Iron Ore Processing Research Articles

Compressive strength, durability, and resilient modulus of cement-treated magnetite and hematite iron ore tailings as pavement material

The extraction and processing of iron ore produce significant amounts of mine tailings, causing environmental problems that require storage in reservoirs or dams. Using these materials in construction helps minimize their adverse impacts. This study analyzed the geotechnical properties of Magnetite and Hematite iron ore tailings (MIOT, HIOT) from the Golgohar mine in Sirjan, Iran. Two IOTs were compacted using the Standard Proctor technique after being treated with 5, 7, and 9 % Portland cement. Following curing time, treated samples were tested at different stress levels for resilient modulus. Based on the results, to meet strength and durability requirements, cement-treated MIOT needs 9 % cement. Contrastingly, only 5 % of the cement for cement-treated HIOT met the criterion. The resilient moduli of untreated MIOT and HIOT materials heavily rely on the confining pressure, resulting in a minimal decrease in modulus by increasing deviatoric stress. The effect of cement on resilient modulus is more pronounced in high confining stresses than in low confining stresses in MIOT and HIOT materials. A comparison of different non-linear models showed that ‘Universal’ model is the best fit for laboratory results of cement-treated MIOT and HIOT materials, as it accounts for hardening and softening behavior.

Effect of particle size distribution on the dewatering circuit design; case study: iron ore tailing of the Gol-E-Gohar mining and industrial company

ABSTRACT Iron ore processing plants of the Gol-E-Gohar mining and industrial company have three thickeners. The thickeners’ underflow's is pumped to a tailings dam, with the solid content of about 50%. To increase water recovery, this research investigated the effect of the particle size distribution on the dewatering circuit design of tailings. Physical and chemical characteristics of the thickeners’ underflows (solid content, XRF, XRD, density, etc.) are determined and three different dewatering circuit designs considered. In the first design, only a pressure filter was considered for each stream separately, and in the second design, all streams were combined, and then particles coarser than 1 mm were removed using the screen and dewatered by a pressure filter. In addition, in the third design, all streams are combined and particles coarser than 250 microns are removed using hydrocyclone-screen. Particles smaller than 250 microns are dewatered using a pressure filter. The results showed that the required filtration area (m2) related to the dewatering circuits to reach 20% moisture of plants’ tailings are 1074, 926, and 912 m2, respectively. Finally, it is determined that because of the positive impact of coarse particles on the filtration performance and the operational problems related to the particles larger than 1 mm, all streams must be combined and dewatered using a pressure filter.

Short overview about iron ore beneficiation: a case study in recovering the iron ore from the tailing pond of the Kip-Tuoc processing plant

Iron is a critical metal for many fields of life and industry. The iron-containing minerals are recovered from the iron run-of-mine (ROM) ore and the tailing pond (TP) of the previous processes. The minerals containing iron are hematite, magnetite, goethite, maghemite, etc. In addition, the invaluable minerals and gangue normally are quartz, kaolinite, gibbsite, pyrite, dolomite, chlorite, etc. Many methods to upgrade the iron content as well as separating the iron minerals and gangue are applied. Those technologies are magnetic separation, gravity separation, flotation, chemical separation, thermal beneficiation, or even the application of biotechnology. In Vietnam, there are many technological research projects on iron ore beneficiation and processing. The main technologies are washing and scrubbing methods, magnetizing roasting combined with a magnetic separator, spiral and magnetic separator, flotation, etc. The article shows a short review of the main methods in order to treat the type of raw material as well as some current applied technology in Vietnam. Based on the knowledge, a study to recover the iron of Kip-Tuoc tailing from the tailing pond is presented. The applied technology is the combination of a trommel screen, spiral and shaking table. The result showed that by applying the rational method and carefully controlling the operational parameters, the iron ore (from the tailing pond with 14.28% Fe) recovered up to 57.57% at the 59.49% Fe grade content. The iron content is suitable for feeding to the blast furnaces in Vietnam. Through the research results, a flowsheet for iron recovery at the tailing pond of the Kip Tuoc beneficiation plant is proposed and scaled up to industrial production's next step.

