AU743968B2 - Beneficiation of iron ore waste - Google Patents
Beneficiation of iron ore waste Download PDFInfo
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- AU743968B2 AU743968B2 AU46860/97A AU4686097A AU743968B2 AU 743968 B2 AU743968 B2 AU 743968B2 AU 46860/97 A AU46860/97 A AU 46860/97A AU 4686097 A AU4686097 A AU 4686097A AU 743968 B2 AU743968 B2 AU 743968B2
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Description
P/00/011 28/5/91 Regulation 3.2
AUSTRALIA
Patents Act 1990
ORIGINAL
COMPLETE SPECIFICATION STANDARD PATENT a.
Name of Applicant: ELTIN LIMITED 14Qornry CQ*4Cer ;C-h Cn4r-c--f P LAA Actual Inventor(s): Address for service is: WRAY ASSOCIATES 239 Adelaide Terrace Perth, WA 6000 a. a a Attorney code: WR Invention Title: "Beneficiation of Iron Ore Waste" Details of Associated Provisional Application No(s): P04003 The following statement is a full description of this invention, including the best method of performing it known to me:- -2- The present invention relates to a beneficiation process for iron ores, including iron ores having a magnetically susceptible component. Particularly, this invention relates to a beneficiation process for iron ores exhibiting a changing variability in the proportion of iron ore present in the stock feed which would otherwise necessitate varying of plant control parameters depending upon the nature of the ore.
Normally it is possible to control the iron ore extraction process by assaying the ore which originates from different parts of the mine, then determining the process parameters to achieve maximum recovery of iron from the ore stock feed, while minimising the amount of gangue in the beneficiated ore. Such a process requires periodic monitoring with follow up modification of the process parameters when required.
oooo The process of this invention may be utilised for beneficiation of iron ores contained in highly variable stock feeds, or where it is desired to avoid process :i 15 control. Particularly, the process of this invention is expected to be applicable to the processing of ores contained in waste dumps from previous mining activities, where variability in the feedstock cannot be predicted.
o In accordance with th. invention, there is provided a process for beneficiation of ore feed stock containing magnetically susceptible ore, to extract beneficiated iron ore therefrom, the process including the steps of grinding the ore feed stock o to produce a ground ore having a particle size up to 1000 micrometres, screening the ground ore to separate a fine fraction having a particle size of less than 75 micrometres, and a coarse fraction having a particle size greater than micrometres, performing a specific gravity separation on the coarse fraction to produce a heavy fraction comprising primarily iron ore, a mid weight fraction which is recycled to be further ground along with further fresh ore feed stock, and a lighter tails fraction which may be disposed of; and performing a magnetic separation on the fine fraction to separate magnetically susceptible ore comprising further iron ore, from gangue.
ELTINAU.DOC 3/1297 -3- The iron ore, and the further iron ore may be combined to produce an iron ore product containing in excess of 65% by weight iron oxides.
Preferably the percentage of iron in the heavy fraction is greater than 60% by weight.
Preferably the heavy fraction specific gravity value is greater than Preferably the heavy fraction specific gravity value is greater than Preferably the heavy fraction specific gravity value is greater than Preferably the heavy fraction specific gravity value is greater than 4.7.
Preferably the heavy fraction specific gravity value is greater than 4.8.
10 The grinding stage may comprise one stage of crushing the ore feed stock to produce a crushed ore having a particle size of up to 8mm diameter, and then milling the crushed ore along with any said mid weight fraction, to produce said ground ore. The crushing stage may comprise a jaw crusher, with oversize material (material exceeding 8mm in diameter) being crushed in an impact crusher.
The milling step may be suitably performed in a ball mill apparatus.
The specific gravity separation stage may preferably comprise a spiral separator, or several spiral separators.
Before the magnetic separation is performed, it is preferred that an additional step of separating any fine clay materials having a particle size less than 15% of the maximum nominal particle size of the fine fraction, which would otherwise coagulate with the magnetic fraction and thereby contaminate it. This additional step may be performed using a cyclone separator. The fine fraction would be ELTINAU.DOC 312197 -4expected to have a maximum nominal particle size of 75 micrometers, in which case the fine clays to be separated would have a particle size of up to micrometers.
