WO2023081971A1 - Modular system and method for beneficiating a ferrous ore - Google Patents
Modular system and method for beneficiating a ferrous ore Download PDFInfo
- Publication number
- WO2023081971A1 WO2023081971A1 PCT/AU2022/051344 AU2022051344W WO2023081971A1 WO 2023081971 A1 WO2023081971 A1 WO 2023081971A1 AU 2022051344 W AU2022051344 W AU 2022051344W WO 2023081971 A1 WO2023081971 A1 WO 2023081971A1
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- WIPO (PCT)
- Prior art keywords
- grinding
- modular system
- stream
- ferrous
- aggregate
- Prior art date
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- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 title claims abstract description 71
- 238000000034 method Methods 0.000 title claims abstract description 11
- 238000000926 separation method Methods 0.000 claims abstract description 52
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 41
- 239000002245 particle Substances 0.000 claims description 27
- 229910052742 iron Inorganic materials 0.000 claims description 21
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 12
- 239000012141 concentrate Substances 0.000 claims description 11
- SZVJSHCCFOBDDC-UHFFFAOYSA-N iron(II,III) oxide Inorganic materials O=[Fe]O[Fe]O[Fe]=O SZVJSHCCFOBDDC-UHFFFAOYSA-N 0.000 claims description 11
- 239000011362 coarse particle Substances 0.000 claims description 9
- 239000002562 thickening agent Substances 0.000 claims description 6
- 238000005265 energy consumption Methods 0.000 claims description 5
- 239000010419 fine particle Substances 0.000 claims description 3
- JTJMJGYZQZDUJJ-UHFFFAOYSA-N phencyclidine Chemical class C1CCCCN1C1(C=2C=CC=CC=2)CCCCC1 JTJMJGYZQZDUJJ-UHFFFAOYSA-N 0.000 claims description 3
- 230000008719 thickening Effects 0.000 claims description 3
- 238000011144 upstream manufacturing Methods 0.000 claims description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 10
- 239000000047 product Substances 0.000 description 10
- 230000009286 beneficial effect Effects 0.000 description 5
- 230000001965 increasing effect Effects 0.000 description 5
- 238000012423 maintenance Methods 0.000 description 5
- 239000000377 silicon dioxide Substances 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000012535 impurity Substances 0.000 description 3
- 239000000696 magnetic material Substances 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 230000009471 action Effects 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 238000004064 recycling Methods 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 238000007670 refining Methods 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 239000005864 Sulphur Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 239000000706 filtrate Substances 0.000 description 1
- 229910052595 hematite Inorganic materials 0.000 description 1
- 239000011019 hematite Substances 0.000 description 1
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 description 1
- LIKBJVNGSGBSGK-UHFFFAOYSA-N iron(3+);oxygen(2-) Chemical compound [O-2].[O-2].[O-2].[Fe+3].[Fe+3] LIKBJVNGSGBSGK-UHFFFAOYSA-N 0.000 description 1
- 239000006249 magnetic particle Substances 0.000 description 1
- 239000006148 magnetic separator Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 230000000116 mitigating effect Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000005456 ore beneficiation Methods 0.000 description 1
- 238000003825 pressing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 210000004761 scalp Anatomy 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03B—SEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
- B03B9/00—General arrangement of separating plant, e.g. flow sheets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C23/00—Auxiliary methods or auxiliary devices or accessories specially adapted for crushing or disintegrating not provided for in preceding groups or not specially adapted to apparatus covered by a single preceding group
- B02C23/08—Separating or sorting of material, associated with crushing or disintegrating
- B02C23/10—Separating or sorting of material, associated with crushing or disintegrating with separator arranged in discharge path of crushing or disintegrating zone
- B02C23/12—Separating or sorting of material, associated with crushing or disintegrating with separator arranged in discharge path of crushing or disintegrating zone with return of oversize material to crushing or disintegrating zone
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B02—CRUSHING, PULVERISING, OR DISINTEGRATING; PREPARATORY TREATMENT OF GRAIN FOR MILLING
- B02C—CRUSHING, PULVERISING, OR DISINTEGRATING IN GENERAL; MILLING GRAIN
- B02C23/00—Auxiliary methods or auxiliary devices or accessories specially adapted for crushing or disintegrating not provided for in preceding groups or not specially adapted to apparatus covered by a single preceding group
- B02C23/08—Separating or sorting of material, associated with crushing or disintegrating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03B—SEPARATING SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS
- B03B7/00—Combinations of wet processes or apparatus with other processes or apparatus, e.g. for dressing ores or garbage
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B1/00—Preliminary treatment of ores or scrap
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03C—MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03C1/00—Magnetic separation
- B03C1/02—Magnetic separation acting directly on the substance being separated
- B03C1/10—Magnetic separation acting directly on the substance being separated with cylindrical material carriers
- B03C1/14—Magnetic separation acting directly on the substance being separated with cylindrical material carriers with non-movable magnets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03C—MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03C1/00—Magnetic separation
- B03C1/02—Magnetic separation acting directly on the substance being separated
- B03C1/30—Combinations with other devices, not otherwise provided for
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03C—MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03C2201/00—Details of magnetic or electrostatic separation
- B03C2201/18—Magnetic separation whereby the particles are suspended in a liquid
Definitions
- the present disclosure relates to beneficiation systems and methods, and in particular a modular system for beneficiating a ferrous ore and a method of using such a system.
