Low grade iron ore beneficiation plant

Low grade iron ore beneficiation plant

Beneficiation is defined as “a variety of processes whereby extracted ore from mining is reduced to particles that can be separated into mineral and waste, the former suitable for further processing or direct use”. Various physical properties can be exploited to separate a low grade fraction including variation in size, density and magnetism.

Two Main Groups Of Iron Ore

High grade – Direct shipping ore (“DSO”), generally contains >60% Fe. It is used in blast furnace and only requires simple preparation. It is crushed for sizing and can be used either as fine ores or lump ore.

Low grade – It is beneficiated, with cut-off grades in the range of 25-30% Fe. It is pulverized into finer particles (pulverized ore) and subjected to pretreatment before blast furnace. The pretreatment process can be either sintering or pelletising.

The Common Impurities In Iron Ore

  • Silica SiO2 (is almost always present in iron ore)
  • Phosphorous
  • Alumina Al2 O3
  • Sulfur S
  • Calcium carbonate CaCO3
  • Manganese oxide MnO2 (especially in hematite)

Iron Ore Beneficiation Process

  • Head assay, mineralogy, ICP multielement scan
  • Milling (crushing and grinding )
  • Thickening
  • Filtration
  • Sizing
  • Gravity concentration
  • Magnetic separation
  • Flotation
  • Agglomeration (pelletizing, sizing, briquetting, or nodulizing)

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