Wet High Intensity Magnetic Separation Research Articles

Chemical and mineralogical characterization to define parameters for comminution, aiming at granulometric adequacy in rock rich in feldspars extracted in Pedra Lavrada-PB

The demand for high purity feldspars with low contaminant content, especially for use in the manufacture of porcelain tiles and white crockery, poses a challenge for processing the ore. Due to the need for very low iron levels, less than 0.15%, operations must be more complex, costly and capable of providing a high purity final product. To this end, it is necessary to employ mineralogical and technological characterization to understand the ore and plan the operations of the processing plant. A sample of rock rich in feldspars collected in an extraction in the municipality of Pedra Lavrada/PB was studied, aiming to identify the chemical composition and release spectrum using XRD and SEM techniques. Aliquots were subjected to preparation, granulometric classification and high-intensity wet magnetic separation steps. The results indicate that the rock has high concentrations of feldspars, quartz and a significant content of magnetite and hornblende. The physical release of magnetic mineral phases occurs below 0.104mm, and fragmentation operations must be designed with this grain size standard in mind. Magnetic separation, with mass recovery of 14.01% in relation to the feed, satisfactorily guaranteed a reduction in the concentration of magnetic minerals in the ore

Tungsten tailings issues and reprocessing solutions

This paper aims to provide an overview of tungsten (W) tailings properties, detrimental impacts of these tailings, approaches to mitigate these impacts, and a presentation of methods to reprocess them to capture their economic value. Since W is widely used in a variety of industries, it has been extensively mined since the 19th century, and the mining continues to generate significant volumes of tailings. Recent data show that global W production stands at 84 kt per year, and more than 100 Mt of W tailings exist containing over 100 kt of WO3. The tailings contain variable amounts of valuable products and deleterious environmental substances. Some of the contained metals are in great demand for the energy transition. However, these tailings usually contain FeS2/Pyrrhotite and FeAsS minerals, which, when exposed to air and water, can produce acid mine drainage. As such, W tailings may pose environmental and human health risks. Globally, the reprocessing of W tailings presents a potential resource that can be regarded as a paradigm of sustainability and circular economy. Flotation, enhanced gravity separation, and wet high-intensity magnetic separation have been reported to be the common approaches to reprocessing W tailings. However, W processing presents particular difficulties owing to complex material properties, such as fine particle size, surface weathering, similarity in surface properties exhibited by gangue materials (fluorite, apatite, calcite), low concentrations of the elements of interest, and poor mineral liberation.

Upgrading silica rock quality by using attrition scrubbing and magnetic separation techniques

The study was carried out to produce high-purity silica sand used for glass making. Generally, all grades of silica sands are comparable in their chemical composition except for iron oxide (Fe2O3) content, which is slightly rigid and its concentration varies for different applications. The objective of this work was to increase silicon dioxide (SiO2) content to at least 99.5% and to reduce iron oxide content to less than 0.015% using attrition scrubbing and magnetic separator technique for the purification process. Gravimetric analysis was carried out on the original sample to determine SiO2 content, and minor elements of Fe2O3 quantification using ultraviolet–visible (UV–VIS). A complete chemical and phase analysis were carried out on the raw sample and post-treatment samples. Field Emission Scanning Electron Microscopy (FESEM) was also employed for morphological and mineral phase identification. In this analysis, 70% of solid percent in pulp was used. The optimization of the scrubbing process was performed by studying the effect of using distilled water and citric acid at various concentrations of 0.25 M, 0.5 M, and 0.75 M. The processing time and rotational speed were kept constant at 20 min and 1250 rpm, respectively. The scrubbed silica rocks were then deslimed and dried before being subjected to a wet high intensity magnetic separator (WHIMS) with a magnetic field intensity of 3A, 5A, and 7A. According to this research work, more than 99.5% of SiO2 content and less than 0.015% of Fe2O3 content was achieved although using only distilled water in the scrubbing process. The optimum consumption of citric acid was 0.5 M in the acidic scrubbing process.

