Modeling and Optimization of Vertical Pulsating High Gradient Magnetic Separator for Iron ore Slime Processing Using Response Surface Methodology

Abstract

Due to the increasing demand in the high grade ores for the metallurgical operations and the stringent environmental conditions on the mining activity it is essential utilize the waste tailing pond slimes, recovery of iron values form these tailing ponds not only enhance the life of the existingoperating mines also finds the route to achieve the sustainable process. The present study aims to recover iron values from waste tailing ponds of Donimali area of Karnataka using vertical pulsating high gradient magnetic separator, a three-level Box–Behnken factorial design combined with response surface methodology (RSM) for modelling and optimizing of process parameters of Vertical Pulsating High Gradient Magnetic Separator (VPHGMS), namely Magnetic Intensity, matrix Pulsation and revolution of the Ring (RPM) for the separation of Fe (Hematite) from a deslimed iron ore slimy sample was studied. Second-order response functions were utilized for the grade and recovery of the Fe in the concentrate fraction. With the advantage of the optimization function in the statistical software MINTAB 14, optimized levels of the process variables have been determined to achieve the maximum grade of 65.6%, and recovery was 80.64% with combined desirability of 0.8 of Fe in the concentrate fraction was predicted. The influence of the process variables of the VPHGMS on grade and recovery of the Iron bearing minerals in the Magnetic fraction was presented as 3D response surface graphs.