Chromite ore

1. Chromite ore beneficiation Prepared by Mukesh Ranjan Behera

2. Contents Introduction Steel scenario Physical and chemical properties Occurrences Classification and uses World chromite production Global reserves and demand List of companies engaged Potential of India Mining methods Beneficiation Cost variation

3. Objectives To gain the basic knowledge of chromite Its formation Global presence Uses Mining methods Beneficiation practice

4. Introduction Chromite occurs as a chromium spinel, a complex mineral containing magnesium, iron, aluminum and chromium in varying proportions depending upon the deposit. Chromium is replaced by ferric iron & aluminum to form hercynite(FeAl2O4)and iron is replaced by magnesium to form magnesio chromite(MgCr2O4). It is this replacement that improves the Cr/Fe ratio in chromite . Chromium ore occurs exclusively in ultramafic igneous rocks .

5. Steel Scenario Indian steel production is likely to grow over 250-300 MTPA from its current 86 MTPA by 2025-30

6. Properties of Chromite Chemical Classification oxide Color dark gray to black, rarely brownish black Streak dark brown Luster metallic to submetallic Diaphaneity opaque Cleavage none Mohs Hardness 5.5 to 6 Specific Gravity 4.0 to 5.1 (variable) Diagnostic Properties luster, streak Chemical Composition FeCr 2 O 4  with magnesium substituting for iron in significant amounts Crystal System isometric Uses an ore of chromium Physical and chemical properties

7. Occurrences/ Deposits Commercial chromite deposits are found in two forms : stratiform seams and irregular podiform/lenticular deposits .

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9. Classification and uses

10. World chromite reserves and production graphs Source: Industrial Minerals 2011

11. Country Production 2011 ('000 metric tons) Production 2012 ('000 metric tons) Reserves('000 metric tons) South Africa 10,200 11,000 200,000 Kazakhstan 3,800 3,800 210,000 India 3,850 3,800 54,000 Others 5,450 5,300 N/A World Total 23,300 24,000 >460,000

12. Demand

13. African Consolidated Resources Plc   Anglo Pacific Group plc   ASA Metals (Pty) Ltd   Chrometco Limited   Chromex Mining   Consolidated Minerals Limited   Eurasian Natural Resources Corporation   International Ferro Metals South Africa (Pty) Limited   Kefid Machinery   Kemai Machinery & Equipment Co Ltd   Kermas Group Limited   Mas Minerals   Merafe Resources Ltd   Metal Bulletin Events   Southbridge International Trade Corporation   vpr Mining Infrastructure Suarl   Zimbabwe Alloys Chrome Limited   Zimbabwe Mining & Smelting Co. ( Pvt ) Ltd List of Company

14. CHROMITE ORE POTENTIAL OF INDIA

15. CHROMITE ORE POTENTIAL IN INDIA POSSIBLE RESERVE (69%) (31%) TOTAL RESOURCE ─ 213 Mt EASTERN INDIAN STATE OF ORISSA (OVER 95% OF TOTAL) SUKINDA ULTRAMAFIC BELT BAULA-NAUSAHI IGNEOUS COMPLEX

16. CHROMITE ORE POTENTIAL IN INDIA “CHEMISTRY” OF CLEAN CHROME SPINELS FROM ORISSA Location Cr/Fe Cr 2 O 3 % MgO% FeO% Al 2 O 3 % Sukinda 3.35 57.5 14.01 15.12 12.60 3.30 58.7 12.57 15.57 11.82 3.86 58.9 16.10 13.40 10.70 3.30 56.6 11.70 15.60 11.10 Boula- Nausahi 2.04 54.9 11.64 23.70 9.82 1.80 52.8 10.50 25.65 9.80 1.67 49.4 8.89 26.08 14.40 INDIA COMES UNDER HIGH-GRADE GROUP WITH COUNTRIES HAVING AVERAGE Cr 2 O 3 GRADE OF 39%.

17. Rock containing chromite ore Mining Method Extraction of the Chromite Ore Both surface and underground mining methods will be used to mine the chromite. Mining produces both ore and waste rock. Waste rock consists of all other non-chromite bearing rock excavated during mining. Surface Mining   Chromite ore is mined by  surface methods.  This includes an open pit from which surf ace material , non-chromite bearing overburden and chromite ore, will be excavated. The chromite ore containing  rock will be drilled, blasted, removed and loaded onto large trucks for hauling to the crusher and ore processing facility Underground Mining  The transition to underground mining will be considered once it is necessary to extract rock from greater depths. The underground mine will be reached from the bottom of the open pit.  Blast hole stopping methods will be used for underground mining .  Stopping  occurs in underground mineral mining when the surrounding rock is strong enough to allow the drilling, blasting, and removal of ore without caving

18. EVOLUTION OF CHROMITE BENEFICIATION IN INDIA

19. CHROMITE BENEFICIATION IN INDIA PAST SCENARIO MINING OF HIGH GRADE ORE LEAVING LOW AND MEDIUM GRADE ORES STACKED AS WASTE USE OF MANUAL METHODS FOR DRESSING

20. Classification Generally Chrome ore deposits are classified as S iliceous type (silica rich) Ferruginous type (iron rich) Associated gangue minerals are Talc Quartz Hematite Goethite Limonite Serpentine Pyroxinite

21. Comminution(to prepare the ore for subsequent unit operations) and concentration. The feed unit incorporates screening of the ROM ore to 75mm from -220mm followed by two stage crushing(primary& secondary crusher) and screening to produce less than 3mm size fraction. This fraction is further ground to less than 1mm and then upgraded utilizing conventional gravity techniques like spiral concentrator and shaking table in the concentration section. Low grade chrome ore with Cr 2 O 3 of about 20-30% of sukinda region of India ,can be beneficiated to a marketable grade of 45% Cr2O3 with 45-50% recovery, by grinding the chrome ore(d80 passing size 260 microns). Circuit description Circuit description

22. CHALLENGES IN BENEFICIATION LOSS IN TAILINGS UTILISATION OF LATERITIC WASTE ORE CHARACTERISTICS CHALLENGES IN BENEFICIATION

23. MAJOR CHROMITE BENEFICIATION PLANTS IN INDIA OPERATOR LOCATION RATED THROUGHPUT CAPACITY ( tpy ) FACOR Boula 200 000 Ostapal 80 000 TATA STEEL Bhimatnagar (Sukinda) 1 100 000 OMC Kaliapani 1 65 000 64 000;50 ± 2% Cr/Fe: 2.4-3.00 <38 65 000; 50 ± 2 Cr/Fe: 2.4-3.0 <38 30000; 46-48 25-30 44 000; 42-45 Cr/Fe = 1.4-4.7 13-21 PROJECTED OUTPUT ( tpy ); (% Cr 2 O 3 ) FEED GRADE (% Cr 2 O 3 )

24. Price variation