Ore Blending Research Articles

使用高Al<sub>2</sub>O<sub>3</sub>铁矿的影响分析及对策探讨

根据2017年预测矿价概算，提高高Al2O3铁矿配比使高炉渣中Al2O3含量每升高0.1%，一年可降低配矿成本808万元。增加高Al2O3铁矿石的使用量将导致烧结矿和高炉炉渣Al2O3含量上升，针对高Al2O3铁矿的生产工艺，结合目前生产实绩和渣系相图等理论方面分析了Al2O3对烧结矿冶金性能和高炉冶炼的影响作用，并给出建议优化方向和调节途径。为降低实际生产采用高Al2O3冶炼时带来的负面影响、打破因Al2O3对降本的限制奠定技术基础，推动降本增效目标的实现。 According to the prediction of iron ore price in 2017, the calculation result showed that if the ratio of high Al2O3 iron ore in blended ore increased, within the content of Al2O3 in blast furnace slag increased by 0.1 percent, the cost of blended ore could reduce 8.08 million yuan per year. How- ever, the increased usage of high Al2O3 iron ore resulted in a rise of Al2O3 in sinter and blast furnace slag. In order to reduce the negative effect brought by the adoption of high Al2O3 smelting in the actual production, the influence of Al2O3 on the metallurgical properties of sinter and blast furnace smelting was analyzed and the countermeasures were given based on the present production performance and the slag phase diagrams. The realization of decreasing costs and increasing benefits was expected.

Idea of Identification of Copper Ore with the Use of Process Analyser Technology Sensors

The Polish resources of the copper ore exploited by the KGHM S.A. underground mines are considered as one of the most complex in the world and - consequently - the most difficult to be processed. The ore consists of three lithology forms: dolomites, shales and sandstones but in different proportions which has a significant impact on the effectiveness of the grinding and flotation processes. The lithological composition of the ore is generally recognised in-situ but after being mined it is blended on its long way from various mining fields to the processing plant by the complex transportation system consisting of belt conveyors with numerous switching points, ore bunkers and shafts. Identification of the lithological composition of the ore being supplied to the processing plant should improve the adjustments of the ore processing machinery equipment aiming to decrease the specific processing (mainly grinding) energy consumption as well as increase the metal recovery.The novel idea of Process Analyser Technology (PAT) sensors - information carrying pellets, dropped into the transported or processed bulk material which can be read directly when needed - is investigated for various applications within the DISIRE project (a part of the SPIRE initiative, acting under the Horizon2020 framework program) and here is adopted for implementing the annotation the transported copper ore for the needs of ore processing plants control. The identification of the lithological composition of ore blended on its way to the processing plant can be achieved by an information system consisting of pellets that keep the information about the original location of the portions of conveyed ore, the digital, geological database keeping the data of in-situ lithology and the simulation models of the transportation system, necessary to evaluate the composition of the blended ore. The assumptions of the proposed solution and the plan of necessary in-situ tests (with the special respect to harsh environment of

Optimization of Sinter Plant Operating Conditions Using Advanced Multivariate Statistics: Intelligent Data Processing

Blast furnace operators expect to get sinter with homogenous and regular properties (chemical and mechanical), necessary to ensure regular blast furnace operation. Blends for sintering also include several iron by-products and other wastes that are obtained in different processes inside the steelworks. Due to their source, the availability of such materials is not always consistent, but their total production should be consumed in the sintering process, to both save money and recycle wastes. The main scope of this paper is to obtain the least expensive iron ore blend for the sintering process, which will provide suitable chemical and mechanical features for the homogeneous and regular operation of the blast furnace. The systematic use of statistical tools was employed to analyze historical data, including linear and partial correlations applied to the data and fuzzy clustering based on the Sugeno Fuzzy Inference System to establish relationships among the available variables.

Sequestration of As and Mo in uranium mill precipitates (pH 1.5–9.2): An XAS study

As- and Mo- bearing secondary mineral phases formed during the neutralization of uranium mill wastes require characterization. Previous studies indicate that arsenate and molybdate adsorbed to ferrihydrite are the dominant controls in the tailings materials. A lab-scale plant was employed to characterize secondary precipitates from a variety of ore blends. Through total elemental analysis of precipitates and As and Mo K-edge X-ray absorption spectroscopy, different ratios of contributing phases were determined for each pH stage (4.2, 6.5, and 9.2) of the neutralization process. Overall, arsenate adsorbed to ferrihydrite was the dominant As mineral phase regardless of pH or sample blend (53–77%), with fractional contribution from ferric arsenates, and adsorption to aluminum phases. Molybdate adsorbed to ferrihydrite was the dominant Mo mineral phase, with fractional contribution decreasing with increasing pH (100–69%). The characterization of these phases in the secondary precipitates provides further understanding of the contributing mineral species in tailing facilities.

