Beruflich Dokumente
Kultur Dokumente
ISSN 2250-2122
Volume 99
Number 1
1 23
Your article is protected by copyright and all
rights are held exclusively by The Institution
of Engineers (India). This e-offprint is for
personal use only and shall not be self-
archived in electronic repositories. If you wish
to self-archive your article, please use the
accepted manuscript version for posting on
your own website. You may further deposit
the accepted manuscript version in any
repository, provided it is only made publicly
available 12 months after official publication
or later and provided acknowledgement is
given to the original source of publication
and a link is inserted to the published article
on Springer's website. The link must be
accompanied by the following text: "The final
publication is available at link.springer.com”.
1 23
Author's personal copy
J. Inst. Eng. India Ser. D (January–June 2018) 99(1):63–70
https://doi.org/10.1007/s40033-017-0147-y
ORIGINAL CONTRIBUTION
Received: 2 March 2017 / Accepted: 27 June 2017 / Published online: 26 July 2017
Ó The Institution of Engineers (India) 2017
123
Author's personal copy
64 J. Inst. Eng. India Ser. D (January–June 2018) 99(1):63–70
grade and sub grade iron ores which hitherto were side (Model JY2000-2 and Make JOBINYVON). The ‘as
lined as waste. The fresh exploration strategy would have received’ sample assayed 40.80% Fe, 40.90% SiO2 and all
to be drawn with cut off grade ores as a target. other constituents are well within the limits. Chemical
MGS was used to concentrate chromite ore and its analysis of the ‘as received’ ROM sample is presented in
tailings to recover chromite values [4–11]. Rao et al. Table 1.
[12–17] carried out extensive studies on beneficiation of Mineralogical studies indicate that the main ore mineral is
low grade and sub grade iron ores to produced pellet grade Hematite and lone gangue mineral is Quartz. The same was
concentrate using spiral concentrator, Floatex Density supported by XRD Studies. The liberation studies indicate
Separator and Multi Gravity Separator. Multi Gravity that the average particle size for liberation is below 100
Separator was also found to be effective to reject graphite microns. Liberation studies are presented in Table 2 which is
from lead concentrate [18–20]. Multi gravity separator was self explanatory. Bond’s Ball Mill Work index for the ‘as
used for recovery of mineral values and recovery of iron received’ ROM sample was found to be 10.45 kW/T.
values from fine iron ore particles [21, 22]. Several A representative sub sample of ‘as received’ sample was
scholars tried to optimise the variable and attempted to drawn by adopting standard sampling methods and sub-
derive equations for concentrate grade and yield [23–26] jected to size analysis by using standard sieves (100, 80,
using enhanced gravity methods. MGS is used in this 50, 40, 30, 20, 10, 6, 3 mm up to 37 micron). All the
experimental process to produce a commercial grade iron products were dried and weighed separately. The screen
ore concentrate from SGIO as the ore and gangue particles assay analysis of ‘as received’ sample is presented in
are being liberated below 100 microns. Table 3. These size fractions were ground to \200 mesh
(75 microns) and subjected to chemical analysis. From
Table 3 it could be observed that the highest concentration
Materials and Methods of Iron (49.20%) is in -3 ? 1 mm size fraction where as
the lowest concentration (22.40%) is found in -65 ? 100
The Sample and its Characterisation mesh (-212 ? 152 micron). From Table 3, it can be
observed that Iron distribution (Fe) is in the range of
The ‘as received’ ROM sample of Sub Grade Iron Ore 22.40–49.2%, whereas, SiO2 ranged from 28.52 to 67.60%
(SGIO) from Bacheli complex, Bailadila, Chhattisgarh, in individual size fractions of ‘as received’ sample.
