Optimum utilisation of rolling stocks for iron ore mining industries

In this paper, a generic and flexible optimisation methodology is developed to represent, model, solve and analyse the iron ore supply chain system by integrating of iron ore shipment, stockpiles and railing within a whole system. As a result, an integrated train-stockpile-ship timetable is created and optimised for improving efficiency of overall supply chain system. The proposed methodology provides better decision making on how to significantly improve rolling stock utilisation with the best cost-effectiveness ratio. Based on extensive computational experiments and analysis, insightful and quantitative advices are suggested for iron ore mine industry practitioners. The proposed methodology contributes to the sustainability of the environment by reducing pollution due to better utilisation of transportation resources and fuel.

Preparation and characterization of TiO2/acid leached serpentinite tailings composites and their photocatalytic reduction of Chromium(VI)

Composite TiO2/acid leached serpentine tailings (AST) were synthesized through the hydrolysis–deposition method and characterized by X-ray diffraction (XRD), scanning electron microscopy (SEM), energydispersive X-ray spectrometry (EDS), Fourier-transform infrared spectroscopy (FT-IR), transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS), and surface area measurement (BET). The XRD analysis showed that TiO2 coated on the surface of acid leached serpentine tailings was mixed crystal phases of rutile and anatase, the grain size of which is 10–30 nm. SEM, TEM, and EDS analysis exhibited that nano-TiO2 particles were deposited on the surface and internal cavities of acid leaching serpentine tailings. The XPS and FT-IR analysis demonstrated that the coating process of TiO2 on AST was a physical adsorption process. The large specific surface area, porous structure, and plentiful surface hydroxyl group of TiO2/AST composite resulted in the high adsorption capacity of Cr(VI). The experimental results demonstrated that initial concentration of Cr(VI), the amount of the catalyst, and pH greatly influenced the removal efficiency of Cr(VI). The removal kinetics of Cr(VI) at a relative low initial concentration was fitted well with Langmuir–Hinshelwood kinetics model with R2 value of about unity. The asprepared composites exhibited strong adsorption and photocatalytic capacity for the removal of Cr(VI), and the possible photocatalytic reduction mechanism was studied. The photodecomposition of Cr(VI) was as high as 95% within 2 h, and the reusability of the photocatalysis was proven.

Studies on interaction of Paenibacillus polymyxa with iron ore minerals in relation to beneficiation

Interaction between Paenibacillus polymyxa with minerals such as hematite, corundum, quartz and kaolinite brought about significant surface chemical changes on all the minerals. Quartz and kaolinite were rendered more hydrophobic, while hematite and corundum, became more hydrophilic after biotreatment. The predominance of bacterial polysaccharides on interacted hematite and corundum and of proteins on quartz and kaolinite was responsible for the above surface-chemical changes. Bio-pretreatment of the above iron ore mineral mixtures resulted in the selective separation of silica and alumina from iron oxide, through bioflotation and bioflocculation. The utility of bioprocessing in the beneficiation of iron ores is demonstrated.

Corrosive and abrasive wear in ore grinding

The relative significance of corrosive and abrasive wear in ore grinding is discussed. Laboratory marked ball wear tests were carried out with magnetic taconite and quartzite under different conditions, namely dry, wet and in the presence of an organic liquid. The effect of different modes of aeration and of pyrrhotite addition on the ball wear using mild steel, high carbon low alloy steel and austenitic stainless steel balls was evaluated. Results indicate that abrasive wear plays a significant role in ore grinding in the absence of sulfides, and rheological properties of the ore slurry influenced such wear. The effect of oxygen on corrosive wear becomes increasingly felt in the presence of a sulfide mineral such as pyrrhotite. Wear characteristics of the three types of ball materials under different grinding conditions are illustrated.