Starch vs. tannin as biodegradable reagents for ultrafine hematite depression

Enrichment of ultrafine liberated valuable minerals from their associated gangue phases is one of the emerging investigation topics within mineral processing and recycling. Using green flotation reagents and turning processes into eco-friendly systems is also one of the challenges in the green transition of ore beneficiation plants. Starch and Tanin as biodegradable depressants for hematite depression have been commercially used in various iron ore processing plants. However, their depression effects on ultrafine particles were not systemically assessed and compared. To fill this gap, this investigation examined the effects of starch, tannin, their mixtures (different ratios), and their different conditioning sequence on the floatability of ultrafine quartz and hematite (− 15 µm). Since the macromolecular polymer of these biodegradable depressants can bind particles together and flocculate them, turbidity analyses were used to assess their optimum ratio for hematite depression without affecting quartz floatability. Turbidity analyses provided a mixture of tannin and starch might enhance the flotation separation of quartz from hematite. Starch could flocculate ultrafine hematite particles, while tannin could disperse ultrafine quartz particles. Floatability experiments indicated that starch had the highest performance in hematite depression (lowest effect on quartz particles) compared to other conditions. Surface analyses (zeta potential and FTIR) proved floatability outcomes and highlighted starch had stronger adsorption on the hematite surface than tannin.

Delay Compensation in a Feeder-Conveyor System Using the Smith Predictor: A Case Study in an Iron Ore Processing Plant.

Conveyor belts serve as the primary mode of ore transportation in mineral processing plants. Feeders, comprised of shorter conveyors, regulate the material flow from silos to longer conveyor belts by adjusting their velocity. This velocity manipulation is facilitated by automatic controllers that gauge the material weight on the conveyor using scales. However, due to positioning constraints of these scales, a notable delay ensues between measurement and the adjustment of the feeder speed. This dead time poses a significant challenge in control design, aiming to prevent oscillations in material levels on the conveyor belt. This paper contributes in two key areas: firstly, through a simulation-based comparison of various control techniques addressing this issue across diverse scenarios; secondly, by implementing the Smith predictor solution in an operational plant and contrasting its performance with that of a single PID controller. Evaluation spans both the transient flow rate during step change setpoints and a month-long assessment. The experimental results reveal a notable increase in production by 355 t/h and a substantial reduction in flow rate oscillations on the conveyor belt, evidenced by a 55% decrease in the standard deviation.

Detection of malignant neoplasms in the population of an industrialized region

Introduction. Malignant neoplasms are the leading cause of the death over the world, ranking second after diseases of the circulatory system. The purpose of the investigation — to study the primary detectability, prevalence, and mortality from malignant neoplasms in the population of the industrialized developed region, propose ways of their early detection to prolong labour longevity. Materials and methods. Using the analysis of retrospective statistical data from the Federal State Statistics Service and the Novokuznetsk Branch of the Kuzbass Clinical Oncological Dispensary named after M.S. Rappoport, from 2013 to 2022 the information on the incidence of oncological diseases in whole and in specific locaion was collected. Results. In recent years, the incidence of malignant neoplasms in Russia, the Siberian Federal District, and the Kemerovo Region, among others, has been at a high level and continues to grow. Among men, lung cancer, colorectal cancer and prostate cancer take first place, and the latter has been competing for 2nd place in the structure of oncological pathology since 2020. At the same time, the gain in oncological diseases prevalence falls in the employable age (45 years and older). In addition to the commonly accepted facts about the risk of developing oncological pathology, there are more than 100 factors of the production environment classified as carcinogenic ones. In this regard, Kuzbass, as one of the most important economic regions of Russia, in which the leading role belongs to the industrial complex for mining and processing of coal, iron ores, and various non-metallic raw materials for metallurgy and the construction industry, refers to the regions unfavourable for the development of malignant neoplasms. Limitations. The limitations of the study relate to the impossibility at present to estimate the number of patients with malignant neoplasms employed in harmful labor conditions. Conclusion. As a result of analyzing own data and numerous studies, we propose screening for the most common oncological diseases (lung, prostate, and colorectal cancer) at periodic medical examinations, which will allow identifying these diseases at early stages for timely successful treatment, thereby prolonging labour longevity.

