Iron Ore Company of Canada
The Secondary Flux Crushing Operation was one of the final upgrades in the Phase 2 expansion for the Iron
Ore Company of Canada. It was part of a program to increase the plant’s overall production from 8 million
tonnes per year to 12.5 million tonnes per year of pelletized ore.
The flux handling system was upgraded to produce a finer size distribution, which improved the ball mill
throughput in the Pellet Plant production. A new Svedala Impactmaster 150/230 Crusher and a Simplicity
M160B Double Deck Screen were installed as part of the secondary crushing operation to satisfy the flux
demand of 450 tph at 3/4" minus product. The new system was designed to crush up to 600 tph of 3/4" minus
product for future capacity increases.
Features incorporated into the new system included a screen to bypass the fines from the crushing operation
and a by-pass system to convey crushed, stockpiled material during screen and crusher downtime periods.
These added features, as well as the upgraded equipment specifications, substantially reduced scheduled
maintenance and nonscheduled downtimes.
Flux is an additive in the pellet making process. Different variations of added flux produce specific products.
Flux is a combination of dolomite, limestone and coke breeze. Dolomite, which is shipped in sizes ranging
from 24" minus, is crushed in two separate crushing phases. The Primary Crushing Operation is known as the
Stamler and the Secondary Crushing Operation is the new vedala/Simplicity. The second additive used in
the production of flux is limestone which is shipped in 3/4" minus. The final and third additive is coke breeze,
which is shipped as a fine mixture. All three are combined and mixed in different variations to form a flux in
JNE’s role in the Flux Handling System Upgrade involved the
engineering and construction management for the structural,
mechanical and electrical disciplines. The structural component
involved modifying the existing structure to accommodate
the new expansion for the additional equipment. The mechanical
component included equipment layouts, modifications required
to the in-feed and discharge conveyors and design of all
material transfer chutes. The electrical component included
providing additional power requirements, controls, services
for lighting; heating and ventilation; and also upgrades to the
existing conveyor equipment.
The project successfully met all scope requirements on time
and on budget.