Magnetic separation for arsenic and metal recovery from polluted sediments within a circular economy

Several metals and metalloids (e.g., As, Cd, Cu, Pb, Zn) are toxic at low concentrations, thus their presence in sediments can raise environmental concern. However, these elements can be of economic interest, and several techniques have been used for their recovery and some of them have been widely applied to mining or to industrial soils, but not to sediments. In this work, wet high-intensity magnetic separation (WHIMS) was applied for As, Cd, Cu, Pb and Zn recovery from polluted sediments. A composite sample of 50 kg was taken in the Avilés estuary (Asturias, North Spain) with element concentrations above the legislation limits. Element distribution was assessed using wet-sieving and ICP-MS analysis, revealing that the 125–500 μm grain-size fraction accounts for the 62 w% of the material and that element concentration in this fraction is lower than in the other grain size fractions. Subsequently, WHIMS was applied at three different voltage intensities for the 125–500 μm and <125 μm fractions, revealing excellent recovery ratios, especially for the coarser material. Furthermore, magnetic property measurements coupled to microscopy analysis revealed that the success of the technique derives from concentrating metal-enriched iron oxides particles (ferro- and para-magnetic material) in a mixture of quartz and other minerals (diamagnetic particles). These results indicate the feasibility of the magnetic separation for metal and metalloid recovery from polluted sediments, and thus offer a double benefit of coastal area restoration and valuable material recovery in the context of a circular economy.

Removal of Iron from Pyrite-Rich Coal Refuse by Calcination and Magnetic Separation for Hydrometallurgical Extraction of Rare Earth Elements

In the metallurgical extraction of rare earth elements (REEs), the ratio of contaminant ions to REEs in the leachate dictates the cost and operational efficiency of the downstream processes. The current study investigated the potential iron contamination removal from the feed to the hydrometallurgical process by calcination followed by magnetic separation. The 2.20 specific gravity sink fraction of Baker coal seam coarse refuse was pulverized to finer than 180 μm, calcined at various temperatures, and separated into magnetic and non-magnetic fractions using a wet high-intensity magnetic separator at different field strengths. The untreated feed, calcined products, and their subsequent magnetic and non-magnetic fractions were subjected to acid leaching tests with 1.2 M sulfuric acid at 75 °C and 1% w/v solids concentration. The recovery of light and heavy rare earth elements (LREEs and HREEs, respectively) along with the concentration of common contaminant ions (Al, Ca, and Fe) were measured as output variables. The weight percent of magnetic material was maximized at approximately 29% by calcination at a temperature of 400 °C. Magnetic removal of this fraction using a field strength of 1.15 Tesla resulted in the rejection of 81% of the iron. Leaching of the magnetic fraction provided significantly higher Fe recovery relative to untreated feed material and the non-magnetic fraction. The non-magnetic fraction was subsequently calcined at 600 °C to dehydroxylate the clays and released the REE minerals in the same manner as the treatment of the original coarse refuse material. A comparison of the leachate elemental concentrations resulting from the leaching of both the calcined non-magnetic and original coarse refuse showed only a slight reduction in the iron content from the non-magnetic material. This finding combined with the REE loss in the magnetic fraction resulted in the conclusion that the magnetic removal step was unfavorable.

RECOVERY OF CHROMITE FROM ENRICHMENT PLANT TAILING

In this study, experimental studies have performed to recover chromite from Eskiköy-Sivas chromite concentrator which is owned Bilfer Madencilik ve Turizm A.Ş. Mineralogical and liberation measurement studies were performed, and it was decided to grind the feed to 100% finer than 300 µm.&#x0D; Gravity concentration and wet high intensity magnetic separation (WHIMS) tests were performed. After grinding to -300 µm, -38 µm fraction which cannot be recovered efficiently was removed. The studies were conducted on 300+100 µm and -100+38 µm fractions. After the beneficiation tests, it was determined a circuit consists of spiral concentrator and shaking tables could produce a concentrate containing 48% Cr2O3 from the tailings having 6,54 % Cr2O3, with a 56% recovery.

Separation of pyritic sulfur from ultrafine coal by pyrolysis & wet high magnetic separation

ABSTRACT Coal plays a major role in the economic development of many countries, especially in metallurgical industries and conventional power generation plants. The removal of sulfur from coal has recently become even more critically important. Existence of sulfur compounds in coal limits its industrial applications due to environmental as well as technical problems. Thus, high sulfur coal is usually upgraded by desulfurization through physical, chemical, and biotechnological processes. In this study, lowering of pyritic sulfur took place after thermal treatment at 500–700°C (pyrolysis) using a wet high-intensity magnetic separation process. The samples were subjected to size reduction to −25 µm and characterized with X-ray diffraction (XRD), proximate and ultimate analysis, and differential thermal analysis (DTA). Then, the experiments were performed based on central composite rotatable design (CCRD) and response surface methodology (RSM) after thermal treatment of coal containing 3.30% total sulfur. Statistical analysis was performed to examine the significance of the effect of different operating parameters. A maximum sulfur rejection of 90.10% with the lowest sulfur content of 0.59 was obtained at 8.38% solid concentration, 4.59 g/min feed rate, and 7810 gauss magnetic field intensity. The confirmation tests at the optimum conditions produced 0.54–0.56% total sulfur with 90.25–92.33% sulfur rejection.