Flotation of calcareous Mussorie phosphate ore

Separation of Mussorie rock phosphate (P2O5 = 20%) from Uttar Pradesh, India, containing pyrite, calcite and other carbonaceous impurities by flotation has been successfully attempted to upgrade the phosphate values. Based on Hallimond cell flotation results of single and synthetic mineral mixtures of calcite and apatite using oleic acid and potassium phosphate, conditions were obtained for the separation of calcite from apatite which is considered to be the most difficult step in the beneficiation of calcareous phosphates. Further studies using 250 g of the mineral (−60 +150 and −150 mesh fractions, deslimed) in laboratory size Fagergren subaeration machine employed a stagewise flotation viz. carbonaceous materials using terpineol, pyrite using potassium-ethyl xanthate and calcite using oleic acid respectively. Separation was, however, found to be unsatisfactory in the absence of a depressant. Among starch, hydrofluosilicic acid and dipotassium hydrogen phosphate, which were tried as depressants for apatite in the final flotation stage, dipotassium hydrogen phosphate proved to be superior to others. However, the tests with the above fractions did not yield the required grade. This was possibly due to insufficient liberation of the phosphate mineral from the ore body and different experimental conditions due to scale up operations. Experiments conducted using −200 mesh deslimed fractions has yielded an acceptable grade of 27.6% P2O5 with a recovery of about 60%. The results have been explained in terms of the specific adsorption characteristics of phosphate ions on apatite and the liberation size of the mineral.

Microbial Aspects of Environmentally Benign Iron Ore

Many types of micro-organisms inhabit iron ore deposits contributing to biogenic formation and conversion of iron oxides and associated minerals. Bacteria such as Paenibacillus polymyxa arc capable of significantly altering the surface chemical behaviour of iron ore minerals such as haematite, alumina, calcite and silica. Differing mineral surface affinities of bacterial cells and metabolic products such as proteins and polysaccharides can be utilised to induce their flotation or flocculation. Mineral-specific bioreagents such as proteins are generated when bacteria are grown in the presence of haematite, alumina, calcite and silica. Alumina-grown bacterial cells and proteins separated from such cells were found to be capable of separating alumina from haematite. Biodegradation of iron ore flotation collectors such as amines and oleates can be effectively utilised to achieve environmental control in iron ore processing mills.

Zeta Potential Studies On Some Iron-Ore Minerals In The Presence Of Starches

Authors perform zeta potential studies on hematite, corundum, and quartz samples using starches to understand the adsorption behavior of polymeric starch flocculants at the oxide mineral-solution interface and to correlate this information with their flocculation characteristics and investigate effects of pH and CaCl#72 on zeta potential of Fe ore minerals.

Flocculation, filtration and selective flocculation studies on haematite ore fines using starch

The flocculation and filtration characteristics of typical Indian iron ore fines have been studied using starch as flocculant in the presence of an inorganic electrolyte, namely calcium chloride. The effect of various parameters such as pH, starch and calcium chloride concentrations and pulp density on the settling and filtration rates, turbidity of the supernatant and on residual starch and calcium ion concentrates has been investigated through a statistical design and analysis approach and subsequently optimised on a laboratory scale. The adsorption mechanisms of starch onto haematite have been elucidated through adsorption density measurements, infrared and X-ray photoelectron spectroscopic techniques. The rheological property of the polymer solutions of relevance to flocculations has also been investigated. Further, the role of metal ion-starch interactions in the bulk solution, has been studied. In order to understand the nature of polymer adsorption at the double-layer, electrokinetic studies have been carried out with the iron ore mineral samples using starch and calcium chloride. Based on the above findings, selective floculaation tests on artificial mixtures of iron ore minerals have been carried out to determine the separation efficiencies from the view point of alumina and silica removal from haematite as well as the control of alumina: silica ratio in Indian iron ores.