Also in accordance with the invention, there is provided a plant for beneficiation of ore feed stock containing magnetically susceptible ore, to extract beneficiated iron ore therefrom, the plant including a grinding stage to grind the ore feed stock to produce a ground ore having a particle size up to 1000 micrometres, a screening stage to screen the ground ore to separate a fine fraction having a particle size of less than 75 micrometres, and a coarse fraction having a particle size greater than 75 micrometres, a specific gravity separation stage to perform a specific gravity separation on the coarse fraction to produce a heavy fraction comprising primarily iron ore, a mid weight fraction which is recycled to be :::further ground along with further fresh ore feed stock, and a lighter tails fraction oooo which may be disposed of; and a magnetic separation stage to perform a magnetic separation on the fine fraction to separate magnetically susceptible ore comprising further iron ore, from gangue.
Preferably the iron ore and the further iron ore are combined to produce an iron ore product containing in excess of 65% by weight iron oxides.
Preferably the grinding stage comprises a crushing stage to crush the ore feed 20 stock to produce a crushed ore having a particle size of up to 8mm diameter, and subsequently a milling stage to mill the crushed ore along with any said mid weight fraction, to produce said ground ore.
Preferably the crushing stage comprises a jaw crusher, with oversize material (material exceeding 8mm in diameter) being crushed in an impact crusher.
Preferably the milling step may be suitably performed in a ball mill apparatus.
Preferably the specific gravity separation stage comprises a spiral separator, or several spiral separators.
ELTINAU.DOC 3/12J97 Preferably before the magnetic separation stage, there is an additional separation stage to separate any fine clay materials having a particle size less than 15% of the maximum nominal particle size of the fine fraction.
Preferably the additional separation stage is performed using a cyclone separator.
The invention will now be described in the following description of one specific embodiment thereof, made with reference to the drawings, in which: Figure 1 is a diagram of the screening and grinding circuit of the process; Figure 2 is a diagram of the specific gravity separation and magnetic stage of the process; and Figure 3 is a diagram of the magnetic concentrate dewatering stage of the process.
Run of mine ore is fed onto an apron feeder from uniformly mixed cakes by front end loader. It is then fed at a uniform rate into a jaw crusher. The crusher 15 discharge is fed to a vibrating screen from which the minus 8mm material is send directly to the mill feed surge hopper. Oversize from the primary screen is sent to an impact crusher where the size is further reduced and the crusher discharge is sent to another screen. The undersize material from this vibrating is also sent to the mill feed surge bin whilst the oversize is sent back 1.
20 the impact crusher.
o *The crushing circuit described above provides mill feed with a top size of 8mm and around 85% by mass passing a 1mm sieve. This mill feed is fed onto the prep screen feed conveyor by means of a belt feeder which provides a very even and controllable feed rate. Now, referring to Figure 1, at the headchute of the conveyor the naturally dry ore is pulped with water and then fed onto a flat vibrating screen 11 fitted with water sprays 13 and slotted 1 mm x 13mm screen panels. The undersize from this screen falls into a hopper 15 from where it is pumped away for further classification. The oversize from the screen is further mixed with seawater and sent to a cylindrical overflow ball mill 17. Mill ELTINAU.DOC 3112/97 -6discharge is passed through a trommel screen to protect the discharge pump from any oversize particles or ball charge that may leave the mill. Trommel undersize is collected into a hopper 19 where more water is added to lower the pulp density for pumping and then the mill discharge pump 21 returns the slurry to the prep screen 11 for classification.
The screen undersize from the hopper 15 is pumped to a single classifying cyclone separator 23 (see Figure 2) with a D50 cut point of Cyclone overflow 25 reports to the wet high intensity magnetic separator (WHIMS) circuit and cyclone underflow 27 reports to the spiral circuit.
