mm) to reduce the primary crushing load.
2	Jaw Crusher	PE900×1200	Primary Crushing	1 Unit	110–132 kW	Handles hard iron ore with an input size of up to 750mm and reduces it to 100–200mm using a deep cavity design.
3	Standard Cone Crusher	HP300 atau GP300 (Tipe Standar)	Secondary Crushing	1 Unit	220–250 kW	Utilizes the laminated crushing principle to extend liner service life while maintaining high capacity when processing abrasive materials.
4	Short Head Cone Crusher	HP300 atau GP300 (Tipe Fine)	Tertiary Crushing	1 Unit	220–250 kW	Crushes material down to <15mm, increasing Ball Mill efficiency and lowering total energy consumption.
5	Vibrating Screen	2YK2460 (atau model lebih besar)	Screening	2 Unit	30 kW × 2	Precisely classifies material; oversize material is returned to the cone crusher to form a closed circuit.
6	Belt Conveyor System	B800 / B1000	Material Conveying	1 Set	Customized	Connects all process stages using heavy-duty belts and impact rollers to ensure automated material flow.
7	Sistem Kontrol Elektrik	Kabinet Kontrol Terpusat PLC	Control System	1 Set	—	Controls the line’s start-stop operations, monitors motor current, provides overload protection, and triggers hydraulic system alarms.

Production Line Performance Advantages

• Fine Milling Input Size & Energy Efficiency: ZME’s multi-stage Cone Crusher configuration produces fine and uniform ore, reducing the Ball Mill load and improving energy savings by 15%–20%.
• High Automation Level: Equipped with an advanced PLC electrical control system for one-touch sequential start-stop, reducing labor intensity and minimizing the risk of operational errors.
• Low Operational Costs: The primary equipment utilizes wear-resistant alloy materials. ZME’s custom component design effectively extends liner replacement cycles when processing abrasive iron ore.
• Eco-Friendly Standards: Supports enclosed conveying systems and dust collector configurations, fully meeting modern green mine development requirements.

ZME provides comprehensive process flowsheet solutions and technical support for our clients. Whether processing Magnetite or Hematite, our 300 TPH production line can be flexibly engineered to match your local site installation conditions, ensuring high-quality ore output for the success of your mineral processing business.