Beneficiation of Iron Ores

These ores ca n be directly used in the production of iron and steel. All other ores need benefaction and certain processing before they are used in t he production of iron and steel. Low grade iron ores cannot be used as such for the production of iron and SST eel and need to be upgraded to reduce its gangue content and increase its Fee content. The process adopted to upgrade the Fee content of air n ore is known as iron ore benefaction (108). However, Iron ores from different sources have their own peculiar mineralogy cal characteristics and require the specific benefaction and teleological treatment to get the best product out of it.Also for effective Ben affectation treatment, effective crushing, grinding, and screening of the ore is necessary for which suitable crushing, grinding, and SC reining technologies are to be employed. The choice of the benefaction treatment depends on the nature of the gangue present and its association with the ore structure. Several methods/technique s such as washing, jigging, magnetic separation, gravity separation, and flotation n etc. Are used to enhance the Fee content of the Iron ore and to reduce its gangue content.These techniques are used in various combination s for the benefaction of iron ores. For benefaction of a particular iron ore the emphasis is usually to develop a cost effective flow she et incorporating necessary crushing, grinding, screening and benefiting techniques which are necessary for the upgrading of the iron or e. A typical flow sheet for iron ore benefaction plant is shown in Fig 1. 3/13 Fig 1 A typical flow sheet of iron ore benefaction plant Some of the common methods/ techniques applicable for iron ore processing are described below.Crushing, grinding and screening technique The purpose of grinding and regrinding is to reduce the ore to a size small en ugh to liberate and recover the valuable minerals. The crushing, grinding and screening systems of an BIB plant are to be designed t aging into acc ount the requirements of the downstream benefaction processes. The crushing units may include primary, secondary, t artery and quaternary crushing systems. Jaw, gyrator, cone, and roll crushers are used for ore crushing. Semi toughens grinding and AU toughens grinding circuits are used for grinding the ore.Both rod mills and ball mills are used for this purpose. Capital investment and proper action costs of grinding equipment are high. Hence economics play a large part in planning for the degree of crushing and grinding perform d to prepare ore for benefaction. Other factors considered in determining the degree of crushing and grinding includes the value concentrate Zion of the ore, its mineralogy, hardness and moisture content. Closed circuit grinding minimizes over grinding of very friable ore normally of undo in the ore bodies of our region.The more the recirculation load the less is the over grinding of particles. Washing and wet scrubbing This process is primitive and widely us ed in lumpy iron ore processing to disco edge and remove friable and soft laterality materials, fine materials and limitation clay particles adhering to the ore. Wet scrubbing is alls o useful in hard and porous ores, which invariably have cavity/ pores filled with clayey material that need substantial removal. Gravity separation This technique is used where iron bearing minerals are free from associated g angle materials.The specific gravity of iron bearing minerals is usually higher than the specific gravity of gangue materials. Effectiveness e efficiency of the gravity separation depends largely on to proper crushing and sizing of the ore so as to ensure a proper size feed to the gravity separation equipment and also removal of slime from the equipment. A large numbers of equipment/ processes functioning on gravity separation principle are available. Some of t hem are described below. Dense media separation -? The process is also known as heavy media separate on. The process is u sed for coarse ores (size range mm to 50 mm.Ground ferry silicon of 300 mesh size is used as suspension to cream et a parting density of 33. 2 which is sufficient for angle materials to float and get separated. The suspension material is recover reed by using low intensity magnetic separators (LIME). Feed for the dense media separation must be hard and compact with non poor us gangue material. Heavy media cyclone – The process is used for iron ore fines with size range o f 0. Mm to 6 mm. The cyclone type separator utilizes centrifugal as well as gravitational forces to make separation between ore an d gangue material.Ground Frederickson of 325 mesh size is used as a media in cyclone. Jigging – Jigging is a gravity concentration technique where the iron ore is seep rated into light density fraction, medium density fraction and heavy density fraction. Size fraction of the iron ore used for gig Eng is 0. 