Three banks of spiral separators are utilised for spiral separation, these being the rougher spiral separators 29, the mids spiral separator 31 and the scavenger o spiral separator 33. Each bank of spiral separators separates the feed into three categories cons, mids, and tails depending on density and to a lesser extent, size distribution in the feed. The rougher spiral separators 29 comprise two banks of spiral separators, while the others each comprise single banks.
o b After exiting the cyclone separator 23 the -1000um +75um slurry is diluted to a suitable density to allow spiral separation and is sent to the rougher spiral separators 29. Discharging this spiral bank, the cons aie fed directly to the o concentrate hopper 35, the tails are sent to the scavenger spiral separator feed hopper 37 and the mids are sent to the mids spiral separator feed hopper 39.
Slurry from the mids spiral separator feed hopper 39 is fed pumped to the mids spiral separator 31. Discharging the mids spirals, the cons goes to the concentrate hopper 35, the mids is sent back to the mill feed in figures 1 and 2) to provide further liberation of composite particles and the tails goes to the scavenger spiral separator feed hopper 37.
A second cyclone separator 41 with a D50 of 75um is mounted ahead of the scavenger spiral separator 33 and is fed from the scavenger spiral separator ELTINAU.DOC 3Y1217 -7feed hopper 37. The fine particles and those very light, coarser particles are sent from the cyclone overflow 43 to the WHIMS (wet high intensity magnetic separator) circuit whilst the underflow 45 is diluted and fed to the spirals. Cons from the scavenger spiral separator 33 are sent to the mids spiral separator feed hopper 39, mids are sent to the WHIMS circuit for further processing and the tails are sent to the thickener 47 for dewatering and disposal at the tailings dam.
It should be noted that the diversion of the scavenger spiral separator 33 mids stream to the WHIMS circuit is performed to remove fines from the spirals circuit.
These fines are present due to attrition in the spiral circuit and through inefficiencies inherent in cyclone classification. Prior to metallurgical testing, these high grade fines had been recirculated to the scavenger spiral separator feed hopper 37 and were ultimately entrained in the gangue and been sent to tails. The diversion of the scavenger spiral separator 33 mids stream necessitated the addition of a vibrating screen in the WHIMS circuit.
15 Minus 75 micron overflow 25 from the primary cyclone separator 23 is received in the WHIMS desliming cyclone feed hopper 49 along with the two streams diverted from the spirals circuit. From this hopper 49 it is pumped through the bank of desliming cyclone separators 51 which have a D50 of 10um. The cyclone overflow 53 contains mainly clay gangue and is sent directly to the 20 thickener 47 for dewatering and disposal to the tailings dam.
Cyclone underflow 55 is then fed to a 1000um square aperture vibrating screen 57 where any coarse particles either from the spirals circuit or light trash material from the ore dumps, are retained.
Screen overflow is stockpiled and underflow 59 is then fed to the wet high intensity magnetic separator 61 (WHIMS) where the magnetic, Fe rich particles are separated from the gangue. A series of magnets produce an undulating magnetic field and appropriately spaced water sprays wash the particles into the appropriate collection hopper as the slurry moves through the magnetic field.
ELTINAU.DOC 3/12/97 -8- The three collection hoppers are the cons collection hopper 63 which collects the very magnetic particles, the mids collection hopper 65 which collects the marginally magnetic particles and the tails collection hopper 67 which collects the non magnetic particles.
The cons collection hopper 63 drains into the main concentrate hopper 35 where it joins the cons from the spiral circuit. The mids collection hopper 65 drains into the WHIMS feed hopper 49 and is therefore re-treated in the WHIMS circuit.
The tails collection hopper 67 drains directly to the thickener 47 for dewatering and disposal to tailings dam.
In order to remove any clay fines still remaining in the concentrate stream which aids filtration and increases final product grade, a desliming cyclone 69 is utilised with a D50 of 10 Oum which removes clay fines and allows the concentrate to be mixed with clean process water prior to pumping to the filtration area.
