Search results for: beneficiation

Authors: M. Das, R. K. Saha, B. C. Meikap

Abstract:

Iron ore and coal are the two major important raw materials being used in Iron making industries. Usually ore fines containing around 5% Alumina are rejected due to higher proportion of alumina. Therefore, a technology or process which may reduce the alumina content by 2% by beneficiation process will be highly attractive . In addition fine coals with ash content is used nearly 12% is directly injected in blast furnace. Fast fluidization is a technology by using dry beneficiation of coal and iron ore can be done. During the fluidization process the iron ore band coal is fluidized at high velocity in the riser of a fast fluidized bed, the heavier and coarse particles is generally settled at the bottom in a dense zone of the riser while the finer and lighter particle are entrained to the top dilute zone and then via a cyclone is fed back to the bottom of the riser column. Most of the alumina and low ash fine size coals being lighter are expected to move up to the riser and by a natural beneficiation of ores is expected to take place in the riser. Therefore in this study an attempt has been made for dry beneficiation of iron ore and coal in a fluidized bed and its hydrodynamic characterization.

Keywords: beneficiation, fluidization, gas-solid fluidization, riser .

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Authors: K.K. Sharma, K.M.K. Sinha, T.G. Charan, D.D. Haldar

Abstract:

An attempt has been made to beneficiate the Indian coking coal fines by a combination of Spiral, flotation and Oleo Flotation processes. Beneficiation studies were also carried out on - 0.5mm coal fines using flotation and oleo flotation by splitting at size 0.063mm.Size fraction of 0.5mm-0.063mm and -0.063mm size were treated in flotation and Oleo flotation respectively. The washability studies on the fraction 3-0.5 mm indicated that good separation may be achieved when it is fed in a spiral. Combined product of Spiral, Flotation and Oleo Flotation has given a significant yield at acceptable ash%. Studies were also conducted to see the dewatering of combined product by batch type centrifuge. It may further be suggested that combination of different processes may be used to treat the -3 mm fraction in an integrated manner to achieve the yield at the desired ash level. The treatment of the 3/1 mm -0.5 mm size fraction by spiral,-0.5-0.63 mm by conventional froth flotation and - 0.063 fractions by oleo flotation may provide a complete solution of beneficiation and dewatering of coal fines, and can effectively address the environmental problems caused by coal fines.

Keywords: coal fines, dewatering, environment, flotation, oleoflotation, spiral

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Authors: G. Martino, F. Silva, E. Marchal

Abstract:

The control over delivered iron ore blend characteristics is one of the most important aspects of the mining business. The iron ore price is a function of its composition, which is the outcome of the beneficiation process. So, end-to-end integrated planning of mine operations can reduce risks of penalties on the iron ore price. In a standard iron mining company, the production chain is composed of mining, ore beneficiation, and client supply. When mine planning and client supply decisions are made uncoordinated, the beneficiation plant struggles to deliver the best blend possible. Technological improvements in several fields allowed bridging the gap between departments and boosting integrated decision-making processes. Clusterization and classification algorithms over historical production data generate reasonable previsions for quality and volume of iron ore produced for each pile of run-of-mine (ROM) processed. Mathematical modeling can use those deterministic relations to propose iron ore blends that better-fit specifications within a delivery schedule. Additionally, a model capable of representing the whole production chain can clearly compare the overall impact of different decisions in the process. This study shows how flexibilization combined with a planning optimization model between the mine and the ore beneficiation processes can reduce risks of out of specification deliveries. The model capabilities are illustrated on a hypothetical iron ore mine with magnetic separation process. Finally, this study shows ways of cost reduction or profit increase by optimizing process indicators across the production chain and integrating the different plannings with the sales decisions.

Keywords: Clusterization and classification algorithms, integrated planning, optimization, mathematical modeling, penalty minimization.

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Authors: Amit Kumar Bhandary, Prithviraj Gupta, Siddhartha Mukherjee, Mahua Ghosh Chaudhuri, Rajib Dey

Abstract:

Chromite ores are primarily used for extraction of chromium, which is an expensive metal. For low grade chromite ores (containing less than 40% Cr₂O₃), the chromium extraction is not usually economically viable. India possesses huge quantities of low grade chromite reserves. This deposit can be utilized after proper physical beneficiation. Magnetic separation techniques may be useful after reduction for the beneficiation of low grade chromite ore. The sample collected from the sukinda mines is characterized by XRD which shows predominant phases like maghemite, chromite, silica, magnesia and alumina. The raw ore is crushed and ground to below 75 micrometer size. The microstructure of the ore shows that the chromite grains surrounded by a silicate matrix and porosity observed the exposed side of the chromite ore. However, this ore may be utilized in refractory applications. Chromite ores contain Cr₂O₃, FeO, Al₂O₃ and other oxides like Fe-Cr, Mg-Cr have a high tendency to form spinel compounds, which usually show high refractoriness. Initially, the low grade chromite ore (containing 34.8% Cr₂O₃) was reduced at 1200 ⁰C for 80 minutes with 30% coke fines by weight, before being subjected to magnetic separation. The reduction by coke leads to conversion of higher state of iron oxides converted to lower state of iron oxides. The pre-reduced samples are then characterized by XRD. The magnetically inert mass was then reacted with 20% MgO by weight at 1450 ⁰C for 2 hours. The resultant product was then tested for various refractoriness parameters like apparent porosity, slag resistance etc. The results were satisfactory, indicating that the resultant spinel compounds are suitable for refractory applications for elevated temperature processes.