Magnetic concentration route for recovering pellet feed fines stored in a mining dam

The greatest and noblest challenge of mining engineering for the present and the future of iron ore treatment could be considered as the pursuit of optimizing the use of mineral resources. The use of mining tailings, in the mineral sector itself, or in another industrial branch, meets the needs of circular economy as it increases the useful service life of this material. In order to investigate this scenario, a technological characterization of a sample from a tailings dam was carried out along with magnetic concentration tests in a Wet High-Intensity Magnetic Separator (WHIMS) to propose a possible concentration route. In relation to the characterization itself, the results demonstrated a relative density of 3.04 x 103 Kg/m3and an average superficial specific area of 3.75 cm3/g. The granulometric analysis classified the material as fine, with d90 of 0.110 mm and d50 ≅ 0.049 mm. Quartz, hematite, goethite, kaolinite and manganese oxide were identified in the sample. The test which presented the best results (66.83% Fe and 1.74% SiO2) consisted of the Rougher, Cleaner and Recleaner phases, using a 1.5 mm grooved GAP matrix, a 7,000 Gauss magnetic field, 30% solids, and water pressure at 0.5 kgf/cm2 (49.0 x 103 Pa). Finally, the conclusive results indicate that the studied material can be concentrated through magnetic concentration, keeping in mind the specifications concerning the pellet feed fines commercial product. Besides the financial gain, the activity prolongs the durability of the tailings dam and reduces the environmental impacts associated with these structures.

Recovery of Hematite from Banded Hematite Quartzite of Southern India by Magnetic Separation and Reverse Flotation

Recovery and grade are the two crucial performance parameters commonly used in mineral processing plant operations. These two parameters are interdependent. An increase in recovery would result in a decreased product grade and vice versa. The present study enumerates concentration efficiency (CE),which can be adopted exclusively for processing low-grade hematite ore by WHIMS—the reverse flotation route to produce a pellet grade concentrate. In this study, the ore’s amenability by wet high-intensity magnetic separation followed by the reverse flotation of a magnetic concentrate route is investigated on BHQ samples of the Sandur schist belt (Kumaraswamy hills), India, after its characterization by microscopic and XRD studies. Dodecyl amine acetate was used as a collector to float siliceous gangue while depressing hematite using the freshly synthesized caustic starch as a depressant. The separation efficiency of the flotation was evaluated by estimating the grade, recovery, and concentration efficiency. The WHIMS conducted using the feed with the particle size minus 106 µm (d80 = 82 µm) followed by reverse flotation produced a pellet grade concentrate assaying 64.60% Fe, a 0.32 alumina-to-silica ratio with 60.4% Fe recovery, and a yield of 37.4% with 79.0% concentration separation efficiency.

A study on the recovery of fine chromite from UG2 tailings

The recovery of chromite from the tailings streams of South African UG2 platinum concentrators adds significant financial returns to these operations. Whilst the coarser fractions are amenable to processing by physical separation, the focus is now also on the recovery of fine (typically −75 µm) chromite by flotation.This paper describes the results of a series of physical separation, and chromite bench flotation tests that have been carried out at acidic and natural pH respectively, on UG2 tailings from Pilanesberg Platinum Mines (PPM) on the western limb of the Bushveld Complex in South Africa. The objective of the work is to find a route that would best produce, from a feed assaying around 18 % Cr2O3 and with 50 % of the chromite in the −38 µm fraction, a concentrate of at least 40 % Cr2O3 and an overall yield of more than 13 %.Results showed that shaking tables and wet high intensity magnetic separation (WHIMS) alone were not capable of upgrading the tailings to the target grade. However, flotation tests at a pH of 2.5 on a sample that was deslimed at 10 µm by cycloning, as well as a sample that was screened at 25 µm and subjected to WHIMS, demonstrated that a product assaying 42 % Cr2O3 could be attained at yields between 8 and 11 %, with recoveries ranging between 19 and 27 %. The results highlighted the importance of desliming prior to flotation, in reducing the dosage of the Flotinor V-2711 collector by more than 60 %.Subsequent flotation tests at natural pH on hot tailings samples with two stages of cleaning showed good upgrading, where a feed grade of 16.1 % Cr2O3 after desliming was converted to a concentrate of 29.4 % Cr2O3 at a yield, based on deslimed feed, of 28.6 % and a recovery of 52.4 %. The overall upgrade ratio in this case of 1.83 was slightly lower than those of the acidic tests (i.e., 1.87 and 2.31 respectively) but also at lower yields (28.6 % vs 33 %) and recoveries (52.4 % vs 62 %). Further work is underway to investigate various flowsheet options, including the flotation of fines spiral concentrates, staged collector addition to the cleaning stages, and froth washing.