Smart ore blending methodology for ferromanganese production process

This study is carried out to develop a smart ore blending methodology for high carbon ferromanganese production units. Geometallurgical characterisation of the ores collected from 10 different mines has been carried out to estimate variation in their aptness for the alloy production process. An evolutionary algorithm-based methodology has been adopted for ore blending to maximise the total manganese content of the ore blend under applied physico-chemical constraints. Analysis provides various blends of the same chemical composition but of different geometallurgical ranks. An artificial neural network model has been developed to predict the operational parameters such as slag and metal composition. This method allows the operator to visualise the impact of combinations of different ore blends on slag–metal composition as well as on electric power and coke required for smelting reduction of ores in the submerged arc furnace. It was observed that best blends could reduce power and coke consumption by 100 kWh ton−1 and 30 kg ton−1, respectively, but optimum values can be established in long run considering conservation of natural resources.

Reduction of Carbon-bearing Pellets of Oolitic Hematite in a Shaft Furnace

AbstractWhen carbon-bearing pellets of oolitic hematite are treated in a shaft furnace, some problems are typically encountered: the metallization ratio of the metal pellets is low; the carbon-bearing pellets bond with each other at high temperatures; and the separation of phosphorus from iron is difficult. To solve these problems, experiments were conducted on oolitic hematite reduction in a resistance furnace and semi-industrial test shaft furnace. The results showed that the metallization rate reached 90% or greater under the conditions of a reduction temperature of 1150 °C, an atmosphere of simulated flue gas, and a reduction time between 1. 5 and 2. 0 h. The problem of high-temperature bonding among pellets can be solved by increasing the strength of the pellets, coating their surface with a surface transfer agent and maintaining an even temperature inside the shaft furnace. The basicity of the ore blend exerted no obvious effect on the magnetic concentrate and phosphorus content. The phosphorus content in the magnetic concentrate can be further reduced by improving the grinding capacity of the ball mills used in the experiments. On the basis of the experimental results related to oolitic hematite reduction with carbon-bearing pellets in a shaft furnace, the experimental requirements were satisfied with an average 88. 27% total Fe content and 0. 581% P content in the pellets.

铁矿粉基础性能对烧结性能影响的研究

铁矿粉基础性能对其制粒、烧结及烧结矿质量具有重要影响，研究两者间的关系，对优化配矿，从而提高烧结矿产量、改善烧结矿质量具有重要意义。本文对铁矿粉新品种进行了基础性能与其烧结性能关系的研究。烧结矿转鼓强度与四项高温反应性能指标之间不存在明显的相关性；烧结矿产量与粘结相自身强度及液相流动性存在一定的正相关性。烧结矿还原性高，低温还原粉化率高，两者呈现正相关。烧结矿的还原性及低温还原粉化率与四项高温性能之间也不存在明显的相关性。 The fundamental characteristics of iron ore fines largely affect their granulation behavior, sintering performance and even the quality of final sinter product. Therefore, it is of significant importance to investigate the internal relationship between fundamental characteristics and sintering performance for optimizing ore blends, increasing the sinter output and improving the quality of sinter product. In this paper, the relevance of fundamental characteristics of a series of new iron ore fines to their sintering performance was studied. The results show no obviously good correlation can be found between the conventional four high temperature sintering characteristics (i.e., assimilation characteristic, self-bonding strength characteristic, fluidity and formation characteristic of SFCA) of iron ore fines and tumble index (TI) of their single ore sinter, but there is to some extent positive correlation between the productivity of sinter and the self strength of bond-ing phases and fluidity properties of iron ore fines. Besides, positive relationship can also be ob-served between the reduction index (RI) and reduction degradation index (RDI) of sinter. However, both of which also show poor correspondence to the four high temperature sintering characteristics.