Referring to Figure 3, arriving at the filtration area, the slurry is fed onto a horizontal vacuum belt filter 71 from a filter feed hopper 70 where the water is "sucked out" of the slurry through a fine woven screen cloth. The resulting cake is discharged onto covered conveyors 73 and stockpiled 75 under cover while awaiting dispatch. The water removed is collected in a break tank 77 and pumped back to the prep screen 11 where it aids slurring of incoming dry feed.
:oo:) S' 20 Water sprays 79 are used to clean the cloth after the cake discharge and the resulting slurry contains very high grade particles which had settled at the base of the cake. This slurry is recycled back to the filter feed Depending upon location, water for this process may include water pumped from the ocean to a holding tank. Any input water is added to the process at a rate required to replace water used in the pumping of tails to the tailings dam, otherwise water is recycled within the process to minimise demand for input water. Clarified water from thickener 47 overflow is used throughout the plant ELTINAU.DOC 3/12/97 -9and filters are installed to provide clean water for all sprays. Other than basic interlocks and feed rate controller, the plant is manually controlled.
An expected typical plant analysis for a plant according to the invention is set out in the table which follows. It will be understood that some parameters will vary, depending upon factors such as the grade and type of ore feedstock.
LOCATION S.G. %Fe SOLIDS LIQUOR t/hr t/hr Feed to the plant 3.3 42.6 179.5 5.6 Ball mill 17 feed 3 33.4 32 1.6 Ball mill 17 discharge 3.2 35.5 70 27 Rougher Spirals 29 Cons 4.8 65.7 21.4 4.4 Rougher Spirals 29 Middles 4.7 62 63.6 17 Rougher Spirals 29 Tailings 3.5 41 37 81.4 Middle Spirals 31 Cons 4.7 65 21 Middle Spirals 31 Middles 3.8 51 37.6 11 Middle Spirals 31 Tailings 3.5 35 21 173 Scavenger Spirals 33 Cons 4.6 55.4 15.6 4.7 Scavenger Spirals 33 Middles 3.3 40 15 14.5 Scavenger Spirals 33 Tailings 3.1 29 35.4 108 WHIMS 61 Feed 3.7 38.7 109 79.5 .i WHIMS 61 Mag Concentrate 4.9 64.7 5.8 160 WHIMS 61 Semi Magnetics 3.2 20.3 29.2 91 WHIMS 61 Non Magnetics 3.2 20 24 45.6 Desliming Cyclone 51 Feed 3.3 34 134 637 Desliming Cyclone 51 Underflow 3.8 41 109 57 Desliming Cyclone 51 Overflow 2.4 18 25 579 Cons Desliming Cyclone 69 Feed 4.2 65.3 42.4 191 Cons Desliming Cyclone 69 U/flow 5.2 65.5 34.4 8.7 Belt Filter 71 Feed 5 65.5 90 113 ELTINAU.DOC 3112/97 It should be appreciated that the scope of this invention is not limited to the particular embodiment described herein. Various modifications will be apparent to a skilled addressee, in particular to details such as substitution of crushing, conveying, and separating apparatus utilised in the process of this invention.
9 *9 °S 9 *e*e* oooe* oO o ELTINAU.DOC 3/12/97
Claims (19)
1. A process for beneficiation of ore feed stock containing magnetically susceptible ore, to extract beneficiated iron ore therefrom, the process including the steps of grinding the ore feed stock to produce a ground-orf having a particle size up to 1000 micrometres, screening the ground ore to separate a fine fraction having a particle size of less than 75 micrometres, and a coarse fraction having a particle size greater than 75 micrometres, performing a specific gravity separation on the coarse fraction to produce a heavy fraction comprising primarily iron ore, a mid weight fraction which is recycled to be further ground along with further fresh ore feed stock, and a lighter tails fraction which may be disposed of; and performing a magnetic separation on the fine fraction to separate magnetically susceptible ore comprising further iron ore, from gangue.
2. A process according to claim 1 further including the step of combining the 15 iron ore and the further iron ore, to produce an iron ore product containing in excess of 65% by weight iron oxides.
3. A process according to claim 1 or 2 wherein the percentage of iron in the heavy fraction is greater than 60% by weight.