Wet High Intensity Magnetic Separation (WHIMS) of Algerian Kaolin: a Potential Application

Wet High Intensity Magnetic Separation (WHIMS) of Algerian Kaolin: a Potential Application

Development of innovation routes for iron ore using high intensity magnetic separators

The mineral processing of low-grade iron ores commonly generates large volumes of slime, which are disposed as tailings. Modern mining requires strives to eliminate the use of tailings dams in a maximum effort to increase metallurgical recovery, the security and reduction of the operational cost. This research aims for the recovery of iron contained in the slime, which consists of a material with 38% Fe and <40 µm, originating from the desliming cyclones. Pilot tests were performed on the Wet High-Intensity Magnetic Separator (WHIMS) and on the Vertical Ring Pulsating High Gradient Magnetic Separator (VPHGMS) considering different configurations in terms of operating parameters and routes. The best results were obtained for VPHGMS with an iron content in the concentrate of 67.06% and mass and metallurgical recovery of 32.42% and 56.86%, respectively. In the best condition tested, around 540 thousand tons of concentrate can be incorporated into production and has great environmental relevance.

Magnetization roasting of waste iron ore beneficiation plant tailings using sawdust biomass; A novel approach to produce metallurgical grade pellets

Minerals recovery and recycling of valuables from industrial waste using biomass (renewable energy resource) is the need of the hour for mineral-rich countries worldwide. Moreover, growing steel demand and fossil fuel consumption led civilization to ponder the alternative raw materials and energy sources apart from conventional coal/coke as an appropriate reductant for the iron and steelmaking process. Therefore, the generated waste iron ore beneficiation plant tailings (IOBPT) containing 56.96% Fe(T), 4.07% Al2O3, 7.23% SiO2 and 4.38% of LOI (contributed mainly from clay and goethite) can be considered a potential secondary mineral resource consumed in the downstream iron making processes. In the current investigation, a novel approach of magnetization roasting of the IOBPT using sawdust biomass (SDB) (generated from the sawmill) as a carbonaceous solid reductant is used to recover the pellet grade magnetite concentrate. On the other hand, the IOBPT was directly subjected to a wet high-intensity magnetic separator (WHIMS) to compare the generated pellet grade concentrate in both methods. In this regard, the quality of the concentrate and indurated pellets obtained from both processes was characterized using X-ray diffraction (XRD), scanning electron microscope (SEM), wet chemical analysis, and X-ray microtomography (X-ray microCT), respectively. Altogether, the innovative way of utilizing SDB as a suitable reductant in magnetization roasting at 950 °C to produce metallurgical grade pellets (CCS:258 kg/pellet, Porosity:25.68%, RI:0.71%/min at Rt = 60, RDI-2:RDI]-2.8 = 2.61%, FSI:19.05%) indicates towards a fossil fuel-free industrialization.

Assessment of Reuse Potential of Low-Grade Iron Ore Fines through Beneficiation Routes

The iron ore deposits are sedimentary in nature. In 2021, approximately 1.95 billion metric tons of crude steel were produced globally, compared to 2.6 billion metric tons of usable iron ore. Iron ore is the primary source of the iron and steel industries, which in turn are essential to maintaining a strong industrial and economic base. Globally, 86% of the total iron produced is used in steelmaking. The most important iron ore minerals include hematite, magnetite, and taconite. The other iron ore minerals include goethite, laterite, etc. Hematite and magnetite are most commonly exploited for their iron values. Considering the non-renewable nature of iron ore, there is a paradigm shift towards the upgrading and beneficiation of low-grade iron ore. The widely accepted techniques for beneficiation include jigging, magnetic separation, enhanced gravity separation, froth flotation, etc. Owing to density contrast, iron can be separated from the gangue in simple jigging cycles. The electromagnetic laboratory-scale Wet High Intensity Magnetic Separator (WHIMS) removes fine magnetics and para-magnetics from mineral slurries. The physical and chemical properties of the ore mineral, as well as their mutual relationship, have a large impact on the beneficiation efficiency. In most of the processing units, the small, dense particles report to the tailing fraction, causing a significant loss in ore values. In such challenging cases, the enhanced gravity technique is useful. It is a combination of centrifugal force and gravitational force that facilitates the separation of low-density ore minerals and gangue. The paper focuses on the importance of a characterization study for the success of beneficiation.