- Iron ore is a raw material from which metallic iron can be extracted, typically in the production of steels or other ferrous-containing alloys.
- metallic iron typically in the production of steels or other ferrous-containing alloys.
- DSO direct shipping ore
- the present disclosure provides a modular system for beneficiating a ferrous ore, comprising: a primary crushing module including a primary crusher for receiving and crushing the ferrous ore into a ferrous aggregate; a first grinding and classification module for receiving the ferrous aggregate, including a first grinding mill for grinding the ferrous aggregate, and first classification equipment for classifying the resultant product into at least a first fine aggregate stream; a first separation module including first separation equipment for receiving and separating the first fine aggregate stream into at least a first ferrous aggregate stream; a second grinding and classification module for receiving the first ferrous aggregate stream, including a second grinding mill, and second classification equipment for classifying the resultant product into at least a second fine aggregate stream; and a second separation module including second separation equipment for receiving and separating the second fine aggregate stream into at least a concentrated ferrous aggregate stream.
- the at least one quality of one of the modules is selected from one or more of: a product quality of an input or an output; and/or an equipment operating variable.
- the product quality of the input or the output is selected from: an aggregate stream iron content; an aggregate stream particle size; an aggregate stream water content; and/or an aggregate stream flowrate.
- the equipment operating variable is selected from: a charge ratio in a grinding mill; a water content in a grinding mill; a grinding mill rotation speed; a feed density to a classifying cyclone; a feed pressure to a classifying cyclone; number of operational classifying cyclones; a separation rate of a separating equipment; energy consumption of a grinding, crushing, classifying, or separating equipment; and/or water consumption of a grinding, classifying, or separating equipment.
- the charge ratio of the grinding mill is the ratio of a bulk volume of grinding media to a working volume of the grinding apparatus.
- the first classification equipment classifies the resultant product into at least two streams including the first fine aggregate stream and a recycle stream for further grinding by the first grinding mill.
- the first classification equipment includes a cyclone with an overflow stream being the first fine aggregate stream and an underflow stream being the recycle stream.
- the cyclone is a hydrocyclone.
- the hydrocyclone has a flat bottom.
- the first classification equipment includes a screen upstream of cyclone to separate fine aggregate particles to the cyclone and coarse aggregate particles to a secondary crushing circuit for further crushing and recycle to the first grinding mill.
- the secondary crushing circuit includes a high-pressure grinding roll (HPGR).
- HPGR high-pressure grinding roll
- the secondary crushing circuit includes a cone crusher.
- the secondary crushing circuit includes both a high-pressure grinding roll (HPGR) and a cone crusher.
- HPGR high-pressure grinding roll
- the first ferrous aggregate stream is received by the second classification equipment and classified into the second fine aggregate stream and a coarse stream for regrinding by the second grinding mill.
- the second classification equipment includes a cyclone with an overflow stream being the second fine aggregate stream and an underflow stream being the coarse stream for regrinding.
- the cyclone is a hydrocyclone.
- the hydrocyclone is a flat bottom hydrocyclone.
- the hydrocyclone is a conical hydrocyclone.
- the coarse stream is recycled to an inlet of the second classification equipment.
- the first separation module and the second separation module include a magnetic drum separator and a desliming elutriation column.
- the first separation module includes a magnetic drum separator.
- the second separation module includes a desliming elutriation column.
- the second separation module includes a magnetic drum separator and the desliming elutriation column.
- the desliming elutriation column is connected in series and downstream of the magnetic drum separator.
- the second separation module includes two desliming elutriation columns.
- the two desliming elutriation columns are connected in series.
- the system further comprises a dewatering module for receiving and removing water from the concentrated ferrous aggregate stream to produce an iron concentrate.
- the dewatering module includes a concentrate thickener and/or a filter press.
- low iron tailings streams produced by the first separation module and/or the second separation module are concentrated in a tailings thickening stage and are discharged into a tailings dam.
- the ferrous ore is a magnetite ore.
- the magnetite ore is a low grade magnetite ore.
- each module includes a single input.
- each module may be individually optimised to enhance at least one quality of one of the modules. For example, in certain embodiments, a particular module may be maintained, repaired, or replaced with a different corresponding module without effecting the processing of any other module, with the intent of enhancing performance in particular module, or any other module, or both.
- the present disclosure provides a method for beneficiating a ferrous ore, comprising: installing a modular system for beneficiating a ferrous ore in accordance with any one of the preceding claims; and using a control system to collect data associated with an aggregate stream in the modular system and using the data to enhance at least one quality of one of the modules.