4. A process according to claim 1 or 2 wherein the heavy fraction specific gravity value is greater than A process according to claim 1 or 2 wherein the heavy fraction specific gravity value is greater than
6. A process according to claim 1 or 2 wherein the heavy fraction specific gravity value is greater than
7. A process according to claim 1 or 2 wherein the heavy fraction specific gravity value is greater than 4.7. ELTINAU.DOC 3/12/97 -12-
8. A process according to claim 1 or 2 wherein the heavy fraction specific gravity value is greater than 4.8.
9. A process according to any one of the preceding claims wherein the grinding step comprises one stage of crushing the ore feed stock to produce a crushed ore having a particle size of up to 8mm diameter, and subsequently a milling stage to mill the crushed ore along with any said mid weight fraction, to produce said ground ore. A process according to claim 9 wherein the crushing stage comprises a jaw crusher, with oversize material (material exceeding 8mm in diameter) being crushed in an impact crusher.
11. A process according to claim 9 or 10 wherein the milling step may be suitably performed in a ball mill apparatus. .o
12. A process according to any one of the preceding claims wherein the specific gravity separation step may preferably comprise a spiral separator, or several spiral separators. 4*
13. A process according to any one of the preceding claims wherein before the magnetic separatiuon step is pedformed, there is an additional step of separating any fine clay materials having a particle size less than 15% of the maximum nominal particle size of the fine fraction.
14. A process according to any claim 13 wherein the additional step is performed using a cyclone separator. A plant for beneficiation of ore feed stock containing magnetically susceptible ore, to extract beneficiated iron ore therefrom, the plant including a grinding stage to grind the ore feed stock to produce a ground ore having a particle size up to 1000 micrometres, a screening stage to screen the ground ore to separate a fine fraction having a particle size of ELTINAU.DOC 3/12g7 -13- less than 75 micrometres, and a coarse fraction having a particle size greater than 75 micrometres, a specific gravity separation stage to perform a specific gravity separation on the coarse fraction to produce a heavy fraction comprising primarily iron ore, a mid weight fraction which is recycled to be further ground along with further fresh ore feed stock, and a lighter tails fraction which may be disposed of; and a magnetic separation stage to perform a magnetic separation on the fine fraction to separate magnetically susceptible ore comprising further iron ore, from gangue.
16. A plant according to claim 15 wherein the iron ore and the further iron ore are combined to produce an iron ore product containing in excess of by weight iron oxides.
17. A plant according to claim 15 or 16 wherein the grinding stage comprises a crushing stage to crush the ore feed stock to produce a crushed ore having :a particle size of up to 8mm diameter, and subsequently a milling stage to mill the crushed ore along with any said mid weight fraction, to produce said ground ore.
18. A plant according to claim 17 wherein the crushing stage comprises a jaw crusher, with oversize material (material exceeding 8mm in diameter) being .:crushed in an impact crusher. 20 19. A plant according to claim 17 or 18 wherein the milling step may be .o suitably performed in a ball mill apparatus. A plant according to any one of claims 15 to 19 wherein the specific gravity separation stage comprises a spiral separator, or several spiral separators.
21. A plant according to any one of claims 15 to 20 wherein before the magnetic separation stage, there is an additional separation stage to separate any fine clay materials having a particle size less than 15% of the maximum nominal particle size of the fine fraction. ELTINAU.DOC 3/12/g7 -14-