Combined processing and dephosphorization of brown iron ore of the Kokbulak deposit

Combined processing and dephosphorization of brown iron ore of the Kokbulak deposit

Evaluation of the effect of desliming and alternatives in iron ore reverse flotation circuits

Iron ore reverse flotation has been the main concentration process applied in iron ore processing plants since the 1970s. The performance of this process has been strongly affected by the control of the previous desliming stages. The presence of ultrafine particles promotes selectivity losses in the flotation circuits, in addition to a significant increase in the consumption of chemical reagents and pumping energy. The removal of ultrafine particles promotes metal losses, the need for additional dewatering steps, difficulties in handling and stacking together with flotation waste. This study focuses on investigating the feasibility of replacing desliming with high intensity vertical magnetic concentrators (VPHGMS). Pilot tests were carried out with this type of magnetic concentrator followed by flotation, the results show an increase in metal recovery of 4% when compared to the traditional desliming and flotation circuit, drastic possibility of reducing energy, chemical reagents and foot print and potential to reduce capex and opex by 22% and 24%, respectively, for new projects.

Optimization of High-Alumina Blast Furnace Slag Based on Exergy Analysis

Raw material with a high Al2O3 content has led to an increase in the Al2O3 content in blast furnace slag, which has affected the normal operation of a blast furnace. The exergy analysis method is an important method for studying the energy utilization of high-alumina blast furnace smelting. In this paper, to investigate the impact of slag composition on exergy efficiency and optimize exergy efficiency during the smelting process of high Al2O3 iron ore, a gray box exergy analysis model of blast furnace smelting and an objective function for minimizing the total exergy loss were developed. The results indicated that the blast furnace smelting process had an exergy efficiency (η) of 28.29% for hot metal and slag; the exergy efficiency of the blast furnace did not significantly increase with the increasing w(MgO)/w(Al2O3) and R (w(CaO)/w(SiO2)), but the exergy efficiency of the blast furnace declined with increasing w(Al2O3). The regional optimal solution for the objective function method was 7129.42 MJ with slag compositions of R = 1.295, w(MgO)/w(Al2O3) = 0.545, and w(Al2O3) = 15%.

Water footprint assessment in an industrial symbiosis system based on environmental, economic, and social sustainability indices

Integrated water resource management requires a comprehensive assessment of all water uses, both direct and indirect, which can be captured by the Water Footprint (WF) concept, especially in Industrial Symbiosis (IS). IS creates links between different industries to reduce resource consumption. This article analyses the environmental, social, and economic sustainability aspects of the WF in an IS system. First, the inventories of these three aspects were carried out simultaneously with the WF inventory. Sustainability indices were presented based on the relative comparison of current WF and sustainably oriented WF (SOWF). SOWF in an IS system is defined as the situation with minimum total WF and is obtained by mathematical programming. The proposed framework was applied to an IS involving three industries in southeastern Iran: steel production, coal concentrate, and power generation. The blue WFs of these industries were calculated as 11.77 m3/ton of steel, 0.87 m3/ton of coal, and 8.31 m3/MWh of power. The sustainability indices revealed that the steel industry exhibited a more favorable environmental and social performance than other industries, while the power generation was economically superior with a higher cost ratio of current WF to SOWF. Subsequently, several sustainability-enhancing solutions were evaluated based on environmental, economic, and social criteria. Among these, solar energy usage, wastewater reuse, and recycling in iron ore processing emerged as effective strategies to enhance overall sustainability by reducing WFs and improving social criteria. Ultimately, the wastewater reuse option was given the highest priority.

