Study of the behavior of iron ore particles in spiral concentrators

Les spirales sont des appareils de séparation gravimétrique principalement utilisés dans l’industrie du traitement du minerai de fer. La classification des particules dans la pulpe s’effectue lors de la descente dans les spires en fonction de leur taille et leur densité, des conditions d’opération et de la géométrie de la spirale. L’effet des conditions d’opération (pourcentage solide, débit d’alimentation et débit d’eau de lavage) est évalué sur la performance des spirales en utilisant une spirale WW6E installée à COREM pour traiter un minerai de fer de ArcelorMittal, Québec. Les résultats montrent l’effet dominant du débit de l’eau de lavage et son impact majeur sur les particules grossières. Un circuit fermé de trois spirales parallèles avec 3, 5 et 7 tours est utilisé afin d’évaluer l’influence du nombre de tours. Les résultats préliminaires indiquent que la spirale trois tours fonctionne bien pour le nettoyage tandis que la 7 tour est robuste pour l’ébauchage et l’épuisage.

Dephosphorization of Iron Ore through Bioleaching

Phosphorus, as phosphate, is frequently found as a constituent of many of the world iron resources. Phosphorus is an extremely harmful element found in iron ore used as a raw material in the steelmaking process because it will affect the quality of iron and steel products. Allowable phosphorus concentration in high quality steel is usually less than 0.08%. Dephosphorization of iron ore has been studied for a long time. Although there are described physical beneficiation and chemical leaching processes, involving inorganic acids, to reduce phosphorus content of iron ores, these processes have several limitations such as poor recovery, require high energy quantity, capital costs and cause environmental pollution. Use of microorganisms in leaching of mineral ores is gaining importance due to the implementation of stricter environmental rules. Microbes convert metal compounds into their water soluble forms and are biocatalysts of leaching processes. Biotechnology is considered as an eco-friendly, promising, and revolutionary solution to these problems. Microorganisms play a critical role in natural phosphorus cycle and the process of phosphate solubilization by microorganisms has been known for many years. This study was performed to analyze the possibility of using bioleaching as a process for the dephosphorization of an iron ore from Northeast of Portugal. For bioleaching, Acidithiobacillus ferrooxidans bacterium were used. For this study two experiments were done with different conditions, which lasts 6 weeks for first experiment and 5 weeks for second experiment. From the result of these preliminary studies, it was observed that for first experiment 6.2 % and for second experiment 3.7 % of phosphorus was removed from iron ore.

FACTORS INFLUENCING MATERIAL LOSS DURING IRON ORE PELLET HANDLING

Iron ore concentrate pellets have the potential to fracture and abrade during transportation and handling, which produces unwanted fine particulates and dust. Consequently, pellet producers characterize the abrasion resistance of their pellets, using an Abrasion Index (AI), to indicate whether their products will produce unacceptable levels of fines. However, no one has ever investigated whether the AI correlates to pellet dustiness. During the course of this research, we investigated the relationship between AI and iron ore concentrate pellet dustiness using a wide range of industrial and laboratory pellet samples. The results showed that, in general, AI can be used to indicate high levels of dust. However, for good-quality pellets, there was no correlation between the two. Thus, dust generation from shipping and handling pellets will depend on the quantity of pellets handled and how much they are handled. These results also showed that the type of industrial furnace used to harden iron ore concentrate pellets may affect their fines generation and potential dustiness.

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.

The Role of Water Chemistry in the Concentration of Hematite Ore

Selective flocculation and dispersion processes rely on differences in the surface chemistry of fine mineral particles (<25 >ìm) to allow for the concentration of specific minerals from an ore body. The effectiveness of selective flocculation and dispersion processes for the concentration of hematite (Fe2O3) ore are strongly dependent on the ionic content of the process water. The goal of this research was to analyze the ionic content of an operating selective flocculation and dispersion type hematite ore concentrator and determine how carbon dioxide affects the filtration of the final product. A detailed water chemistry analysis of the entire process was determined to show concentration profiles throughout the process. This information was used to explain process phenomena and promote future research into this subject. A subsequent laboratory study was conducted to show how carbon dioxide affects filtration rate and relate this effect to the zeta potential of the constituents of the concentrated hematite ore.