Beneficiation of Low-Grade Rare Earth Ore from Khalzan Buregtei Deposit (Mongolia) by Magnetic Separation

The global demand for rare earth elements (REEs) is expected to increase significantly because of their importance in renewable energy and clean storage technologies, which are critical for drastic carbon dioxide emission reduction to achieve a carbon-neutral society. REE ore deposits around the world are scarce and those that have been identified but remain unexploited need to be developed to supply future demands. In this study, the Khalzan Buregtei deposit located in western Mongolia was studied with the aim of upgrading low-grade REE ore via magnetic separation techniques. The total REE content in this ore was ~6720 ppm (~3540 ppm light REE (LREE) + ~3180 ppm heavy REE (HREE)) with bastnaesite, pyrochlore, synchysite, and columbite-(Fe) identified as the main REE-bearing minerals. As the particle size fraction decreased from −4.0 + 2.0 mm to −0.5 + 0.1 mm, the recovery by dry high-intensity magnetic separation (DHIMS) increased from 20% to 70% of total rare earth oxide (TREO) while the enrichment ratio reached 2.8 from 1.3. Although effective, gangue minerals such as quartz and aluminosilicates were recovered (~22%) due most likely to insufficient liberation. Meanwhile, the wet high-intensity magnetic separation (WHIMS) could produce a magnetic concentrate with TREO recovery of ~80% and enrichment ratio of 5.5 under the following conditions: particle size fraction, −106 + 75 μm; feed flow rate, 3.2 L/min; magnetic induction, 0.8 T. These results indicate that combining DHIMS and WHIMS to upgrade the low-grade REE ore from the Khalzan Buregtei deposit is an effective approach.

Applicability of carbothermic reduction for upgrading Sri Lankan ilmenite ores: towards converting ilmenite into synthetic rutile by mechanical activation

BackgroundIlmenite and rutile are naturally occurring titanium-bearing heavy minerals. Sri Lanka consists of ilmenite and rutile in placer deposits mainly along the northeast coast. The commercial value of rutile is higher than ilmenite. Therefore, the current study focuses to upgrade Sri Lankan ilmenite ores using commercially available activated carbon as a reducing agent. Ilmenite fraction was initially separated from raw beach sand using an industrial-scale magnetic separator (Wet high-intensity magnetic separator: sixteen pole model). The mixtures of ilmenite and activated carbon (4 to 1 ratio by weight) were milled using a planetary ball mill for one to four hours at one-hour intervals.ResultsThe milled samples were subsequently heated for two hours continuously at temperatures of 800 °C, 900 °C, 1000 °C, 1100 °C, and 1200 °C, respectively. Initial and annealed samples were analysed using X-ray diffraction (XRD), Fourier-transform infrared (FTIR) spectroscopy, and X-ray fluorescence (XRF) analyses. XRD pattern of the initial sample was characterized by less percentage of rutile (TiO2) peaks and low crystallinity. However, the number of rutile peaks and crystallinity were increased with respective milling hours and annealed temperature. Besides, XRD analysis indicates a higher number of sharp and intense rutile and elemental iron peaks in the samples annealed above 1000 °C. FTIR analysis of raw ilmenite indicates mainly stretching vibrations of Fe–O. However, vibrational spectral bands around 700 cm−1 in samples annealed above 1000 °C are assigned to Ti–O–Ti stretching vibrations. High TiO2 and TiO2 + Fe2O3 (total) wt. (%) can also be observed in samples annealed above 1000 °C.ConclusionsThe optimum conditions for carbothermic reduction were obtained at 4 h of ball milling of ilmenite with activated carbon and continuously annealing at 1000 °C for 2 h. Carbothermic reduction is applicable to upgrade Sri Lankan ilmenite ores, and thus this method adds value to heavy mineral resources in Sri Lanka.