Magmatic Intrusion during the Yanshanian Period and Multi-Mineral Enrichment Mechanisms in the Eastern Margin of the North China Craton

The mineralization within the North China Craton (NCC) is intricately linked to Mesozoic large-scale extension in eastern China and is a consequence of a unified geodynamic tectonic background. Despite previous attempts to elucidate the relationship between large-scale mineralization and magmatic activity in the NCC, a lack of systematic research has hindered the identification of connections among deposits with inconsistent metallogenic ages. This study focuses on the coal measures of the Huanghebei Coalfield (HHBC) in western Shandong, presenting a regional magmatic–hydrothermal metallogenic system with a genetic connection. It delves into the intricate interplay between the multi-mineral enrichment mechanism, metallogenic regularity, and the NCC’s destruction. The findings reveal that: (1) Various stages of magmatic intrusion during the Yanshanian period significantly influenced the Late Paleozoic coal measures in the HHBC. The coal measures exhibit distinct ranks, ranging from medium-rank bituminous C to A and high-rank anthracite C, resulting in noticeable differences in gas generation among different coal ranks. The shale between the coal seams C5 and C7 emerges as excellent with a good hydrocarbon-generating capacity during the middle-maturity stage. (2) The “Intrusion along the rock layer type” proves most conducive to shale gas enrichment, while the “laccolith type” is more favorable for shale gas enrichment compared to “dike type” intrusions, which have a limited impact on shale gas enrichment. (3) The mineralization process of CBM, shale gas, and iron ore is influenced by Yanshanian-period magma. The enrichment degree of CBM and shale gas exhibits an inverse correlation with the distance from the magmatic intrusion. Iron deposits demonstrate a close association with the magmatic intrusion, with enhanced enrichment along the rock layer. The results indicate that the destruction of the NCC triggered intense metasomatism in the deep cratonic fluids, serving as the primary driving mechanism for large-scale mineralization during the Yanshanian period. Magmatic intrusions bring hydrothermal fluids conducive to mineralization, and the heat release from these intrusions promotes thermal evolution, hydrocarbon generation, and the enrichment of organic-rich strata.

Utilization of rice husk substituting fossil fuel for pelletization process of goethite iron ore

The study investigated the pelletization of goethite iron ore using rice husk as a renewable carbon and energy substitute for coke breeze, which is a traditional fuel used as pellet feed in integrated steel plants. Cold Crushing Strength and porosity of the indurated pellets with rice husk addition were assessed to determine the utilization potential in the blast furnace iron making process. The X-ray diffraction studies showed the presence of iron rich magnetite and wustite, along with hematite and other oxide slag phases, which may impart high strength to the indurated pellets. FESEM studies showed the absence of free granules, which in turn confirmed the occurrence of particle-particle fusion. 3D skeleton image analyses of the indurated pellets in an X-ray micro-CT show uniform formation of round pores with good pore compactness and narrow pore size distribution inside the pellets, which are favorable properties to achieve high strength and porosity of the indurated pellets.

Transforming Mining Waste to Wealth: A Novel Process for the Sustainable Recovery and Utilization of Iron Tailings through HCl Leaching and MOFs Absorption

Rapid economic development and increased demand for mineral products in China have led to extensive extraction of various ores, resulting in significant environmental challenges associated with the generation of industrial solid waste, particularly iron tailings. Despite being a major mining nation, China faces issues of wasteful practices, with substantial amounts of valuable elements lost during the processing of iron ore. This study addresses the urgent need for sustainable solutions by proposing an innovative approach for the recovery of valuable elements from iron tailings. The proposed process involves a sequential application of acid leaching, chemical precipitation, and Metal-Organic Frameworks (MOFs) ion adsorption. The pre-treated iron tailings were leached in HCl solution with pH 1.5 at 70 °C for 2 h, and the co-leaching efficiency of 98.1% V, 98.2% Mo, 99.3% Fe, and 98.7% Mg was obtained. Chemical precipitation is then employed to isolate Fe, Mg V, and Mo and promote the formation of targeted compounds, ensuring concentration and purity. The integration of MOF ion adsorption, known for its high surface area and tunable pore structures, provides an efficient platform for selectively capturing and recovering target ions. 97.7% V and 96.3% Mo were selectively extracted from Zirconium 1,4-carboxybenzene metal-organic framework (UiO-66) adsorption system with pH 5.0 at 30 °C for 6 h, and 91.7% V and 90.3% Mo were selectively extracted from 2-methylimidazole zinc salt metal-organic framework (ZIF-8) adsorption system with pH 5 at 30 °C for 6.0 h. This three-stage process offers an efficient method for the recovery of valuable elements from iron tailings.