THE DISPERSION AND SELECTIVE FLOCCULATION OF HEMATITE ORE

Iron ore is one of the most important ores in the world. Over the past century, most mining of iron ore has been focused on magnetite (Fe3O4). As the name suggests, magnetite is magnetic in nature and is easily separated from gangue (unwanted) minerals through magnetic separation processes. Unfortunately, the magnetite ore bodies are diminishing. Because of this, there has been a recent drive to pursue technology that can economically separate hematite (Fe2O3) from its gangue minerals as hematite is a much more abundant source of iron. Most hematite ore has a very small liberation size that is frequently less than 25μm. Beneficiation of any ore with this fine of a liberation size requires advanced processing methods and is seldom pursued. A single process, known as selective flocculation and dispersion, has been successfully implemented at a plant scale for the beneficiation of fine liberation size hematite ore. Very little is known about this process as it was discovered by the U.S. Bureau of Mines by accident. The process is driven by water chemistry and surface chemistry modifications that enhance the separation of the hematite from its gangue minerals. This dissertation focuses on the role of water chemistry and process reagents in this hematite beneficiation process. It has been shown that certain ions, including calcium and magnesium, play a significant role in the process. These ions have a significant effect on the surface chemistry as reported by zeta potential studies. It was shown that magnesium ions within the process water have a more significant impact on surface chemistry than calcium ions due to steric hindrance effects at the hematite surface. It has also been shown that polyacrylic acid dispersants, if used in the process, can increase product quality (increase iron content, decrease phosphorus content, decrease silica content) substantially. Water, surface and reagent chemistry experiments were performed at a laboratory, pilot, and full plant scale during the course of this work. Many of the conclusions developed in the laboratory and pilot scale were found to be true at the full plant scale as well. These studies are the first published in history to develop theories of water chemistry and surface chemistry interactions at a full plant scale.

The International Competitiveness of the Biscayan Iron and Steel Industry (1880-1913)

This study has a double objective: to provide foreign colleagues with an insight into the controversy surrounding the international competitiveness of pig iron produced in Bilbao and also to present previously unpublished documentation regarding the European iron industry, which I have retrieved from the historical archive of Credit Lyonnais of Paris. This information includes the costs of Biscayan, French, British, German and Belgium pig iron broken down into five components (iron ore, coke, flux, labour and other costs), which is useful in determining the reasons why the pig iron from Bilbao became less competitive. The article is made up of three parts. Firstly, I will synthesise the controversy surrounding the competitiveness of the Basque iron and steel industry. Then I will present the itemised costs which provide information to illustrate how Biscayan pig iron was not competitive because it was produced with English coal which was more expensive than that consumed by the European factories located "on top of" or near coal seams. The article will finish with a section that, by way of conclusion, explains the comparative advantage and disadvantage of Bilbao, applying the first model of Alfred Weber's Theory of Industrial Location to three technological advances, occurring between the 1860s and 1913 (malleable iron, Bessemer steel and Thomas steel).

40Ar/39Ar geochronological constraints on the evolution of lateritic iron deposits in the Quadrilatero Ferrifero, Minas Gerais, Brazil

Weathering profiles overlying the Sapecado, Pico and Andaime iron ore deposits, Quadrilátero Ferrífero (QF), Minas Gerais, Brazil, reach depths of 150–400 m and host world-class supergene iron orebodies. In addition to hosting supergene ore bodies of global economic significance, weathered banded iron-formations at the Quadrilátero Ferrífero and elsewhere (e.g., Carajás, Hamersley) are postulated to underlie some of the most ancient continuously exposed weathering profiles on earth. Laser incremental-heating 40Ar/39Ar results for 69 grains of hollandite-group manganese oxides extracted from 23 samples collected at depths ranging from 5 to 150 m at the Sapecado, Pico and Andaime deposits reveal ages ranging from ca. 62 to 14 Ma. Older Mn-oxides occur near the surface, while younger Mn-oxides occur at depth. However, many samples collected at the weathering–bedrock interface yield ages in the 51–41 Ma range, suggesting that the weathering profiles in the Quadrilátero Ferrífero had already reached their present depth in the Paleogene. The antiquity of the weathering profiles in the Quadrilátero Ferrífero is comparable to the antiquity of dated weathering profiles on banded iron-formations in the Carajás Region (Brazil) and the Hamersley Province, Western Australia. The age versus depth distributions obtained in this study, but not available for other regions containing similar supergene iron deposits, suggest that little further advance of the weathering front has occurred in the Quadrilátero Ferrífero lateritic profiles during the Neogene. The results suggest that weathering in some of these ancient landscapes is not controlled by the steady-state advance of weathering fronts through time, but may reflect climatic and geomorphological conditions prevailing in a remote past. The geochronological results also confirm that the ancient landsurfaces in the Quadrilátero Ferrífero probably remained immune to erosion for tens of millions of years. Deep weathering, mostly in the Paleogene, combined with low erosion rates, account for the abundance and widespread distribution of supergene iron, manganese, and aluminum orebodies in this region.

