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In our previous studies, we investigated the performance of a novel pneumatic planar magnetic separator (PMS) for the dry beneficiation of a selected magnetite ore. In the present study, we have extended the studies on the PMS with the focus on investigating how various PMS processing flowsheet configurations influence its performance. The outcomes were subsequently compared with those of a Davis tube recovery (DTR) tester. The study demonstrated that the use of PMS in the dry beneficiation of magnetite ores is feasible, and operating the PMS in different flowsheet configurations positively influences the magnetite concentrate grade and purity. Finally, the study showed that the PMS performance compares well with that of DTR and can potentially replace DTR in operations that are carried out in arid regions.

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In our previous studies, we demonstrated the performance of novel superfine crusher and pneumatic planar magnetic separator as energy-efficient technologies for dry processing of magnetite ores. The present study investigates the economic and socio-environmental benefits of applying these technologies in conceptual dry magnetite ore processing flowsheet. The outcome of the study is compared with that of a conceptual wet processing flowsheet for the same ore. The cost estimations used are based on the Brook Hunt C1 methodology whilst revenue estimations are based on the Platts Iron Ore Index specification. The demonstrated economic and socio-environmental benefits show that dry processing flowsheet offers significant energy and cost savings and improved revenue generation compared with the wet process flowsheet. These findings are vital to the magnetite industry, particularly in water- and energy-scarce regions as a benchmark for future studies aimed at deepening and expanding the knowledge base of dry beneficiation of magnetite ores.