Laboratory Column flotation studies for reduction of alumina and silica in iron ore slimes of an operating plant

A typical iron ore washing plant for treating iron ore fines (<10 mm) consist of sizing of the ore by dry / wet screening, washing, classification by screw classifiers followed by single or multi-stage hydrocycloning of screw classifiers overflow. The underflow of the hydrocyclones forms the concentrate which is suitable for pellets making. Since the cut-point of hydrocyclones is usually at 20 µm or less, relatively lower diameter cyclones in a cluster with parallel feeding are used. This is found to, often, result in choking of the spigots, at times, by extraneous material reporting along with the slurry. It is observed to lead to sub-optimum performance of the cyclones with loss of iron values into cyclone overflow and thereafter into tailings. Analysis of the data of an operating beneficiation plant (Beneficiation plant - 1) of M/s Jindal South West (JSW) Steel Limited, Karnataka, India over a period of one year indicated that weight recovery of the concentrate from two-stage hydrocycloning was 45.9% (with respect to feed to the cyclones) and assaying 63.43% Fe, 4.43% SiO2 and 2.23% Al2O3. Considering the fineness of the slimes (d80: 40.5 µm), generated as screw classifier overflow, flotation is thought to be better alternative vis-à-vis hydrocyclones to recover iron values from it. The present study aims at improving the recovery of the iron values from the screw classifier overflow by adopting reverse cationic column flotation technology. After selecting a suitable collector, process parameters like collector and depressant dosages are optimized by statistically designed experiments on a Denver D12 flotation cell. Later, the effect of important operating parameters of flotation column like air flow-rate, froth depth and wash water on the separation process is studied and optimized. It was established that a typical screw classifier overflow analyzing 60.43% Fe, 6.88% SiO2 and 3.26% Al2O3 could be improved to 63.30% Fe, 4.04% SiO2 and 2.32% Al2O3 with 59.10% weight and 61.70% Fe recovery. This is an improvement of 29% in weight recovery of the concentrate at equivalent metallurgy compared to what is being obtained, by two-stage cycloning

Interaction of Oleate Molecules on Sillimanite and Garnet minerals.

Adsorption of oleate on sillimanite and garnet was studied using electrokinetic measurements. Both the systems exhibit a characteristic shift in iep by increasing the concentration of oleate in solution. This shift in iep has been quantified in terms of specific interaction between the surface sites and oleate molecules. The shift in iep was estimated separately for both the systems using the equation derived on the basis of electrical double layer theory. The specific free energy of adsorption was estimated to be 7.94 kcal/mole for sillimanite-oleate system and 7.49 kcal/mole for gamet-oleate system

Geochemical assessment of a siliceous limestone sample for cement making

A low grade siliceous limestone sample from the Jayantipuram mine of Andhra Pradesh, India, has been investigated for its suitability for cement making. Petrological as well as X-ray diffraction pattern studies indicated that the limestone sample was crystalline and dominantly composed of calcite and quartz. They are simple in mineralogy, and yet they have variable silica and lime contents. Geochemical analysis results of twenty five hand picked samples indicated that the limestone from the Jayantipuram mine shows a wide range of variations in LOI (29.94% to 40.64%), SiO2 (6.14% to 27.18%), CaO (37.93% to 50.78%), Al2O3 (0.49% to 2.27%) and Fe2O3 (0.28% to 2.4%). MgO, K2O, Na2O, TiO2 and MnO2 are present in traces. CaO with LOI shows a strong positive correlation where as CaO with SiO2 shows a strong negative correlation because of mineralogical factors. The chemical composition of the limestone reflects its mineralogical composition. The distribution of various elements in the acid-soluble fraction has been studied by the factor analysis method in order to interpret in terms of their mineralogy, sedimentary environment and diagenesis. Mineralogy, recrystallization and other diagenetic changes are the main factors affecting the distribution of the elements and their mutual relationships in the limestone. The aim of this paper is also to analyze how significantly the two parameters, silica modulus and lime saturation factor, influence this low grade siliceous limestone sample from the Jayantipuram mine of Andhra Pradesh, India, for the cement making process from the geochemical data

Alteration characteristics of illmenites from south India

Two different placer samples from the Navaladi and Surungudi area of Teri, Tamilnadu. in southern India. were collected and characterized in terms of their heavy mineral content. Mineralogical analysis on both the samples revealed the presence of high amounts of garnet and ilmenite. The alteration characteristics of ilmenite from these deposits were investigated by optical and electron probe microanalysis. Optical microscopic studies revealed that the alteration of ilmenite was seen to proceed along grain boundaries and/or fractures resulting in an amorphous to crypto- or microcrystalline mass resembling leucoxene. The alteration is in the nascent stage. Mineral chemistry by electron probe micro-analysis revealed the enrichment of Ti02, MgO, A1203•Cr203. Si02, V205 and Na20 in the altered products and loss of iron oxide and manganese oxide from the ilmenite grains during weathering leading to the formation of leucoxene. Similarly EPMA studies on garnet indicated that it is of the almandine variety. This study reveals that the alteration of ilmenite by weathering leads to unstable phases, with complex elemental distribution patterns. The physico-chemical characteristics of the mineral and, in turn, the down-stream metallurgical processing are affected by such alteration processes

Column flotation technology for the beneficiation of coking and non-coking coal fines

