Hi

Ore sorting for +6 mm.   Works a treat

Allair separator for -6mm + 0.25mm?  I think

Also dry high intensity magnetic separators

The problem you will have is nothing is 100% dry. You can screen off the coarse material (+6mm?) But going finer will cause problems with blinded screens and separation devices in this range. For coarser material, look art size by assay, a simple screening may make an upgrade. Ore sorters, cobblers (magnetic). I have heard of air jigs getting better/ being developed. For fines, gets difficult due to residual moisture and clays. Air tables? Dry jigs.?

You can use some technologies to reduce the amount of water being used, but it is virtually impossible to do screening and concentration without using water at some point in the flowsheet. Wet size reduction and separation are often more economical than dry versions.

Possible reduction methods:

Use airfall AG Mill or High Pressure Grinding Rolls for some of the size reduction (particularly at the front end of the plant).

You can use dry magnetic separation and dry jigging, but your ore and recovery will dictate whether such techniques are sufficiently viable.

Recycle process water as far as possible. Dry stack the tailings (using appropriate filters). Use water treatment to allow water to be re-used for pump seals or cooling purposes.  Cover tanks and thickeners to reduce evaporation. 

Typically your greatest loss will be in the moisture content of the product concentrate. You either have to have a minimum moisture content to avoid dust formation or use special means of transport (pneumatic conveyors, sealed rail wagons etc.).  If you have to thermally dry the concentrate, consider water recovery methods (scrubbers, heat exchangers etc) to get maximum moisture recovery from the dryer off-gas.  

There are ways to get around alot of things these days, but this is highly dependent on your ore. Is it magnetite or hematite or goethite? what size does it liberate at. Can you make a preconcentrate and sell that for further processing where there may be more water. As most people have said it is almost impossible to be fully dry because at some point you need to collect the dust and keep it from being spread across the land and this is will require some water (sometimes lots, depending on what you do with ). Think dry grinding and air cyclones... The iron ore company of canada originally had a flowsheet like that. It's a matter of how you handle it after that. There are some interesting proprietary processes out there these days.....