A detailed design study of leaching and ancillary processes in the hydrometallurgical extraction of iron from iron bearing feedstocks

A systematic survey of the possible methods of chemical extraction of iron by chloride formation has been presented and supported by a comparable study of :feedstocks, products and markets. The generation and evaluation of alternative processes was carried out by the technique of morphological analysis vihich was exploited by way of a computer program. The final choice was related to technical feasibility and economic viability, particularly capital cost requirements and developments were made in an estimating procedure for hydrometallurgjcal processes which have general applications. The systematic exploration included the compilation of relevant data, and this indicated a need.to investigate precipitative hydrolysis or aqueous ferric chloride. Arising from this study, two novel hydrometallurgical processes for manufacturing iron powder are proposed and experimental work was undertaken in the following .areas to demonstrate feasibility and obtain basic data for design purposes: (1) Precipitative hydrolysis of aqueous ferric chloride. (2) Gaseous chloridation of metallic iron, and oxidation of resultant ferrous chloride. (3) Reduction of gaseous ferric chloride with hydrogen. (4) Aqueous acid leaching of low grade iron ore. (5) Aqueous acid leaching of metallic iron. The experimentation was supported by theoretical analyses dealing with: (1) Thermodynamics of hydrolysis. (2) Kinetics of ore leaching. (3) Kinetics of metallic iron leaching. (4) Crystallisation of ferrous chloride. (5) Oxidation of anhydrous ferrous chloride. (6) Reduction of ferric chloride. Conceptual designs are suggested fbr both the processes mentioned. These draw attention to areas where further work is necessary, which are listed. Economic analyses have been performed which isolate significant cost areas, und indicate total production costs. Comparisons are mode with previous and analogous proposals for the production of iron powder.

Phosphorus bearing minerals in iron ores and their possible benefication

Modern electron optical techniques together with X-ray and mineralogical examination have been used to study the occurrence and form of phosphorus bearing minerals in iron ores. Three ores have been studied - Bahariya and Aswan from Egypt and Frodingham ironstone from U.K. The iron in the Bahariya iron ore is mainly as hematite and goethite. The gangue minerals are halite, gypsum, barytes, quartz and calcite. Iron content is between 49.8 to 63.2% and phosphorus 0.14 to 0.34%. The phosphorus occurs as very fine particles of apatite which are distributed throughout the ore. Removal of the phosphorus would require very fine grinding followed by acid leaching. Aswan iron ore is an oolitic iron ore; the iron content between 41-57% and phosphorus content 0.1 to 2.9%. It is mainly hematitic with variable quantities of quartz, apatite and small amount of clay minerals. In the oolitic iron ore beds, apatite occurs in the hematite matrix; filling in the pores of the oolithic surfaces, or as matrix cementing the ooliths with the hematite grains. In sandstone claybeds the distribution of the apatite is mainly in the matrix. It is suggested that the liberation size for the apatite would be -80 m and flotation concentration could be applied for the removal of apatite from Aswan ore. Frodingham ironstone occurs in the lower Jurassic bed of the South Humberside area. The average iron content is 25% and the phosphorus is 0.32%. Seven mineral phases were identified by X-ray; calcite, quartz, chamosite, hematite, siderite, apatite, and chlorite. Apatite occurs as very fine grains in the hematite and chamosite ooliths; as matrix of fine grains intergrown with chamosite and calcite grains; and as anhedral and sub rounded grains in the ooliths (8-28 m). It is suggested that two processes are possible for the dephosphorisation; the Flox process or a reduction roast followed by fine grinding, magnetic separation, and acid leaching.