India is an admixture of lump, fines and friable ore; where A representative portion of ‘as received’ ROM sample
the fines contribute in higher proportion (up to 36%). The was stage crushed and ground to\100 mesh (150 microns).
size of the ‘as received’ sample varies from 150 mm to less A portion of the representative ground sample was sub-
than 1 mm. The lump samples show alternate bands of iron jected to wet size analysis. All the size fractions were dried,
and silica. weighed and subjected for chemical analysis individually.
The ‘as-received’ sample was mixed thoroughly and The screen assay analysis of stage crushed and ground to
representative samples were drawn for size analysis, 0.150 mm is presented in the Table 4. The size analysis of
characterisation, Screen Assay Analysis and beneficiation ‘as received’ sample and ground sample are presented in
studies. Chemical analysis was carried out by standard Fig. 1. The P80 size of ‘as received’ sample and ground
procedures (wet) and Induction Coupled Plasma (ICP) sample are 55 mm and 75 microns respectively.
Assay % 40.80 0.70 40.90 0.24 0.22 0.05 \0.01 0.091 0.119 0.110 0.045
Table 2 Liberation studies of ‘as received’ Sub Grade Iron Ore sample
Ore/Gangue mineral Grain size (Microns) Area (%) Unliberated grains (%) Fully liberated grains (%)
123
Author's personal copy
J. Inst. Eng. India Ser. D (January–June 2018) 99(1):63–70 65
Table 4 Screen assay analysis of stage crushed and ground to 0.150 mm sample
Product size (mesh) Size (Micron) Wt% %Fe %SiO2
Distribution of Iron and Silica in various size fractions of Experimental Results and Discussion
stage crushed and ground sample, is presented in Fig. 2,
which is the feed for the experimental work. XRD pattern Experimental Method
(Difractogram) of as received SGIO sample is presented as
Fig. 3. From XRD studies and mineralogical studies it was The Multi Gravity Separator (MGS) of 200 kg/h capacity
confirmed that the main minerals are Hematite and Quartz. (Make: Richard Mozley Ltd, UK Model: C900) was used
From the Table 4 and Fig. 2, it can be observed that iron in this experimental work. Its structure and operating
(Fe) is distributed in the range of 36.00–43.00% and Silica conditions are reported elsewhere [4]. Feed to MGS was
(SiO2) 36.00–48.20% in the stage crushed and ground prepared by mixing 500 grams of dry sample with 1 litre of
sample.
123
Author's personal copy
66 J. Inst. Eng. India Ser. D (January–June 2018) 99(1):63–70
120
Fig. 1 Size analysis of ‘as received’ sample and stage crushed and ground sample
50
48
46
44
Percentage
42
40
38
36
34
32
30
30 40 50 60 70 80 90 100 110
Size in microns
%Fe % SiO2
Fig. 2 Distribution of Iron and silica in size fractions of stage crushed and ground -0.150 mm product
Counts
Si O2
3000
2000
Fe2 O3
Fe2 O3; Si O2
1000
Fe2 O3
Si O2
Fe2 O3
Si O2
Fe2 O3
Si O2
Fe2 O3
Si O2
Si O2
Si O2
0
10 20 30 40 50 60 70 80 90
123
Author's personal copy
J. Inst. Eng. India Ser. D (January–June 2018) 99(1):63–70 67
water which gives 33.33% solids concentration (by second cycle of experiments wash water flow rate of 4
weight). The mixture was stirred continuously to maintain LPM and shake frequency of 4 cps were maintained
uniform suspension. The MGS variables were adjusted at constant. The experimental variable were selected based
the required level as per the experimental design. The feed on Box Behnken Model [12] and responses were recor-
slurry was then fed to the MGS feed vessel at a constant ded. The products were collected weighed, dried and
flow rate while MGS was in operation. The machine was subjected for chemical analysis. Concentrate grade, yield
kept running until the material flow is finished, which took and percent recovery of iron values are calculated and
about 2–3 min and cleaned thoroughly for the next presented in Table 5.