5 mm to mm. Http://asparagus. Com/beneficiationofironores/ Spirals à ¢â‚¬â€œ Spiral concentrators are flowing film separation devices. General pop ration is a continuous gravitational laminar flow down on an inclined surface. The mechanism of separation involves primary and SE secondary flow patterns.The primary flow is essentially the slurry flowing down the spiral trough under the force of gravity. The sec Andrea flow pattern is radial across the trough. Here the uppermost fluid layers comprising higher density particles move away from t he centre while the lowermost concentrate layers of higher density particles move towards the centre. Spirals require addition of water at various points down the spiral to assist washing of the iron ore, I. E. Transporting away the light gangue from the dense ore. The e amount of wash water and its distribution down the spiral trough can be adjusted to meet the operating requirements.Point count roll minimizes the total water requirements by efficiently directing water into the flowing pulp at the most effective a ngle. Feed size app logicality is in the range of 0. 3 mm to 1 mm. Spirals are normally operated at a pulp density of 25 % to 30 % solids. Tables -? Tables have wide range of application in gravity treatment of iron ore s. Tables are normally used in cleaning and scavenging circuits. Feed size applicability is in the range of 0. 3 mm to 1 mm. Spirals are n armorial operated at a pulp density of 25 % to 30 % solids.Multi gravity concentrator – They are under development stage and are design Ned to treat fines and ultramarine particles Of iron ore. They are useful in processing of valuables from slimes and tails. Cyclones – Cyclones used for concentration of iron ores are of several types. T hose include hydrochloric, stub cyclone and heavy media cyclone. Cyclones are cost effective and simple in their construction. The e main parts of a cyclone consist of cyclone diameter, the inlet nozzle at the point of entry into the feed chamber, vortex finder, cyclic medical sectio n and cone section.They have proper geometrical relationship between the cyclone diameter, inlet area, vortex find ere, apex orifice, and sufficient length providing retention time to properly classify particles. As the feed enters the chamber, a rotation Of the slurry inside of the cyclone begins, causing centrifugal forces to accelerate the movement of the particles towards the oh term wall. The particles migrate downward in a spiral pattern through the cylindrical section and into the conical section. At this poi NT the smaller mass particles migrate toward the center and spiral upward and out through the vortex finder, discharging through the overflow pipe.This product, which contains the finer particles and the majority of the water, is termed the overflow and should be discharged at or near atmospheric pressure. The higher ass particles remain in a downward spiral path along the walls of the conical I section and gradually exit through the apex orifice. This product is termed the underflow and also should be discharged at or nee r atmospheric pressure. Magnetic separation Magnetic separation technologies are used to take the advantage Of the differ once in the magnetic properties for separating iron ore from the non magnetic associated gangue materials.Magnetic separation can be condo acted in either a dry or wet environment, although wet systems are more common. Magnetic separation operations can also be categorized as either low or high I density. Low intensity separators use magnetic fields between 1000 to 3000 gauss. Low intensity techniques are normally used on magnetite ore as an inexpensive and effective separation method. High intensity separators employ fields as strong as 20,000 gauss. This method is u seed to separate weakly magnetic iron ores such as hematite, from nonmagnetic or less magnetic gangue materials.Other factors important t in determining which type of magnetic separator system is used include particle size and the solids content of the ore slurry feed. Http:// asparagus. Com/beneficiationofironores/ 5/13 Typically magnetic separation involves three stages of separation namely (I) c bobbling, (ii) cleaning/roughing and (iii) finishing. Each stage may employ several drums in a series to improve separation efficiency. Each s successive stage works on finer particles as a result of the removal of oversized particles in earlier separations. Cobblers work on larger particles and reject substantial percent of feed as tails.Several types of magnetic separation technologies are used. These are descried bed below. Wet and dry, low intensity magnetic separation (LIME) High gradient magnetic separation (HIGHS) Wet high intensity magnetic separation (WHIMS) Roll magnetic separators for processing weak magnetic ores Induction roll magnetic separation (RIMS) for concentrating dry ores Flotation process Flotation process uses a technique where particles of one mineral or group of minerals are made to adhere preferentially to air bubbles in the presence of a chemical reagent.This is achieved by using chemical reagents t hat that preferentially react with the desired mineral. Several factors are important to the success of flotation activities. These include unify remit of particle size, use of reagent compatible with the mineral, and water conditions that will not interfere with the attachment of the e reagents to the mineral or the air bubble. Today flotation is primarily used to upgrade concentrates resulting from mage entice separation.Flotation to be used all alone as a benefaction method is used rarely. Chemical reagents used are mainly of three main groups namely (I) collectors/ amines, (ii) brothers, and (iii) antifoam. Reagents may be added in a number of forms which include solid, immiscible liquid emulsion a ND solution in water. The concentration of reagents need to be loosely controlled during conditioning since adding more reagent than needed d retards the reaction and reduce efficiency.