Abstract
In our previous studies, we demonstrated the performance of novel superfine crusher and pneumatic planar magnetic separator as energy-efficient technologies for dry processing of magnetite ores. The present study investigates the economic and socio-environmental benefits of applying these technologies in conceptual dry magnetite ore processing flowsheet. The outcome of the study is compared with that of a conceptual wet processing flowsheet for the same ore. The cost estimations used are based on the Brook Hunt C1 methodology whilst revenue estimations are based on the Platts Iron Ore Index specification. The demonstrated economic and socio-environmental benefits show that dry processing flowsheet offers significant energy and cost savings and improved revenue generation compared with the wet process flowsheet. These findings are vital to the magnetite industry, particularly in water- and energy-scarce regions as a benchmark for future studies aimed at deepening and expanding the knowledge base of dry beneficiation of magnetite ores.
Highlights
Iron (Fe) ores play a significant role in the global mining industry judging by the high tonnes of ore processed yearly and the associated energy, water, and tailings storage facility (TSF) requirements [1].Historically, the steel industry has been supported by iron products sourced from hematite and magnetite ores
We investigated the performance of a novel superfine crusher (SFC) [15] and a pneumatic planar magnetic separator (PMS) [16,17] as dry comminution and magnetic separation technologies, respectively, for processing fine-grained magnetite ores
The cost estimations presented in this study show that using Flowsheet 1 offered a 31% reduction in the cost associated with the electrical power consumption per tonne of IOC compared with Flowsheet 2
Summary
Iron (Fe) ores play a significant role in the global mining industry judging by the high tonnes of ore processed yearly and the associated energy, water, and tailings storage facility (TSF) requirements [1].Historically, the steel industry has been supported by iron products sourced from hematite and magnetite ores. Unlike the high-grade hematite ores which are processed into saleable iron products, through crushing, grinding or milling, concentration by screening, and/or using hydraulic or magnetic classification [2], magnetite ores require extensive beneficiation to produce iron concentrates. This is because most magnetite ores are fine-grained and mineralogically complex, require fine and ultrafine milling (usually finer than 45 μm) [3] to sufficiently liberate the magnetite mineral from the predominantly silica gangue. Typical magnetite beneficiation is carried out as a wet process, and it consists of comminution, wet magnetic separation (to concentrate the magnetite mineral), reverse flotation (for silica removal), and concentrate dewatering.
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