Effects of Sodium Iso-butyl Xanthate Dosage on The Froth Flotation of Bead Milled Middle Group 1-3 PGM Ore Blend

An investigation was carried out to determine the effects of collector concentration on the grade and recovery in the flotation of middle group 1-3 Platinum Group Metal (PGM) ore mixture. The ore mixture pulp at a relative density of 1.29 was subjected to “bead milling” test, particle size distribution analysis and the 55% passing 75 µm was froth floated at 180, 200 and 220 g/t dosages of sodium isobutyl xanthate (SIBX) and 30 and 80 g/t of Senfroth and Sendep 30D frother and depressant, respectively. The results obtained indicated the predominance of the 38 µm PGM values in the ore and confirmed the need for tertiary milling for better liberation of the PGMs. The grade of the PGM concentrate obtained when dosing at 200 g/t of sodium isobutyl xanthate was highest at 94 g/t and gave the lowest recovery of 53%. The 180 g/t SIBX dosage resulted in highest PGM recovery of 70% and lowest grade of 84 g/t, while dosing at 220 g/t SIBX gave average PGM grades of 90 g/t and recoveries of 60%. The results obtained thus showed that that an SIBX dosage of 180 g/t SIBX would be appropriate when higher recoveries are targeted, while 200 g/t dosage will yield higher grades

Reduction Behaviour of Iron Ores by Agricultural Waste Chars

Iron and steelmaking are two of the largest energy intensive industries with the highest growth rate in energy consumption of all energy utilisation sectors. In order to meet the growing greenhouse challenges, incorporation of renewable resources to the existing and emerging metallurgical operation are desirable. In this respect, agricultural wastes can be potentially applied as fuel for ironmaking process to stabilise the greenhouse emissions as it is renewable and CO2 neutral. Thus, the present study investigates the reduction behavior of iron ore minerals and growth of metallic iron in reduction process. The process was utilized palm shells char (pyrolyzed) as reducing agent at high temperature (1000°C) with inert gas oxygen within 2 hours of reduction reactions. Reducing agent plays a vital role in the reduction process where metallic iron was produced. After the reduction for sample mass ratio of 30:70 palm char over iron ore blend. Metallic iron produced was detected by XRD pattern as well as the other oxides through SEM/EDS analysis. The result indicates that palm shells char can be used as reducing agent by producing metallic iron effectively. The beneficial effect on the environment through decrease use of coke/coal consumption and carbon dioxide emissions in steelmaking process.

Vanadium–titanium magnetite ore blend optimization for sinter strength based on iron ore basic sintering characteristics

Vanadium titanium magnetite (V–Ti) ore is one kind of important polymetallic minerals in China and the mainstream route of comprehensive utilization process is blast furnace (BF)→basic oxygen furnace (BOF). V–Ti sinter is one of the main burdens employed for BF and poor tumbler strength (TI) limits its efficiency. In order to optimize the V–Ti blends for sinter TI, the basic sintering characteristics (BSCs) of 5 kinds of V–Ti ores, 2 ordinary ores and 3 groups of optimization V–Ti blends were studied. In addition, the sinter pot tests were conducted to obtain the TI of the produced sinter. The influencing factors on assimilation temperature (AT), the relations between the 4 characteristics of BSCs, and the factors influencing the V–Ti sinter TI were analyzed. The results showed that the BSCs of 5 kinds of V–Ti ores DB, HW, YT, JL and FH were good except liquid phase fluidity characteristic index (LF). The key reason why V–Ti sinter had a poor TI was the low LF, which caused the sinter with a large-pore structure. Therefore, the matching ores for optimization V–Ti blends should have a high LF. In addition, self-strength of the bonding phase (BS) and crystal intensity (CI) had an important impact on TI when the melt formed was sufficient and meanwhile the melt had a high LF. Moreover, the proper AT was the prior factor for the melt generation. In addition, the optimization V–Ti blends had good BSCs. The sinter TI with 7% NF ore addition could meet the production requirements for its TI was higher than 65%. Totally, the method of V–Ti magnetite ore blend optimization for sinter strength based on iron ore basic sintering characteristics was useful.

Mineralogy of Iron Ores of Different Alumina Levels from Singhbhum Belt and Their Implication on Sintering Process

To increase the life of the mines, ores of lower quality are blended with the higher quality ores. In general, the blending of ores at mines site is controlled by the chemical composition of the ores by controlling the Al2O3 and SiO2 levels on the lowest side possible. However, if there is a change in mineralogy, like an increase in hydrous phase the composition may still be the same, but this difference may affect the sinterability and sinter quality. The mineralogical investigation of iron ores and their chemistry are required to avoid the increase in deleterious elements during sintering. By the know-how of the behavior of individual iron ores in terms of their sinterability, in advance, the quality of the iron ores blend can be optimized to produce quality sinter and productivity. Characterisation studies conducted on iron ores of Singhbhum Orissa belt revealed that hematite, goethite, clay, gibbsite and quartz occur in all the iron ore samples but in variable proportions. Traces of alumina, present as solid solution in the iron oxide minerals, has also contributed Al2O3 to the ores.

