Skip to main content
SpringerLink
Log in

Beneficiation of Clay-Rich High-LOI Low-Grade Iron Ore Fines: Assessment of Conventional Deep Beneficiation and Magnetization Roasting Using High-Ash Non-coking Coal

  • Published:
Mining, Metallurgy & Exploration Aims and scope Submit manuscript

Abstract

The unutilized iron ore fines (IOF, − 10 mm, 45% to < 60% Fe(T)) left at various mine sites during blasting and processing are rich in goethetic-hematite associated with high clay and considered a potential iron ore resource. The variation of loss on ignition (LOI) from mines to mines is based on the goethite and clay mineral content. The clay containing below 45 μm is mostly brittle, causing beneficiation problems. The IOF has an LOI of 7.83%, with high silica (5.52%) and alumina (4.57%), and 57.17% of Fe(T) subjected to both conventional deep beneficiation (CDB) and magnetization roasting using high-ash non-coking coal to adopt the suitable upgradation process. The CDB and magnetization roasting concentrate has 62.61% and 67.58% Fe(T) with 64.69% and 85.19% yield, respectively. However, the presence of 6.40% LOI in CDB makes the ore challenging for pelletization. Characterization like X-ray diffraction(XRD), scanning electron microscope(SEM), and chemical analysis was used to assess the concentrate quality and potential industrial application.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3

Similar content being viewed by others

References

  1. Sahu SN, Baskey PK, Barma SD, Sahoo S, Meikap BC, Biswal SK (2020) pelletization of synthesized magnetite concentrate obtained by magnetization roasting of Indian low-grade BHQ iron ore. Powder Technol 374:190–200. https://doi.org/10.1016/j.powtec.2020.07.004

    Article  Google Scholar 

  2. Iron & steel - vision 2020, (2005)

  3. Singh GP, Sundeep RP, Choudhary H, Vardhan M, Aruna AB (2015) Akolkar, Iron ore pelletization technology and its environmental impact assessment in eastern region of India – a case study. Procedia Earth Planet Sci 11:582–597. https://doi.org/10.1016/j.proeps.2015.06.060

    Article  Google Scholar 

  4. Bhagat RP, Bhagat RP (2019) Induration of Green Pellets, in: Agglom. Iron Ores, CRC Press, pp. 335–360. https://doi.org/10.1201/9781315269504-14

  5. Jankovic A (2015) Developments in iron ore comminution and classification technologies, in: Iron Ore Mineral. Process Environ Sustain, Elsevier Inc.,: pp. 251–282. https://doi.org/10.1016/B978-1-78242-156-6.00008-3.

  6. Maré E, Beven B, Crisafio C (2015) Developments in non-magnetic physical separation technologies for hematitic/goethitic iron ore, in: iron ore mineral. Process Environ Sustain, Elsevier Inc., pp. 309–338. https://doi.org/10.1016/B978-1-78242-156-6.00010-1

  7. Sahu SN, Sahu AK, Biswal SK (2015) Study on mixing and segregation behaviors in particulate fluidized bed system for mineral processing. Int J Min Sci Technol 25:459–464. https://doi.org/10.1016/j.ijmst.2015.03.021

    Article  Google Scholar 

  8. Sahoo S, Sahu SN, Sahoo RK, Soren S, Biswal SK (2021) A study on removal of clay minerals from barbil region iron ore; effect of scrubbing followed by pelletization, mining. Metall Explor 38:105–116. https://doi.org/10.1007/s42461-020-00292-9

    Article  Google Scholar 

  9. Sahu SN, Biswal SK (2021) Alleviating dependency on fossil fuel by using cow-dung during iron ore pelletization; assessment of pellet physical and metallurgical properties. Powder Technol 381:401–411. https://doi.org/10.1016/j.powtec.2020.12.027

    Article  Google Scholar 

  10. Jain V, Rai B, Waghmare UV, Tammishetti V (2013) Pradip, Processing of alumina-rich iron ore slimes: is the selective dispersion-flocculation-flotation the solution we are looking for the challenging problem facing the indian iron and steel industry? Trans Indian Inst Met 66:447–456. https://doi.org/10.1007/s12666-013-0287-1