A Review of Tungsten Resources and Potential Extraction from Mine Waste

Tungsten is recognized as a critical metal due to its unique properties, economic importance, and limited sources of supply. It has wide applications where hardness, high density, high wear, and high-temperature resistance are required, such as in mining, construction, energy generation, electronics, aerospace, and defense sectors. The two primary tungsten minerals, and the only minerals of economic importance, are wolframite and scheelite. Secondary tungsten minerals are rare and generated by hydrothermal or supergene alteration rather than by atmospheric weathering. There are no reported concerns for tungsten toxicity. However, tungsten tailings and other residues may represent severe risks to human health and the environment. Tungsten metal scrap is the only secondary source for this metal but reprocessing of tungsten tailings may also become important in the future. Enhanced gravity separation, wet high-intensity magnetic separation, and flotation have been reported to be successful in reprocessing tungsten tailings, while bioleaching can assist with removing some toxic elements. In 2020, the world’s tungsten mine production was estimated at 84 kt of tungsten (106 kt WO3), with known tungsten reserves of 3400 kt. In addition, old tungsten tailings deposits may have great potential for exploration. The incomplete statistics indicate about 96 kt of tungsten content in those deposits, with an average grade of 0.1% WO3 (versus typical grades of 0.3–1% in primary deposits). This paper aims to provide an overview of tungsten minerals, tungsten primary and secondary resources, and tungsten mine waste, including its environmental risks and potential for reprocessing.

A Combined Soda Sintering and Microwave Reductive Roasting Process of Bauxite Residue for Iron Recovery

In this study an integrated process is presented as a suitable method to transform Fe3+ oxides present in bauxite residue into magnetic oxides and metallic iron through a microwave roasting reduction, avoiding the formation of hercynite (FeAl2O4). In the first step, all the alumina phases were transformed into sodium aluminates by adding sodium carbonate as a flux to BR and then leached out through alkali-leaching to recover alumina. Subsequently, the leaching residue was mixed with carbon and roasted by using a microwave furnace at the optimum conditions. The iron oxide present in the sinter was converted into metallic iron (98%). In addition, hercynite was not detected. The produced cinder was subjected to a wet high intensity magnetic separation process to separate iron from the other elements.

Enrichment Of Low Grade Ferruginous Manganese Ore By Pilot Scale Wet High Intensity Magnetic Separation (WHIMS)

Enrichment Of Low Grade Ferruginous Manganese Ore By Pilot Scale Wet High Intensity Magnetic Separation (WHIMS)

Development of impurities removal process for low-grade Sanje iron ore using mineral processing technologies

In this study, the impurities removal process for low-grade Sanje iron ore was developed using Wet High-intensity magnetic separation (WHIMS) and Reverse flotation (RF). Sanje Iron Ore is the low-grade hematite ores found in Nampundwe area of Zambia from which Iron is to be extracted and used as the feed in the steelmaking process. The ore contains 34.18 mass per cent Iron grade, 31.10 mass% of Silica (SiO2) and 7.65 mass per cent Alumina (Al2O3). Magnetic Separation experiments were done using Series L Model 4 laboratory magnetic Separator (L-4 Machine) as the first stage impurity removal process and the effect of various magnetic separation parameters such as magnetic flux density, particle size density and pulp density of the feed were studied. The results showed that 10 T was optimal magnetic flux density which enhanced the recovery of 93 per cent of iron with 53.22 mass per cent grade. The iron concentrate produced from magnetic separation contained 12.04 massper cent Silica and 3.94 massper cent Alumna and therefore, it was further treated using Reverse flotation. In reverse flotation, various parameters such as pH, collector dosage, Iron depressant dosage and quartz activator dosage were investigated. The results showed that 81.94 per cent was recovered at the concentrate’s pH of 6.8 using 200 g/T of 0.1 per cent calcium oxide (CaO) as silica activator and one kg/T of 0.1 per cent causticised starch as Iron depressant. Sodium Oleate (NaOL) and Dodceylamine Acetate (DAA) each with discrete dosage, were used as Anionic and Cationic collectors respectively. Alumina was consequently reduced to 1.04 mass per cent and Silica to 2.04 mass per cent at optimum respective collector’s dosage of 0.250 kg/T using 0.02 kg/T of Methyl Isobutyl Carbinol (MIBC) frother. Additionally, phosphorous was also observed to be reduced from 0.05 mass per cent to 0.01 mass per cent. The designed multi-stage process involving feeding the concentrate from WHIMS into RF process therefore produced a high-grade iron concentrate iron with 67.27 mass per cent grade, 2.04 mass per cent silica, 1.04 mass per cent alumina.