South Australian (SA) mining technology company DryFlow Magnetics recently sold its first waterless mineral processing unit, which is now being prepared for export to a mine in the Western U.S. The technology was developed with the backing of the Commonwealth Scientific and Industrial Research Organisation (CSIRO) and the SA Government.
The patented technology is
designed to process iron ore, recover critical minerals, and can process 200
tons per hour with very low water use. It is expected to be deployed in areas
where water is scarce.
According to Global Data:
“According to DryFlow Magnetics, the technology is
intended to enhance ore quality and may provide new market opportunities for
mine operators.”
“The company is also establishing a research laboratory
in Texas as part of a collaborative venture focused on critical minerals
research.”
“The US deployment is expected to guide the development
of DryFlow Magnetics’ next-generation modular system, which is designed to
process 200t per hour.”
“The company indicates that the initial units of this
new platform will be used in SA under a commercial agreement with Peak Iron
Mines, with additional support from a Federal Government grant.”
Below is a schematic
depiction showing how the processing technology works. Iron is magnetic, which
makes it quite amenable to magnetic separation.
Below is an example flow
diagram from mine to final use.
From the graphic below, it
looks like the unit(s) exported to the U.S. will be 20-tons per hour units
banked together. The end product for these includes iron sulfate fertilizers.
200 tons per hour units will be used to process high-magnetite Australian iron
ore to be used in sustainable steel-making with electric arc furnaces.
The paragraph below explains
the company’s Kuchel separation process:
“Invented by Ian Kuchel and protected by a global patent
portfolio, the Kuchel Process is DryFlow’s innovative stacked magnetics
technology for efficient dry mineral separation, especially for producing DRI
Grade high-grade iron concentrates. This advanced process employs a continuous
magnetic induction field along the ore carrying belt, allowing magnetic
particles the necessary residence time to disentangle from gangue and form a
clean concentrate of high purity iron. Unlike conventional dry separation technologies,
DryFlow’s approach does not depend on energy-intensive drying or forced air
fluidisation. Instead, the ore self-fluidises within the magnetic field,
enabling effective separation even at moisture levels exceeding 10%. The
outcome is a robust, waterless mineral processing system designed for real mine
conditions, including those in remote, arid, and variable ore environments,
thus exemplifying a sustainable mining technology.”
Below is a video
demonstration of the process.
References:
DryFlow
prepares first commercial mining technology for US export. Shree Mishra. Global
Data. Mining Technology. August 5, 2026. DryFlow
prepares first commercial mining technology for US export
Dry
Magnetic Separation Technology for Sustainable Mining: Waterless Mineral
Processing. Dryflow Magnetics. Dry Magnetic
Separation for Sustainable Mining Solutions
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