In response to the challenge of recovering particles smaller than -0.45 microns in Mineral Processing, GAUSTEC^® has significantly enhanced the Wet High Intensity Magnetic Separation (WHIMS) technology. By Extending the Height of the Magnetic Grooved Plate Matrix, a core component of Jones Magnetic Separator Technology, GAUSTEC^® has raised the industry standards. For over fifty years, since the installation of the first Jones separator at VALE Cauê Mine in 1972, the standard matrix height has remained at 220 mm. The worldwide demand to reduce tailings prompted a team of researchers to look for new solutions to improve slimes recovery. After trying traditional methods and process variables it was decided to extend the matrices heights to increase the processing time inside the magnetic field. Evaluating four matrix heights, researchers found that doubling the standard height (2H) provided outstanding results. The 2H matrix recovered 2.5 times more mass from slimes compared to the standard 1H matrix height, in this study.

Renewed interest in dry processing has arisen due to challenges in water management. In dry iron ore beneficiation, flowability of bulk solids is a key concern, leading to issues like plugging and clogging in bins and chutes. Handling also faces challenges from environmental regulations, particularly regarding dust emissions. Enclosed conveyor technologies, such as air-assisted conveyors that use fluidization, offer effective solutions, though the maximum particle size that can be conveyed is a limitation that needs consideration. This paper examines how the size and chemical composition of bulk iron ore materials affect their handling behavior. By employing Geldart’s and Jenike’s methods, this document provides technical parameters and recommendations, which are lacking in the current literature, for the designing of dry processing plants. Findings indicate that ultrafines can have a flow function as low as 2.05, indicating cohesive behavior even when dried, while fluidization tests support these characteristics. In contrast, coarser fractions are easy for free-flowing materials. Samples with a top size of 0.5 mm fall between sand-like and spoutable groups in Geldart’s classification. Denser materials did not fluidize, while less dense ones did. Thus, air slides should avoid handling materials at this threshold and focus on finer materials. This paper offers guidance for designing dry processing plants to address handling bottlenecks.