experiment. Upper cover of the separator was removed and
remaining material in the drum was thoroughly washed. Optimisation Studies
Tailing (light product) was collected through back launder
and Concentrate (heavy product) through front launder. From the Table 5, it could be observed that it is not pos-
sible to produce pellet grade concentrate in the first cycle
Experimental Results of experiments. Hence, this has to be further processed for
obtaining a concentrate suitable for pellet feed. This can be
Experiments were conducted in two stages by using Multi done after optimising the responses of the rougher MGS
Gravity Separator. The first stage (rougher MGS) was cycle. It is a known fact that the concentrate grade and
aimed to recover maximum possible iron values in the yield are always inversely proportional to each other in any
concentrate and the second stage (cleaner MGS) was aimed mineral processing operation. It can be observed from the
to produce commercial grade pellet concentrate. test results that rougher MGS cannot produce a mar-
The main operating variables of MGS are shake ketable product of 65% Fe in a single unit operation eco-
amplitude, shake frequency, drum rotational speed nomically. It may be possible to produce pellet grade
(RPM), drum angle of inclination, wash water flow rate concentrate of around 65% Fe from rougher MGS Con-
(LPM) and feed percent solids. In the Rougher MGS centrate after subjecting to cleaner MGS cycle. To produce
experiments drum rotational speed (RPM), drum angle of an economically viable Blast Furnace grade or Direct
inclination and wash water are varied and all other Reduction (DR) grade product (pellet feed) and yield
parameters are kept constant. A sinusoidal shake with should be optimised for rougher MGS concentrate. Opti-
amplitude varying between 12 and 25 mm is superim- misation of rougher MGS were done based on percent
posed upon the motion of the drum in an axial direction. recovery of iron values and its grade. Experiment no. 10
The shake frequency ranges between 2 and 6 cps. For the could produce a concentrate of 55.80% Fe, 19.90% SiO2
first cycle of experiments shake amplitude 18 mm and the with a recovery of 84.42% Iron values. The variation of
shake frequency 4 cps are maintained constant and for concentrate grade (%Fe) and concentrate yield (wt%) for
Table 5 First cycle of Experimental results with ground sub grade iron ore
Experiment Process variables (Coded/Actual) Response variables of concentrate % SiO2 in
run no. concentrate
Drum angle of inclination Wash water flow rate Drum speed Yield Grade Recovery of iron
(degrees) (LPM) (RPM) (wt%) (%Fe) values
123
Author's personal copy
68 J. Inst. Eng. India Ser. D (January–June 2018) 99(1):63–70
64.00 the first cycle (rougher MGS) is shown in the Fig. 4. From
62.00 the Fig. 4, it can be observed that as the concentrate yield
increases, the concentrate grade decreased and vice versa.
Concentrate Grade (%Fe)
60.00
Relation between MGS concentrate grade (%Fe) and yield
58.00
(wt%) is shown in Fig. 4 which resembles theory. Figure 5
56.00 shows the distribution of iron and silica content in the
54.00 rougher MGS concentrate produced.
52.00
Second Cycle (MGS Cleaner) Studies
50.00
48.00 In the second cycle also the parameters were selected based
10.00 20.00 30.00 40.00 50.00 60.00 70.00 on Box Behnken Method design table. In the second cycle
Concentrate Yield (Weight percent)
the variables are drum angle of inclination, drum amplitude
Fig. 4 Relation between concentrate yield and concentrate grade and drum speed. All other parameters, except the ones
(%Fe) mentioned, are maintained constant. 13 No’s of experi-
ments were conducted in the second cycle. Products were
30.00
collected, dried, weighed and subjected for chemical
Concentrate Silica content (Percent)
Table 6 Second cycle of Experimental results with Concentrate produced from first cycle
Experiment Actual values of variables Concentrate Concentrate Concentrate Yield (With Recovery of
Run No. yield (wt%) grade (%Fe) grade (%SiO2) respect to iron values
Drum angle of Stroke Drum original)
inclination (degrees) length speed
(mm) (RPM)
123
Author's personal copy
J. Inst. Eng. India Ser. D (January–June 2018) 99(1):63–70 69
Legend
Weight % % Fe
%SiO2 % Iron values
Recovery
Fig. 6 Process flow sheet adopted for producing pellet grade concentrate from SGIO with Metallurgical balance
used for pelletisation. The process adopted for production 2. The main mineral constituents of the ‘as received’
of pellet grade concentrate from SGIO by using MGS is sample are Hematite and Quartz.