Risk Management Incorporated to Life-of-Mine Planning at Sossego Copper Mine, Carajás, Brazil

Open pit mine design and production scheduling deals with the quest for most profitable mining sequence over the life of a mine. The dynamics of mining ore and waste, and spatial grade uncertainty make predictions of the optimal mining sequence a challenging task. Valuation and related decision-making in surface mining require the assessment and management of orebody risk in the generation of a pit design and long term production scheduling. As the most profitable mining sequence over de life of a mine determines both economic outcome of a project and the technical plan to be followed from mine development to mine closure, the adverse effects of orebody risk on performance is critical and are documented in various studies. Ignoring such a consequential source of risk and uncertainty may lead to unrealistic production plans. This paper presented a set of procedures that enable mine planning engineers to carry out a series of analysis, which can be used to evaluate the sensitivity of incremental pit shells and pit designs to grade uncertainty. The results obtained from the analysis have shown to provide valuable information, which can be used to develop mining strategies that are risk resilient in relation to grade uncertainty. A real life application at Sossego copper mine ensure that such procedures are technically implementable, supporting decision-making as (a) in-fill drilling programs; (b) review of mining sequence; (c) identification of areas of upside potential and downside risk and (d) ore blending between mining areas in order to minimize the impact of high risk areas. The goal of this work is to provide an approach for clear risk analysis and management in mine planning cycle to various aspects of pit optimisation and design, resulting in more technically and economically sustainable life-of-mine production plans and mineral reserve depletion.

High-temperature performance prediction of iron ore fines and the ore-blending programming problem in sintering

The high-temperature performance of iron ore fines is an important factor in optimizing ore blending in sintering. However, the application of linear regression analysis and the linear combination method in most other studies always leads to a large deviation from the desired results. In this study, the fuzzy membership functions of the assimilation ability temperature and the liquid fluidity were proposed based on the fuzzy mathematics theory to construct a model for predicting the high-temperature performance of mixed iron ore. Comparisons of the prediction model and experimental results were presented. The results illustrate that the prediction model is more accurate and effective than previously developed models. In addition, fuzzy constraints for the high-temperature performance of iron ore in this research make the results of ore blending more comparable. A solution for the quantitative calculation as well as the programming of fuzzy constraints is also introduced.

Laboratory iron ore sintering studies. 1. Process simulation and airflow rate

Iron ore sintering is the most popular process used to produce a suitable feed for the blast furnace. With changing iron ore supplies and composition, steel mills have to continually adjust the blended ore mix composition to the sinter plant. To help decision making in this area, and also obtain increased understanding of the process to allow improvements in sintering operations, laboratory-scale sinter pot tests are conducted. The use of a pot for routine testing and for research is discussed. When used as a research tool, the experimental approach used to simulate a plant will have to be modified to facilitate the interpretation of results. Airflow rate through a bed is a critical parameter and this paper highlights the important relationship between post- and pre-ignition airflow rates and also the effect of changing bed suction and coke level in the sinter mix.

A process mineralogy approach to geometallurgical model refinement for the Namakwa Sands heavy minerals operations, west coast of South Africa

The original geometallurgical model for the Namakwa Sands deposit was modified to accommodate ore blends in addition to the various single ore types. A process mineralogy approach was followed in a structured and systematic manner to evaluate the integrity of the adjusted model, particularly for ilmenite and zircon, the minerals of highest intrinsic value. This study reproduced recovery relationships predicted by the geometallurgical model for each of the key process functions, and as a result the integrity of the geometallurgical model is validated. Overall, the recovery potential determined for ilmenite and zircon are well adjusted to model estimates. Poor mineral liberation, an anomalously high abundance of garnet and pyroxene and variation in particle chemistry are recognized as the key recovery penalties. The gangue content is the most significant constraint to ilmenite recovery, whereas zircon chemistry is the most important negative factor in the production of a premium quality zircon product. Results of this study contributed to the refinement of the current geometallurgical model and also identified opportunities to optimise mineral resource utilisation in the future.

Ore blending ratio optimisation for sintering based on iron ore properties and cost

The iron ore blend for sintering depends to a great extent on ore properties. It is hard to determine the final sinter reducibility from the reducibility and ratio of single iron ores in a mixture. For production cost reduction, optimised blending ratios were designed according to ore prices and properties (microstructure, crystal water decomposition, assimilation ability, liquid phase fluidity), ensuring nearly identical chemical composition as the mixture used in actual sintering. Sinter pot tests were conducted to determine the optimum mix. The results indicate that properties of iron ores vary greatly, which should be considered for the design of ore blending ratio. The total content of the two Australian ores tested should not exceed 45%. The cost of sintering process could be further reduced together with an improvement of economic and technical indices, only by ratio adjustment of present ores.

