Iron Ore Benification process Presentation.pptx

Presentation for Iron Ore Benification Process

1. IRON ORECONCENTRATE NGEMA KWAZOKUHLE : SHEBANG FALTENI

2. Iron Ore Iron is the most abundant element on earth by mass Hematite (𝐹𝑒 2 O 3 ) and magnetite (𝐹𝑒 2 O 3 ) are the most common iron ores found in nature. Iron Ore deposits are found in sedimentary rock Gangue refers to the unwanted minerals It includes silica (SiO2), alumina (Al2O3), Phosphorus: These gangue materials are crucial considerations in iron ore processing as they can significantly affect the quality of the final product and the efficiency of the production process.

3. USE OF IRON Used for the production of iron and steel. Almost all (98%) iron ore is used in steelmaking produce pig iron, sponge iron, and other iron-based products. •Iron catalysts are used in Haber process and in Fisher- Tropsch process

4. Process flowsheet

5. Surface mining Iron Ore Beneficiation Process Crushing& Grinding Washing Wet scrubbing Removes lateritic clay and soft material Separation & Classification Separation into grades using classifiers Blending and Dispatch

6. Separation Gravity and dense medium separation Magnetic separation Floatation

7. Dense medium separation Dense Media Cyclones: Particle Size Range: 3-50mm Media: Ferrosilicon (-300 mesh) slurry with a density of 3-3.2 Heavy Media Cyclone: Particle Size Range: 0.2-6mm Media: Ferrosilicon (-325 mesh) slurry as the media Jigging Equipment: Particle Size Range: 0.5-30mm Function: Separates the feed into: Light density fraction Medium density fraction Heavy density fraction

8. Dense medium separation Spiral Separators: Particle Size Range: Typically finer particles (0.1mm to 2mm) Media: Water and gravity Function: Utilizes the principle of gravity separation, where denser particles settle faster than lighter particles. The spiral design helps in the efficient separation of different density materials as they flow down the spiral chute or trough Tables for Dense Media Separation: Particle Size Range: 0.3mm to 1mm Solids Concentration: 25% to 30% Capacity: Can treat up to 2 phases (maximum)

9. Magnetic separation Magnetic separation is a process used to separate materials based on their magnetic properties. Low-Intensity Magnetic Separation (LIMS): Uses a weaker magnetic field. Effective for separating coarse magnetic particles like magnetite. Suitable for initial stages of ore concentration High-Intensity Magnetic Separation (HIMS): Employs a stronger magnetic field. Separates finer magnetic particles. Enhances ore purity and is used for refining concentrates.

10. FLOATATION Feed Size: Typically finer than 625 mesh. Floatability of Minerals: Crystallite hematite can be effectively floated. Limonite and earthy hematite show poor response to flotation. Floatability of Minerals: Crystallite hematite can be effectively floated. Limonite and earthy hematite show poor response to flotation .

11. SOUTH AFRICA- IRON ORE BENEFICIATION There are more than 922 iron ore mine in the world and 15 are located in south Africa The following are the 5 of the largest iron ore by production scale in SA Sishen Mine: surface mine located in Northern Cape Khumani Mine surface mine Located in Northern Cape Kolomela Mine surface mine  located in Northern Cape.   Beeshoek Iron Ore Mine  surface mine located in Northern Cape Sedibeng Iron Ore Project surface mine located in Northern Cape

12. Production amount of iron ore in Sishen mine Sishen Mine is one of the largest iron ore mines in South Africa. producing millions of tons of iron ore concentrate annually. Ore reserves were estimated to be 519.4Mt, including 507.1Mt from open-pit and 12.2Mt from run-of-mine buffer stockpiles, in 2019. The mine produced 29.2Mt in 2019.

13. Economics: Sishen mine Mining costs Drilling Blasting Excavation transportation Beneficiation costs Crushing Screening Milling Magnetic separation Infrastructure costs Rail network Ports Processing facilities Market prices Geopolitical factors Global economic conditions Revenue and Profitability Ore grade Competition Efficiency of operation

14. HEALTH AND SAFETY Exposure to dust can result in occupational lung diseases Tree dust fraction i.e. inhalable, thoracic and respirable Respirable potential impact on lung functioning. Kolomela mine uses closed cabin drills opposed to open cabin drills Available at: https://www.angloamericankumba.com/sustainability/safety-and-health.aspx (Accessed: 14 May 2024).

15. References Lu, L. ed., 2015.  Iron ore: mineralogy, processing and environmental sustainability . Elsevier. Haque, N., Hughes, A., Lim, S. and Vernon, C., 2014. Rare earth elements : Overview of mining, mineralogy, uses, sustainability and environmental impact .  Resources ,  3 (4), pp.614-635 . Basson , I.J., Anthonissen , C.J., McCall, M.J., Stoch, B., Britz , J., Deacon, J., Strydom, M., Cloete, E., Botha, J., Bester, M. and Nel, D., 2017. Ore-structure relationships at Sishen Mine, Northern Cape, Republic of South Africa, based on fully-constrained implicit 3D modeling .  Ore Geology Reviews ,  86 , pp.825-838 Michaud, D. (2024)  Mineral Processing Froth Flotation ,  911 Metallurgist . Available at: https://www.911metallurgist.com/blog/mineral-processing-froth-flotation (Accessed: 14 May 2024). Dry beneficiation of iron ore  (2022)  Mineral Processing . AT Minerals. Available at: https://www.at-minerals.com/en/artikel/at_dry_beneficiation_of_iron_ore-3789713.html (Accessed: 14 May 2024). Wills, B., & Finch, J. (2016). Mineral Processing Technology, Elsevier Ltd.