shown in Fig. 6. 3. The mineral liberation studies indicated that the
hematite is getting liberated below 150 microns.
4. It was not possible to produce pellet grade concentrate
Conclusion by rougher unit operation using Multi Gravity Separa-
tor. During this operation the highest grade concentrate
1. The ‘as received’ sample is very low grade and termed produced assayed 62.00% Fe, 11.00% SiO2 with a
as Sub Grade Iron Ore which assayed 40.80% Fe, and yield of 18.34% by weight and the lowest grade is
40.90% SiO2 and all other elements are within their 50.00% Fe with an yield of 65.37% by weight.
critical limits.
123
Author's personal copy
70 J. Inst. Eng. India Ser. D (January–June 2018) 99(1):63–70
5. The highest recovery of iron values in the rougher Processing Technology (MPT-2010), NML Jamshedpur,
MGS unit operation is 84.42% and assayed 55.80% Fe, December 2010
13. G.V. Rao et al., Process amenability studies of sub grade iron ore
19.90% SiO2 with an yield of 61.73% by weight. from Bacheli complex, Bailadila sector, India. XXVI IMPC 2012
6. A cleaner MGS concentrate of 66.67% Fe and 3.16% Proceedings, New Delhi, India. Paper No. 793, pp 1842–1860
of SiO2 with a yield of 45.08% by weight and 73.67% (2012)
iron values were recovered. 14. G.V. Rao, R. Markandeya, S.K. Sharma, Application of gravity
methods for beneficiation of sub grade iron ore. In Proceedings of
7. The concentrate produced by two stage concentration XIII International Conference on Mineral Processing Technol-
using Multi Gravity Separator is well within the range ogy, MPT-2013, CSIR – IMMT, Bhubaneswar
of pellet feed concentrate. 15. G.V. Rao, S.K. Sharma, R. Markandeya, Modeling and optimi-
sation of Multi Gravity Separator for recovery of Iron values from
Sub grade Iron ore. in Proceedings of XXVII International Min-
Acknowledgements The authors wish to thank NMDC management eral Processing Congress (IMPC 2014), 2014, Santiago, Chile
for permitting to conduct studies and to publish this paper. The 16. G.V. Rao, R. Markandeya, R. Kumar, Feasibility studies on
authors wish to acknowledge all the individuals for their assistance in beneficiation of Sub Grade iron Ore from Deposit 5, Bacheli
executing the test work, particularly scientists of R&D Centre, Complex, Bailadila, Chattisgarh using Mozley Mineral Separator.
NMDC Limited, Hyderabad for their valuable discussion and in Proceedings of XV International Conference on Mineral
suggestions. Processing Technology, MPT – 2016, TCS- TRDDC Pune during
05-01-2016 to 07-01-2016
17. G.V. Rao, R. Markandeya, Rajan Kumar, Optimisation of process
variables for Recovery of Iron Values from Sub Grade Iron Ore
References
by using Enhanced Gravity Separation. Int. J. Eng. Res. Technol.
(IJERT) 5(1), 900–909 (2016)
1. G.S. Roonwal, Iron ore deposits and Banded iron ore formations 18. K.U. Bhaskar, B. Govindarajan, J.P. Barnwal, R. Venugopal,
of India (Daya Publishing house, New Delhi, 2012), p. 123 M.R. Jakhu, T.C. Rao, Performance and modeling studies of an
2. Deepak Vidhyarthi, Indian Iron ore Mining, 1st edn. (Mintech MGS for graphite rejection in a lead concentrate. Int. J. Miner.