An open pit multistage mine production scheduling model for drilling, blasting and excavating operations

This paper proposes a new multi-resource multi-stage scheduling problem for optimising the open-pit drilling, blasting and excavating operations under equipment capacity constraints. The flow process is analysed based on the real-life data from an Australian iron ore mine site. The objective of the model is to maximise the throughput and minimise the total idle times of equipment at each stage. The following comprehensive mining attributes and constraints have been considered: types of equipment; operating capacities of equipment; ready times of equipment; speeds of equipment; block-sequence-dependent movement times of equipment; equipment-assignment-dependent operation times of blocks; distances between each pair of blocks; due windows of blocks; material properties of blocks; swell factors of blocks; and slope requirements of blocks. It is formulated by mixed integer programming and solved by ILOG-CPLEX optimiser. The proposed model is validated with extensive computational experiments to improve mine production efficiency at the operational level. The model also provides an intelligent decision support tool to account for the availability and usage of equipment units for drilling, blasting and excavating stages.

A new open-pit multi-stage mine production timetabling model for drilling, blasting and excavating operations

This paper proposes a new multi-resource multi-stage mine production timetabling problem for optimising the open-pit drilling, blasting and excavating operations under equipment capacity constraints. The flow process is analysed based on the real-life data from an Australian iron ore mine site. The objective of the model is to maximise the throughput and minimise the total idle times of equipment at each stage. The following comprehensive mining attributes and constraints are considered: types of equipment; operating capacities of equipment; ready times of equipment; speeds of equipment; block-sequence-dependent movement times; equipment-assignment-dependent operational times; etc. The model also provides the availability and usage of equipment units at multiple operational stages such as drilling, blasting and excavating stages. The problem is formulated by mixed integer programming and solved by ILOG-CPLEX optimiser. The proposed model is validated with extensive computational experiments to improve mine production efficiency at the operational level.

Impact of riparian land use on stream insects of Kudremukh National Park, Karnataka state, India

The impact of riparian land use on the stream insect communities was studied at Kudremukh National Park located within Western Ghats, a tropical biodiversity hotspot in India. The diversity and community composition of stream insects varied across streams with different riparian land use types. The rarefied family and generic richness was highest in streams with natural semi evergreen forests as riparian vegetation. However, when the streams had human habitations and areca nut plantations as riparian land use type, the rarefied richness was higher than that of streams with natural evergreen forests and grasslands. The streams with scrub lands and iron ore mining as the riparian land use had the lowest rarefied richness. Within a landscape, the streams with the natural riparian vegetation had similar community composition. However, streams with natural grasslands as the riparian vegetation, had low diversity and the community composition was similar to those of paddy fields. We discuss how stream insect assemblages differ due to varied riparian land use patterns, reflecting fundamental alterations in the functioning of stream ecosystems. This understanding is vital to conserve, manage and restore tropical riverine ecosystems.

Microbially induced selective flocculation of hematite from kaolinite

Microbially induced selective flocculation of hematite from kaolinite has been demonstrated using Bacillus subtilis. Growth of bacterial cells in the presence of kaolinite resulted in enhanced production of extracellular proteins while that of hematite promoted significant secretion of exopolysaccharides. Bacterial cells were adapted to grow in the presence of the minerals and use of hematite-grown and kaolinite-grown cells and their metabolic products in the selective flocculation of hematite and dispersion of kaolinite illustrated. Bacterial cells and extracellular polysaccharides exhibited higher surface affinity towards hematite, rendering it hydrophilic; while significant protein adsorption enhanced surface hydrophobicity of kaolinite. Bacterial interaction with hematite and kaolinite resulted in significant surface chemical changes on the minerals. Due to higher surface affinity towards extracellular proteins, zeta potentials of kaolinite shifted in the positive direction, while those of hematite shifted in the negative direction due to higher adsorption of extracellular polysaccharides. Bacterial interaction promoted selective flocculation of only hematite, while kaolinite was efficiently dispersed. Mineral-specific stress proteins were generated on growing B. subtilis in the presence of kaolinite. Interfacial aspects of microbe-mineral interactions are illustrated to explain microbially-induced selective flocculation of hematite from kaolinite with relevance to clay and iron ore beneficiation. (C) 2013 Elsevier B.V. All rights reserved.