The importance of coal is bound to increase for the coming years with the growth of coal consuming industries. Power sector is the most potential consumer of the non-coking coal and for coking coal iron & steel sector remains the major consumer. In future, coal gasification which is successfully adopted in China, an advanced coal-based power generation technology has the potential to provide higher generating efficiency and can be adopted to efficiently burn India’s high-ash coals. In the present study investigations are carried out on coal fines for both coking and non coking coals by conventional and column flotation techniques to suit industrial applications. Coking coal sample is taken from Jamadoba area in Jharkhand and non-coking coal is drawn from coal belt in Central Coal Fields, Jharkhand. For both the coals detailed studies are in progress for optimizing the reagent consumption and to establish the feasibility of column flotation technology for producing low ash concentrates with reasonably high recoveries

Characterization of Srikurmum and Navaladi Beach Placer Minerals

Two different beach placer samples from Srikurmum of Andhra Pradesh and Navaladi of Tamilnadu were collected and characterized in terms of their total heavy mineral content by heavy media as well as magnetic separation studies. Navaladi beach placer sample contains higher amounts of total heavy minerals than that of the Srikur-mum beadh. Mineralogical analysis on both the samples revealed high amounts of garnet and minor quantities of ilmenite. The particle size of garnet is coarser than that of ilmenite. EPMA results indicated that garnet is of almandine variety. The Eastern Ghats metarnotphic belt, covering both the areas, is considered to be the source of these beach placer minerals

Value Addition of Indian Iron Ore Fines by Column Flotation - Few Case Studies

The Government of India highlighted Processing and utili-zation of iron ore fines as a prerequisite to meet the domestic raw material requirements for the projected 110 million tonnes of domestic steel production by the year 2019-20 in the National Steel Policy announced in Nov-ember 2005. This would require 190 million tonnes of iron ore. The depletion of high grade iron ore and increased generation of fines during mining and handling and demand for high grade iron ore fines for export has necessitated the processing of low to medium grade fines. The R&D efforts undertaken at NML-Madras Centre, India in this direction have been highlighted. Flotation in general and Column Flotation in particular appear to be promising in addressing this problem. This would also mitigate the environmental problem created by the dumping of huge quan-tities of low and medium grade iron ore fines. Three case studies involving iron ore fines of varying silica and alumina content from Goa and Bellary-Hospet regions of India were discussed. The results clearly indicate the feasibility and significance of flotation process in treat-ing the fines to obtain marketable concentrates

Development, testing and plant trails of single reagent system for coal flotation

Flotation is an important means of upgrading the fine fraction of raw coal, typically particles finer than 0.5 mm. Due to increased use of highly mechanized mining techniques large quantities of fines (< 0.5 mm) are being generated. These fines presently account for approximately 20–30% of the total plant feed. More than 140 million tones of fine coals are beneficiated by flotation worldwide annually. In coal flotation, reagents are required to enhance the hydrophobicity of coal surface. In addition to hydrophobic character, the selectivity, proper froth structure, stability and less sensitive to water chemistry are important. Water insoluble hydrocarbons are widely used as collectors in coal flotation. These collectors are basically non-polar oils like diesel, kerosene, etc. along with some frothers. Thus, it is necessary to add collector and frother separately in coal flotation. It is generally accepted that in coal flotation a single reagent system is more advantageous than the present practice of two reagent system. National Metallurgical Laboratory is involved in the flotation of coal fines using alternative single collector systems to developed specially replace fuel oils and frothers. For this purpose NML has entered into an agreement with M/s Somu Organo-Chem Pvt. Ltd. (SOCPL) Bangalore, a leading reagent manufacturer. Under this collaboration M/s SOCPL developed reagents and NML evaluated their selectivity index and application in coal flotation. Among many reagents developed and evaluated one best reagent was selected and full scale plant trails were conducted. The paper deals with the results obtained with several reagents in the laboratory and the plant trails

Recovery of values from tailing ponds of iron ore washing plants

Most of the Iron ore washing plants set up in India in the earlier days consist of sizing of the ore by dry / wet screening, washing and classification by screw classifiers. In this classical approach, iron values were lost in the form of fines and utrafines into the tailing ponds as they had little commercial value in those days and accumulated in huge quantities over the years. As the high grade deposits are getting exhausted and the demand for high grade finer material for pellet making is ever increasing, focus is shifting towards recovering the values from the erstwhile tailing ponds by column flotation. This is also supposed to mitigate to certain extent the environmental problems caused by the ever expanding and unmanageable tailing dams. A case study is presented wherein a composite sample is prepared from samples drawn systematically from multi - locations in a sprawling tailing dam. Laboratory scale column flotation tests on this composite tailings sample, basically originating from two operating iron ore beneficiation plants of JSW Steel Ltd., one of the leading producers of steel in India, are found to be encouraging. De-sliming followed by reverse and cationic flotation tests using flotation column resulted in the concentrate of 61.88% Fe, 4.81% SiO2, 2.52% Al2O3 and 3.30% loss on ignition (LOI) from the tailings analysing 57.86% Fe, 7.10% SiO2, 3.52% Al2O3 and 6.14% LOI with 52% weight recovery. The causes for the quality improvement could be attributed to de-sliming of unliberated ultra fines of kaoline and hydrated iron oxides and their further reduction by efficient flotation process. The process and the cationic collector developed for this purpose are adopted in the new flotation plant created to treat these tailings

Alteration characteristics of manavalakurichi beach placer illmenite, Tamilnadu.

The mineralogy and alteration characteristics of beach placer ilmenite from the Manavalakurichi coast were investigated by optical microscopy and electron probe microanalysis. Mineral chemistry by electron probe micro-analysis indicated ;enrichment of TI02, MgO, AI203, Cr203, Si02. K20, V205,. CaO and Na20 in the altered products ofilmenitc:. while there was a loss of iron oxide, maganesc oxide and zinc oxide from the ilmenite grains during weathering leading to leucoxen