    Article  Google Scholar 

  11. Gururaj B, Sharma JP, Baldawa A, Arora SCD, Prasad N, Biswas AK (1983) Dispersion-flocculation studies on hematite-clay systems. Int J Miner Process 11:285–302. https://doi.org/10.1016/0301-7516(83)90050-9

    Article  Google Scholar 

  12. Srivastava U, Kawatra SK (2009) Strategies for processing low-grade iron ore minerals. Miner Process Extr Metall Rev 30:361–371. https://doi.org/10.1080/08827500903185208

    Article  Google Scholar 

  13. Raghukumar C, Tripathy SK, Mohanan S (2012) Beneficiation of Indian high alumina iron ore fines – a case study. Int J Min Eng Miner Process 1 (2012) 94–100. https://doi.org/10.5923/j.mining.20120102.11

  14. Srivastava MP, Pan SK, Prasad N, Mishra BK (2001) Characterization and processing of iron ore fines of Kiruburu deposit of India. Int J Miner Process 61:93–107. https://doi.org/10.1016/S0301-7516(00)00030-2

    Article  Google Scholar 

  15. Richards RG, MacHunter DM, Gates PJ, Palmer MK (2000) Gravity separation of ultra-fine (-0.1 mm) minerals using spiral separators. Miner Eng. 13: 65–77. https://doi.org/10.1016/S0892-6875(99)00150-8

  16. Prasad PSR, Prasad KS, Chaitanya VK, Babu EVSSK, Sreedhar B, Murthy SR (2006) In situ FTIR study on the dehydration of natural goethite. J Asian Earth Sci. 27: 503–511. https://doi.org/10.1016/j.jseaes.2005.05.005

  17. Yang DC, Bozzato P, Ferrara G (2003) Iron ore beneficiation with packed column jig. J Miner Mater Charact Eng 02:43–51. https://doi.org/10.4236/jmmce.2003.21004

    Article  Google Scholar 

  18. Upadhyay RK, Venkatesh AS, Roy S (2010) Mineralogical characteristics of iron ores in Joda and Khondbond areas in Eastern India with implications on beneficiation. Resour Geol 60:203–211. https://doi.org/10.1111/j.1751-3928.2010.00126.x

    Article  Google Scholar 

  19. Umadevi T, Sridhara K, Rameshwar S, Srinidhi R (2019) Usage of high-LOI iron ore fines in pellet making. Trans Indian Inst Met 72:2599–2611. https://doi.org/10.1007/s12666-019-01729-6

    Article  Google Scholar 

  20. Yu J, Han Y, Li Y, Gao P (2020) Recent advances in magnetization roasting of refractory iron ores: a technological review in the past decade. Miner Process Extr Metall Rev 41:349–359. https://doi.org/10.1080/08827508.2019.1634565

    Article  Google Scholar 

  21. Sahu SN, Sharma K, Barma SD, Pradhan P, Nayak BK, Biswal SK (2019) Utilization of low-grade BHQ iron ore by reduction roasting followed by magnetic separation for the production of magnetite-based pellet feed, Metall Res Technol 116. https://doi.org/10.1051/metal/2019039

  22. Iwasaki I, Prasad MS (1989) Processing techniques for difficult-to-treat ores by combining chemical metallurgy and mineral processing, miner. Process Extr Metall Rev 4:241–276. https://doi.org/10.1080/08827508908952639

    Article  Google Scholar 

  23. Yu J, Han Y, Li Y, Gao P (2017) Beneficiation of an iron ore fines by magnetization roasting and magnetic separation. Int J Miner Process 168:102–108. https://doi.org/10.1016/j.minpro.2017.09.012

    Article  Google Scholar 

  24. jun i Y, ang R, xin an Y, chao ei X (2015) Phase transformation in suspension roasting of oolitic hematite ore. J Cent South Univ 22: 4560–4565. https://doi.org/10.1007/s11771-015-3006-8

  25. Monzavi M, Raygan S (2020) Beneficiation of an oolitic-iron ore by magnetization roasting and magnetic sepration. Iran J Mater Sci Eng 17: 27–39. https://doi.org/10.22068/ijmse.17.3.27

  26. Zhang X, Han Y, Sun Y, Li Y (2019) Innovative utilization of refractory iron ore via suspension magnetization roasting: A pilot-scale study. Powder Technol 352:16–24. https://doi.org/10.1016/j.powtec.2019.04.042

    Article  Google Scholar 

  27. Beneficiation Plants and Pelletizing Plants for Utilizing Low Grade Iron Ore Tsutomu NOMURA *1 , Norihito YAMAMOTO *2 , Takeshi FUJII *2 , Yuta TAKIGUCHI *3 *1, n.d.