Keywords: Apparent porosity, beneficiation, low grade chromite, refractory, spinel compounds, slag resistance.

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Authors: Mercy M. Ramakokovhu, Henry Kasaini, Richard K.K. Mbaya

Abstract:

The copper flotation tailings from Konkola Copper mine in Nchanga, Zambia were used in the study. The purpose of this study was to determine the leaching characteristics of the tailings material prior and after the physical beneficiation process is employed. The Knelson gravity concentrator (KC-MD3) was used for the beneficiation process. The copper leaching efficiencies and impurity co-extraction percentages in both the upgraded and the raw feed material were determined at different pH levels and temperature. It was observed that the copper extraction increased with an increase in temperature and a decrease in pH levels. In comparison to the raw feed sample, the upgraded sample reported a maximum copper extraction of 69% which was 9%, higher than raw feed % extractions. The impurity carry over was reduced from 18% to 4 % on the upgraded sample. The reduction in impurity co-extraction was as a result of the removal of the reactive gangue elements during the upgrading process, this minimized the number of side reaction occurring during leaching.

Keywords: Atmospheric leaching, Copper, Iron, Knelson concentrator

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Authors: Jefrey Pilusa, Edison Muzenda

Abstract:

This research investigated treatment of crude carbon black produced from pyrolysis of waste tyres in order to evaluate its quality and possible industrial applications. A representative sample of crude carbon black was dry screened to determine the initial particle size distribution. This was followed by pulverizing the crude carbon black and leaching in hot concentrated sulphuric acid for the removal of heavy metals and other contaminants. Analysis of the refined carbon black showed a significant improvement of the product quality compared to crude carbon black. It was discovered that refined carbon black can be further classified into multiple high value products for various industrial applications such as filler, paint pigment, activated carbon and fuel briquettes.

Keywords: Activated Carbon, Briquettes, Fuel, Filler, Pyrolysis.

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Authors: K. Yılmaz, B. Birol, M. N. Sarıdede, E. Yiğit

Abstract:

A bauxite ore can be utilized in Bayer Process, if the mass ratio of Al2O3 to SiO2 is greater than 10. Otherwise, its FexOy and SiO2 content should be removed. On the other hand, removal of TiO2 from the bauxite ore would be beneficial because of both lowering the red mud residue and obtaining a valuable raw material containing TiO2 mineral. In this study, the low grade diasporic bauxite ore of Yalvaç, Isparta, Turkey was roasted under reducing atmosphere and subjected to magnetic separation. According to the experimental results, 800°C for reduction temperature and 20000 Gauss of magnetic intensity were found to be the optimum parameters for removal of iron oxide and rutile from the nonmagnetic ore. On the other hand, 600°C and 5000 Gauss were determined to be the optimum parameters for removal of silica from the non-magnetic ore.

Keywords: Low grade diasporic bauxite, magnetic separation, reduction roasting, separation index.

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Authors: C. Lanzerstorfer, M. Hinterberger

Abstract:

The iron content of the ore used is crucial for the productivity and coke consumption rate in blast furnace pig iron production. Therefore, most iron ore deposits are processed in beneficiation plants to increase the iron content and remove impurities. In several comminution stages, the particle size of the ore is reduced to ensure that the iron oxides are physically liberated from the gangue. Subsequently, physical separation processes are applied to concentrate the iron ore. The fine-grained ore concentrates produced need to be transported, stored, and processed. For smooth operation of these processes, the flow properties of the material are crucial. The flowability of powders depends on several properties of the material: grain size, grain size distribution, grain shape, and moisture content of the material. The flowability of powders can be measured using ring shear testers. In this study, the influence of the moisture content on the flowability for the Krivoy Rog magnetite iron ore concentrate was investigated. Dry iron ore concentrate was mixed with varying amounts of water to produce samples with a moisture content in the range of 0.2 to 12.2%. The flowability of the samples was investigated using a Schulze ring shear tester. At all measured values of the normal stress (1.0 kPa – 20 kPa), the flowability decreased significantly from dry ore to a moisture content of approximately 3-5%. At higher moisture contents, the flowability was nearly constant, while at the maximum moisture content the flowability improved for high values of the normal stress only. The results also showed an improving flowability with increasing consolidation stress for all moisture content levels investigated. The wall friction angle of the dust with carbon steel (S235JR), and an ultra-high molecule low-pressure polyethylene (Robalon) was also investigated. The wall friction angle increased significantly from dry ore to a moisture content of approximately 3%. For higher moisture content levels, the wall friction angles were nearly constant. Generally, the wall friction angle was approximately 4° lower at the higher wall normal stress.

Keywords: Iron ore concentrate, flowability, moisture content, wall friction angle.

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