Laboratory studies on ball wear in the grinding of a hematite-magnetite ore

Marked-ball grinding tests were carried out under different grinding conditions and environments. Three types of balls were used, namely, cast hyper steel, high chrome cast iron and EN-31 (forged), which cover a wide range of chemical composition, microstructure and media hardness. The effect of pulp density on ball wear and grinding efficiency was also studied. Relative pulp viscosities at different percent solids for the ore slurry were also determined. As the Kudremukh ore contained about 0.2% pyrite, the effect of addition of pyrite on ball wear was studied separately. Results of marked-ball grinding tests indicated that ball wear increased with time and showed a sharp increase for wet grinding over dry grinding. Ball wear under wet grinding conditions was also influenced by the gaseous atmosphere in the mill. At 70% solids, the best results in terms of reduced ball wear coupled with satisfactory grinding efficiency were obtained. The influence of oxygen on the corrosive wear of grinding balls was increasingly felt only if sulphide minerals such as pyrite were also present in the ore. The various ball materials could be arranged in the following order with respect to their overall wear resistance: high chrome cast iron > EN-31 (forged) > cast hyper steel.Possible ball wear mechanisms involved in the grinding of Kudremukh ore are discussed.

Ball wear and its control in the grinding of a lead-zinc sulphide ore

Marked ball grinding tests were carried out in the laboratory with a lead-zinc sulphide ore under different experimental conditions using high carbon low alloy steel (cast and forged) and high chrome cast iron balls. Relative ball wear as a function of grinding period and milling conditions was evaluated for the different types of ball materials. The role of corrosion and abrasion-erosion in the wear of grinding media is brought out. Methods to minimise ball wear through control of mill atmosphere and addition of reagents are discussed.

A Geostatistical Study pf Alumina-Content in Ores of An Indian Iron-Ore Deposit

Mining and blending operations in the high grade iron ore deposit under study are performed to optimize recovery with minimal alumina content while maintaining required levels of other chemical component and a proper mix of ore types. In the present work the regionalisation of alumina in the ores has been studied independently and its effects on global and local recoverable tonnage as well as on alternatives of mining operations have been evaluated. The global tonnage recovery curves for blocks (20m x 20m x 12m) obtained by simulation closely approximated the curves obtained theoretically using a change of support under the discretised gaussian model. Variations in block size up to 80m x 20m x 12m did not affect the recovery as the horizontal dimensions of the blocks are small in relation to the range of the variogram. A comparison of the local tonnage recovery curves obtained through multiple conditional simulations made with that obtained by the method of uniform conditioning of block grades on an estimate of panel 100m x 100m x 12m panel grade reveals comparable results only in panels which have been well conditioned and possesing an ensemble simulation mean close to the ordinary kriged value for the panel. Study of simple alternative sequence of mining on the conditionally simulated deposit shows that concentration of mining operations simultaneously on a single bench enhances the fluctuation in alumina values of ore mined.

Laboratory studies on ball wear in the grinding of a chalcopyrite ore

Wear of high carbon low alloy (HCLA) cast steel balls during the grinding of a chalcopyrite ore was evaluated under different experimental conditions. The role of oxygen in enhancing ball wear during wet finding is brought out. The influence of pH on ball wear was also examined from the view point of acid production during grinding and reactivity of sulphides. Contributions from corrosion and abrasion towards ball wear are quantified in terms of ball wear rates as a function of time, particle size and gaseous atmosphere in the mill.

Recovery of copper from vanadiferrous magnetite ore of Masanikere area, Shimoga district

Studies have been carried out to recover copper from vanadiferrous magnetite ores by a novel reaction with lime in the presence of water vapour. The ore, mixed with different proportions of lime, has been roasted in the presence of steam. The roasted product is either directly leached with dilute mineral acids or subjected to magnetic separation and then leached. The effect of various parameters such as amount of lime added, temperature and duration of roasting and time of leaching on the recovery of copper has been investigated. The results indicate that over 90% copper could be recovered under optimum conditions of roasting and leaching.

Reverse flotation of silica from Kudremukh iron ore .1. Selection of cationic reagents

Four types of cationic collectors were tested and evaluated for their performance in the reverse flotation of silica from the spiral preconcentrate of Kudremukh iron ore. A stagewise flotation was conducted by adding the reagent in three stages. Starch was used to depress hematite. Silica flotation was found to be very sensitive to the amount of cationic reagent added. The performance of the reagents was evaluated based on the percentage of silica and iron in the concentrate and percent recovery of iron obtained in the concentrate. Tests of significance, namely, t-test and F-test were performed to select the best two reagents for further investigations.