  28. Sun J, Zhang JZ (2013) Beneficiation study on an oolitic hematite, in: Adv. Mater. Res, pp. 202–205. https://doi.org/10.4028/www.scientific.net/AMR.690-693.202

  29. Li S, Sun Y, Han Y, Shi G, Gao P (2011) Fundamental research in utilization of an oolitic hematite by deep reduction, in: Adv Mater Res pp. 106–112. https://doi.org/10.4028/www.scientific.net/AMR.158.106

  30. Peng T, Gao X, Li Q, Xu L, Luo L, Xu L (2017) Phase transformation during roasting process and magnetic beneficiation of oolitic-iron ores. Vacuum 146:63–73. https://doi.org/10.1016/j.vacuum.2017.09.029

    Article  Google Scholar 

  31. Zhang Q, Sun Y, Han Y, Li Y, Gao P (2020) Effect of thermal oxidation pretreatment on the magnetization roasting and separation of refractory iron ore. Miner Process Extr Metall Rev 1–6. https://doi.org/10.1080/08827508.2020.1837126

  32. Li C, Sun H, Bai J, Li L (2010) Innovative methodology for comprehensive utilization of iron ore tailings. Part 1. The recovery of iron from iron ore tailings using magnetic separation after magnetizing roasting. J Hazard Mater 174: 71–77. https://doi.org/10.1016/j.jhazmat.2009.09.018.

  33. Journal AI, Chen X, Peng Y (2018) Managing clay minerals in froth flotation — a critical review. Miner Process Extr Metall Rev 39:289–307. https://doi.org/10.1080/08827508.2018.1433175

    Article  Google Scholar 

  34. Dey S, Mohanta MK, Singh R (2017) Mineralogy and textural impact on beneficiation of goethitic ore. Int J Min Sci Technol 27:445–450. https://doi.org/10.1016/j.ijmst.2017.03.017

    Article  Google Scholar 

  35. Wu Y, Fang M, Lan L, Zhang P, Rao KV, Bao Z (2012) Rapid and direct magnetization of goethite ore roasted by biomass fuel. Sep Purif Technol 94:34–38. https://doi.org/10.1016/j.seppur.2012.04.008

    Article  Google Scholar 

  36. V. 2020b, 06062017101137Iron and Steel 2020_3.pdf, (n.d.).

  37. Sahu SN, Meikap BC, Biswal SK (2022) Magnetization roasting of waste iron ore beneficiation plant tailings using sawdust biomass; a novel approach to produce metallurgical grade pellets. J Clean Prod 343:130894. https://doi.org/10.1016/j.jclepro.2022.130894

    Article  Google Scholar 

Download references

Acknowledgements

The authors are thankful to the Director, CSIR-IMMT Bhubaneswar, for permitting us to publish this paper. The authors are also grateful for the scientific inputs from the scientists and technical staff of CSIR-IMMT, Bhubaneswar.

Author information

Authors and Affiliations

  1. CSIR - Institute of Minerals and Materials Technology, Bhubaneswar, Odisha, 751013, India

    Sachida Nanda Sahu & Surendra Kumar Biswal

  2. Indian Institute of Technology, Kharagpur, West Bengal, 721302, India

    Sachida Nanda Sahu & B. C. Meikap

Authors
  1. Sachida Nanda Sahu
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. B. C. Meikap
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Surendra Kumar Biswal
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Sachida Nanda Sahu.

Ethics declarations

Conflict of Interest

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Supplementary Information

Below is the link to the electronic supplementary material.

Supplementary file1 (DOCX 159 kb)

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sahu, S.N., Meikap, B.C. & Biswal, S.K. Beneficiation of Clay-Rich High-LOI Low-Grade Iron Ore Fines: Assessment of Conventional Deep Beneficiation and Magnetization Roasting Using High-Ash Non-coking Coal. Mining, Metallurgy & Exploration 39, 1655–1666 (2022). https://doi.org/10.1007/s42461-022-00626-9

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s42461-022-00626-9

Keywords

Search

Navigation