Sustainable assessment and synergism of ceramic powder and steel slag in iron ore tailings-based concrete.

Solid waste management is a critical issue worldwide. Effectively utilizing these solid waste resources presents a viable solution. This study focuses on Iron ore tailings (IOTs), a solid waste generated during iron ore processing, which can be used as supplementary cementitious materials (SCMs) but have low reactivity, hindering their large-scale application in concrete production. To address this, ternary SCMs were prepared using ceramic powder (CP) and steel slag (SS) to enhance the performance of concrete incorporating IOTs. The study found that the synergistic effect of CP and SS significantly improved the compressive strength of concrete, with a notable increase of up to 21% compared to concrete with IOTs alone. Mercury intrusion porosimetry (MIP) and backscattering electron (BSE) analyses revealed that the ternary SCMs significantly optimized the characteristics of the interfacial transition zone (ITZ), which in turn enhanced the compressive properties of the concrete. This contributed to maintaining the structural integrity of the concrete, even amidst variations in the pore structure. Importantly, the incorporation of ternary SCMs led to a 23% reduction in carbon emissions, from 400.01kg CO2/m3 to 307.48kg CO2/m3, and elevated eco-strength efficiency from 0.1 to 0.14. The study highlights the role of multi-material synergy in developing composite SCMs systems, fostering the sustainable advancement of green building materials.

Investigation of physicochemical characterization and magnetic enrichment of iron ore from Sidi Maarouf deposit

The establishment of a new metallurgical complex in Bellara, located in El-Milia in the Jijel region, is geographically advantageous due to its proximity to the Sidi Maarouf deposit (Algeria). This proximity has been a fundamental motivation for the completion of the current study. The object of research is the quality of iron products from Sidi Maarouf. The research is aimed at developing a treatment process aimed at improving the quality of iron products from Sidi Maarouf, while reducing the impurities of quartz and clay present in this ore. This approach will be based on an approved technological treatment scheme, implemented through an experimental approach to ensure reliable results that meet the requirements of the steel industry. The problem issue revolves around the difficulties encountered in the production of steels due to the natural characteristics of the raw material. In the absence of a physico-chemical characterization of the Sidi Maarouf iron ore deposit, samples taken undergo a series of thorough analyses, including microscopic examinations, X-ray diffraction (XRD), as well as additional chemical analyses using X-ray fluorescence (XRF). The identified minerals are predominantly composed of hematite in terms of iron. As for the gangue, it is mainly composed of calcite and quartz. Through to the pre-treatment process involving washing, we have successfully removed lightweight particles, resulting in a concentrate containing dense particles. This approach was crucial in achieving satisfactory results during the high-intensity dry magnetic separation. As a result of the research it is shown that the enrichment of the Sidi Maarouf iron ore through high-intensity dry magnetic separation, a final concentrate was obtained with a Fe2O3 content exceeding 67 %, along with a significant reduction in silica impurities to 0.92 % and alumina to 0.77 %. It was concluded that this concentrate, derived from the -1+0.5 mm fraction and obtained under a current intensity of 12 A, meets the requirements of the steel industry. Following the work carried out, it is found that the methods of valorization of iron ore through mineralogical processes consistently require a high level of efficiency and performance in terms of equipment and characterization of the products obtained. In the future, iron ore processing will be conducted using innovative methods, integrating advanced technologies to enhance its characteristics while adopting environmentally friendly practices.

A Study on the Influence of Drying and Preheating Parameters on the Roasting Properties of Limonite Pellets

In this experiment, a pellet preparation method was investigated to study the drying, preheating, and roasting properties of limonitic iron ore from a plant in Yunnan. The aim was to improve the subsequent iron-making process of limonitic iron ore and make it a substitute for sintered ore. This substitution would reduce the amount of blast furnace slag in the iron-making process. Bentonite is commonly used as a primary binder in many pelletizing plant operations. However, its excessive usage leads to a higher risk of slagging and coking in the furnace. In this paper, we aim to decrease the quantity of bentonite added, enhance the iron content in the pellets, and reduce impurities to improve the grade of limonite pellets. The results show that the optimal drying, preheating, and roasting temperatures of limonite pellets are 200 °C, 700 °C, and 1250 °C, respectively, and the optimal roasting time is 20 min, when the diameter of the pellets is 8–13 mm. The compressive strength of limonite pellets with the addition of 1.5% bentonite was the highest, meeting the demands of a general blast furnace, based on which the iron grade of limonite pellet ore was increased by 10.63%.