22. A plant according to any claim 21 wherein the additional separation stage is performed using a cyclone separator.
23. An iron ore beneficiation plant substantially as herein described with reference to the drawings
24. An iron ore beneficiation process substantially as herein described with reference to the description of the embodiment. SEC Dated this third day of December 1997. Henry yUVe ElV% Q^l;\g O ELTIN LIMITE Applicant Wray Associates Perth, Western Australia Patent Attorneys for the Applicant t. C C o *i ELTINAU.DOC 3/12/97
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU46860/97A AU743968B2 (en) | 1996-12-03 | 1997-12-03 | Beneficiation of iron ore waste |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AUPO4003 | 1996-12-03 | ||
| AUPO4003A AUPO400396A0 (en) | 1996-12-03 | 1996-12-03 | Beneficiation of iron ore waste |
| AU46860/97A AU743968B2 (en) | 1996-12-03 | 1997-12-03 | Beneficiation of iron ore waste |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| AU4686097A AU4686097A (en) | 1998-06-04 |
| AU743968B2 true AU743968B2 (en) | 2002-02-14 |
Family
ID=25627666
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU46860/97A Ceased AU743968B2 (en) | 1996-12-03 | 1997-12-03 | Beneficiation of iron ore waste |
Country Status (1)
| Country | Link |
|---|---|
| AU (1) | AU743968B2 (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2010023692A1 (en) * | 2008-08-30 | 2010-03-04 | Tata Steel Limited | A novel method for production of iron ore concentrates suitable for iron and steel making processes. |
| CN103394459A (en) * | 2013-07-31 | 2013-11-20 | 重庆市昌博矿产品有限公司 | Technology for washing high-grade iron ore from sulfate slag |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN101161351B (en) * | 2007-11-29 | 2011-03-16 | 王少祖 | Ore-sorting system and technique of ferro-sulphur ore powder |
| CN103412489B (en) * | 2013-08-12 | 2015-11-11 | 东北大学 | A kind of grinding particle size online forecasting system and method |
| CN107661814B (en) * | 2017-10-31 | 2023-08-22 | 中冶北方（大连）工程技术有限公司 | Screening-magnetic separation-ore grinding-magnetic separation flow equipment arrangement system |
| CN111389582B (en) * | 2020-03-26 | 2022-03-01 | 中国恩菲工程技术有限公司 | Method for separating chromite from laterite-nickel ore |
| CN112207037A (en) * | 2020-09-22 | 2021-01-12 | 攀钢集团攀枝花钢铁研究院有限公司 | Method for improving TFe grade of vanadium titano-magnetite iron ore concentrate |
| CN115161470A (en) * | 2022-07-20 | 2022-10-11 | 万宝矿产有限公司 | Preparation method for processing ores with different clay contents |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4303204A (en) * | 1976-10-28 | 1981-12-01 | Reynolds Metals Company | Upgrading of bauxites, bauxitic clays, and aluminum mineral bearing clays |
| SU1503881A1 (en) * | 1987-09-29 | 1989-08-30 | Днепропетровский горный институт им.Артема | Method of benificating bog iron ore |
-
1997
- 1997-12-03 AU AU46860/97A patent/AU743968B2/en not_active Ceased
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4303204A (en) * | 1976-10-28 | 1981-12-01 | Reynolds Metals Company | Upgrading of bauxites, bauxitic clays, and aluminum mineral bearing clays |
| SU1503881A1 (en) * | 1987-09-29 | 1989-08-30 | Днепропетровский горный институт им.Артема | Method of benificating bog iron ore |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2010023692A1 (en) * | 2008-08-30 | 2010-03-04 | Tata Steel Limited | A novel method for production of iron ore concentrates suitable for iron and steel making processes. |
| CN102317481A (en) * | 2008-08-30 | 2012-01-11 | 塔塔钢铁有限公司 | Production is suitable for the novel method that iron and steel are made the iron ore concentrate of process |
| CN103394459A (en) * | 2013-07-31 | 2013-11-20 | 重庆市昌博矿产品有限公司 | Technology for washing high-grade iron ore from sulfate slag |
| CN103394459B (en) * | 2013-07-31 | 2015-06-10 | 重庆市昌博矿产品有限公司 | Technology for washing high-grade iron ore from sulfate slag |
Also Published As
| Publication number | Publication date |
|---|---|
| AU4686097A (en) | 1998-06-04 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PC1 | Assignment before grant (sect. 113) |
Owner name: HENRY WALKER ELTIN CONTRACTING PTY LTD Free format text: THE FORMER OWNER WAS: ELTIN LIMITED |
|
| FGA | Letters patent sealed or granted (standard patent) | ||
| MK14 | Patent ceased section 143(a) (annual fees not paid) or expired |