Integrated Optimization and Management of Mining Engineering─Coordinative Operation and Optimal Management of Five processes in Mining Engineering

In the view of engineering philosophy, the min- ing engineering is a dynamic operating process of ferrous material flow, in which the ferrous material flow is processed orderly through a series of continual coordinated procedures. It is also a process of discarding the dross, selecting the es- sential, and extracting the original metal. The object of man- agement is to fulfill the multi-objective optimization. The proportion of lean ores in iron ore resources is 82% in the world and even 97% in China but their utilization is very low. Aiming at the bottleneck and weakness of China's resource development, this paper analyzes and plans the mining engi- neering system as a whole based on the ideas and methods of system theory and engineering philosophical thinking. And the paper proposes the "grade decision-based multi-system integration" engineering management mode, which consid- ers the relationship between engineering and environment and complies with the natural law. In the mode, the mining engineering, including geologic mining, ore blending, con- centration and pelleting, can be viewed as a whole and the geological grade, mined ore grade, feed grade, concentrate grade and feed grade of blast furnace can be considered comprehensively. The mode reflected the overall structural optimization idea, realized the analysis, coordination and optimization among the multiple functions and processes, and thus drove the overall efficient and profit optimization throughout the processing flow. The establishment and the ap - plication of the "grade decision-based multi-system integra- tion" mode have solved the lean iron ores exploitation prob- lem and supported the "self-sufficiency" resource strategy.

Changing Bed Bulk Density and other Process Conditions during Iron Ore Sintering

Iron ore sintering blends in the Asia-Pacific contain significant levels of Australian ores which are lower in bulk density compared to Brazilian ores. This study explores the impact of further decreasing the bulk density of a fairly typical ore blend. This was done by introducing small amounts of a very porous ore into the blend. Measured decreases in bulk density were up to 3%. All the sinter quality parameters could be maintained or improved without the need to increase coke rate. Changes in sinter density results were not significant, indicating that the changes in bed bulk density did not have a significant effect on sinter porosity. The study was then extended to include a comparable blend and two hematite blends of higher bulk density. Decreasing green bed bulk density, bed shrinkage and sinter density did not have a detrimental effect on sinter tumble strength. The associated increase in porosity with the measured changes in sinter density is estimated to be up to 10%. Results showed that sinter density values obtained for the low bulk density mixes at increased coke addition were still lower than equivalent values for the hematite mixes. As expected flame front speed was dependent on post-ignition airflow rate and both these parameters influence sinter strength. Many blends studied have binders and results indicated that their inclusion into sinter mixes gave increased post-ignition airflow values.

Sintering Performance of Magnetite–Hematite–Goethite and Hematite–Goethite Iron Ore Blends and Microstructure of Products of Sintering

Parallel experimentation allowing comparison of magnetite–hematite–goethite inland and hematite–goethite coastal mill blends in terms of sintering performance is reported. Magnetite–hematite–goethite blend affords slightly lower productivity, tumble index, and yield than hematite–goethite blend. However, magnetite–hematite–goethite blend required 9.2 kg · t−1 lower solid fuel rate than the hematite–goethite blend. The lower sintering temperature of the magnetite–hematite–goethite blend than that of the hematite–goethite blend contributed to higher reducibility and lower low temperature degradation under reduction. Its sinter product also contained lower proportions of columnar silico-ferrite of calcium and alumina, magnetite, and fayalite.

Iron Ore Blending Based on Linear Programming

Ore Blending is an important problem that the majority of mining enterprises have to face. To solve the ore blending problem, the production plan should be made firstly, and then small adjustments should be made in according to the actual condition. By effective control and management, the balance of ore quality and stability will be realized. This paper introduced the linear programming and the concept of ore blending. A mathematical model is established by linear programming, solving the problems about ore blending of multi-seam mining in iron Mine of Tangshan hebei minging Ltd., giving the countermeasure aiming at the problem, realizing the effective management and control of ore quality. Preface In mine enterprises ore Blending is mixxing different grade ore evenly in a planned way in mining and shipment process, according to the existing resources and production capacity, according to the relevant indicators, to ensure that the final ore quality standard (such as ore grade, reserves, etc.) meet demand department requirements. At the same time collocating part lean ore in a planned way help to meet the industrial economic use standard, which is helpful to rational utilization of mineral resources, improve relationship between time and space for stope mining, avoid the phenomenon of pressure ore, maintain the normal production of mine to create favorable conditions. Improving the quality of the part lean ore grade help to increase the price standard and mining economic income. Linear programs arise in a variety of practical applications. It is capable of handling a variety of problems such as Portfolio [, Land consolidation optimization [, watershed management [, capacity allocation [,etc.