Valorisation of iron ore tailing piles: utilisation of element-to-mineral conversion and association index to building mineralogical modal

ABSTRACT The objective of this study is to employ the Element-to-Mineral Conversion (EMC) method for determining the mineralogical modal distributions of tailings from iron ore processing plants. Initially, mineralogical studies were conducted by sampling tailing piles to identify textural characteristics and chemical composition in each size fraction. Utilizing the obtained data, the EMC method (HSC-Chemistry software-V.9) was employed to determine the mineralogical modal. The results reveal an increase in the grade of iron oxide minerals, especially magnetite, with decreasing particle size. The highest magnetite grade is associated with the size fraction of −250 + 106 microns (26%). The gangue minerals in the tailings consist of the diopside/calcite phase with an average grade of 35% and the garnet/quartz phase with an average grade of 26%, while pyrite and chalcopyrite are identified as minor minerals. The calculated values for the Association Index (AI) indicate that, in all size fractions, magnetite exhibits the highest interlocking with the diopside/calcite phase, followed by the garnet/quartz phase. The ratio of AI to grade suggests that, in the size range of +1 mm, magnetite is preferred over pyrite, chalcopyrite, chlorite, and tremolite phases. Calcite/diopside and quartz/garnet phases are preferred in all size fractions, with magnetite identified as an accompanying phase.

Study of Iron Ore Processing Technology of Tamir Gol Deposit in Mongolia

Study of Iron Ore Processing Technology of Tamir Gol Deposit in Mongolia

Поиск резервов повышения производительности экскаваторно-автомобильных комплексов с применением компьютерного моделирования

An analysis of the performance indicators of the main high-performance excavators used at leading coal mines and iron ore mining and processing plants in Russia showed that the actual average monthly productivity of excavators achieved at mining enterprises is lower than the calculated technical one by 30% or more. To increase it, it is necessary to minimize negatively influencing factors and optimize the operation of the excavator-automobile complexes. The possibility of this is confirmed by the information available in the scientific and technical literature on record productivity indicators established at mining and processing plants and open-pit mines during full-scale experiments. The choice of excavator-automobile complexes is a relevant and important task at the design stage of new enterprises, or justification of the optimal parameters of the loading and hauling equipment in conditions when the existing quarries are going deeper or expanding and the productivity of mining and processing plants is increasing, as well as for comparing various technological options for the development of deposits. One way to solve this issue may be computer simulation of the functioning of both the individual elements (excavators, dump trucks, excavatorautomobile complexes, etc.) and the quarry transport system as a whole. The Institute of Mining of the Ural Branch of the Russian Academy of Sciences has developed the In-Pit Transport System software suite, aimed, among other things, at solving these problems.

Particle-based characterization and process modeling to comprehend the behavior of iron ores in drum-type wet low-intensity magnetic separation

Drum-type wet low-intensity magnetic separation is a versatile technique traditionally implemented in the mining industry since the mid-19th century. Yet, comprehending the process from a fundamental point of view remains challenging and its implementation still relies on “rules of thumb” that commonly disregard the ore properties and the effects of the operating conditions. This work describes an approach that combines comprehensive particle-based characterization and process modeling to integrate particle properties and equipment characteristics to describe the behavior of an iron ore in a laboratory-scale drum-type magnetic separator. Such a proposal is based on (1) laboratory testing, (2) automated mineralogy for particle-scale ore characterization, and (3) process modeling to compute the particle separation kinetics as a function of the ore intrinsic attributes and the physical principles involved in magnetic separation. This approach proposes the guidelines to obtain early information on the iron ore processing behavior, which represents a promising tool for decision-making at different stages of the beneficiation chain.