Publication, Bhubaneswar, 2007) Process. 67(1–4), 59–70 (2002)
3. Anonymous, Iron & Steel Vision-2020, Indian Bureau of Mines, 19. D.P. Patil, B. Govindarajan, T.C. Rao, V.P. Kohad, R.K. Gaur,
Ministry of Mines, August 2011, Chapter 2, pp 13–35 Plant trials with the multi-gravity separator for reduction of
4. B.S. Chan, R.H. Mozley, G.J.C. Childs, Extended trails with the graphite. Miner. Eng. 12, 1127–1131 (2000)
High Tonnage Multi Gravity Separator. Miner. Eng. 4, 489–496 20. P. Yerriswamy, J.P. Barnwal, B. Govindarajan, B.K. Gupta, T.C.
(1991) Rao, Influence of variables of multigravity separator on rejection
5. B.S. Chan, R.H. Mozley, G.J.C. Childs, The Multi Gravity sep- of graphite from a lead concentrate. Miner. Process. Extr. Metall.
arator (MGS): A Mine scale Machine. Red ruth, Richard Mozley 111(3), 156–159 (2002)
Limited 1993 21. R. Singh, P. Bhattacharyya, K.K. Bhattacharyya, Studies on
6. A. Bandopadyaya, Multi gravity separator – An equipment for recovery of mineral values using an enhanced gravity separator.
separation of fines. Process. Fines 2, 81–92 (2000). (NML Advanced Gravity Seoaration (AGS), NML Pub, pp. 47–56
Jamshedpur) 22. S. Roy, Recovery improvement of fine iron ore particles by multi
7. N. Gence, Beneficiation of Elazig-Kefdag Chromite by Multi gravity separation. Open Miner. Process. J. 2, 17–30 (2009)
gravity separator. Trans. J. Eng. Environ. Sci. 23, 473–475 (1999) 23. A.K. Majumder, J.P. Barnwal, Modeling of enhanced gravity
8. H. Ozdag, Enrichment of chromite from slimes and tailings of concentrators - present status. Miner. Process. Extr. Metall. Rev.
shaking tables by multi gravity separator. Innovation of Mineral 27(1), 61–86 (2006)
Processing Sudbury, Canada, p. 267 (1994) 24. N. Aslan, H. Kaya, Beneficiation of chromite concentration waste
9. S.G. Ozkan, B Ipekoglu, in Concentration studies on chromite by multi gravity separator and high intensity induced roll mag-
tailings by multi gravity separator. 17th International Mining netic separator. Arab. J. Sci. Eng. 34(2B), 285–297 (2009)
Congress and Exhibition (IMCET) (Turkey, 2001), pp. 765–768 25. N. Aslan, Multi-objective optimization of some process param-
10. T. Çiçek, I. Cöcen, Applicability of Mozley Multi-Gravity eters of a multi gravity separator for chromite concentration. Sep.
Separator (MGS) to Fine chromite Tailings of Turkish Chromite Purif. Technol. 64, 237–241 (2008)
Concentrating Plants. Miner. Eng. 15, 91–93 (2002) 26. N. Aslan, Application of response surface methodology and
11. K.T. Sunil, M.Y. Rama, V. Tathavadkar, B.D. Mark, Efficacy of central composite rotatable design for modelling and optimisation
multi gravity separator for concentrating ferruginous chromite of multi gravity separator for chromite concentration. Powder
ore. J. Min. Metall. 48A(1), 39–49 (2012) Technol. 185, 80–86 (2008)
12. G.V. Rao, et al, Beneficiation of BHQ from Bacheli, Bailadila,
Chattisgarh, India. XI International Seminar on Mineral
123