- the present disclosure provides a grinding and classification module for use in beneficiating a ferrous aggregate, comprising: a grinding mill for grinding the ferrous aggregate, and classification equipment for classifying the ferrous aggregate after grinding into a fine aggregate stream and a coarse aggregate stream, wherein the coarse aggregate stream is fed to a crushing circuit in a feedback loop with the grinding mill, for further crushing and recycle to the grinding mill, wherein the crushing circuit includes a high-pressure grinding roll (HPGR).
- HPGR high-pressure grinding roll
- the crushing circuit further includes a screen for separating finer particles of the coarse aggregate stream to the HPGR and coarser particles of the coarse aggregate stream for further crushing elsewhere.
- the coarser particles are crushed by a circuit cone crusher.
- the coarser particles crushed by the circuit cone crusher are recirculated back to the screen for further separation.
- some or all of the coarse particles from the screen are discharged into the grinding mill.
- the abovementioned screen is a dry single deck screen.
- the crushing circuit further includes a screen for separating fine particles to be returned to the first grinding mill and coarse particles for crushing by the HPGR.
- the coarse particles crushed by the HPGR are recirculated back to the screen for further separation.
- the abovementioned screen is a dry double deck screen.
- the crushing circuit includes both a dry single deck screen and a dry double deck screen.
- a portion of the coarse particles crushed by the HPGR is recirculated back to the HPGR as a feed.
- this recirculated portion provides sufficient fine particles such as to protect the HPGR grinding surface in use.
- this HPGR grinding surface may be an HPGR tyre.
- the HPGR tyre is a hardened surface applied to the periphery of the grinding rolls of the HPGR to protect a centre portion of the grinding rolls.
- the HPGR grinding surface may include grinding studs.
- the crushing circuit includes a bypass cone crusher installed in parallel with the HPGR to operate as a bypass to the HPGR.
- This embodiment may be particularly useful for maintaining smooth operation of the grinding and classification module during HPGR shutdown/maintenance, or when the HPGR is operating at or over capacity.
- Figure 1 illustrates a schematic diagram of a system for beneficiating a ferrous ore according to a first embodiment of the invention
- Figure 2 illustrates a schematic diagram of a system for beneficiating a ferrous ore according to a second embodiment of the invention
- Figure 3 illustrates a schematic diagram of a system for beneficiating a ferrous ore according to a third embodiment of the invention
- Figure 4 illustrates a primary crushing module of the first, second and third embodiments of the invention
- Figure 5 illustrates a first grinding and classification module and a first separation module of the first embodiment of the invention
- Figure 6 illustrates a first grinding and classification module and a first separation module of the second and third embodiments of the invention
- Figure 7 illustrates a first grinding and classification module and a first separation module of the third embodiment of the invention
- Figure 8 illustrates a second grinding and classification module of the first, second and third embodiments of the invention
- Figure 9 illustrates a second separation module of the first embodiment of the invention
- Figure 10 illustrates a second separation module of the second and third embodiments of the invention
- Figure 11 illustrates a dewatering module of the first, second and third embodiments of the invention
- Figure 12 illustrates a tailings treatment system of the first, second and third embodiments of the invention.
- FIGS 1 , 2 and 3 illustrate schematic flow diagrams of modular systems according to three embodiments of the invention. These systems are comprised of: a primary crushing module, a first grinding and classification module, a first separation module, a second grinding and classification module, a second separation module, a dewatering module, and a tailings treatment system, and the systems will be described with reference to their individual modules.
- each module includes a single input and may be individually optimised such as to enhance a quality of one or more of the modules. This quality may be a product quality of an output of the module, or an input of a sequential module, or an equipment operating variable used in one or more of the modules.
- Such qualities may include: an aggregate stream iron content, an aggregate stream particle size, an aggregate stream water content, and/or an aggregate stream flowrate, a charge ratio in a grinding mill, a water content in a grinding mill, a grinding mill rotation speed, a feed density to a classifying cyclone, a feed pressure to a classifying cyclone, a number of operational classifying cyclones, a separation rate of a separating equipment, energy consumption of a grinding, crushing, classifying, or separating equipment, or water consumption of a grinding, classifying, or separating equipment.
- the primary crushing module includes a ferrous ore input into the system, shown in the form of rear tipping dump trucks depositing the ferrous ore into a vessel in the form of a hopper 10 for storage.
- the ferrous ore may be transported from the hopper 10 to a primary crusher, shown in the form of a gyratory crusher 11 , for crushing the ferrous ore into a ferrous aggregate.
- the ferrous aggregate is then conveyed to a first grinding and classification module in stream S1 .
- FIG. 5-7 Three variations of the first grinding and classification module are shown in Figures 5-7, in which the ferrous aggregate is received in stream S1 and fed to a first grinding mill, shown in the form of an autogenous mill 20, for grinding to reduce the ferrous aggregate size.
- the resultant material is classified by the first classification equipment, including a screen 21 which separates the fine aggregate material, which is provided to hydrocyclone 23, and the coarse aggregate material, for secondary crushing and recycle.
- the overflow from the hydrocyclone 23 is provided to the first separation module, while the underflow is recycled to the inlet of the autogenous mill 20.
- hydrocyclone 23 may have a flat bottom which, in pilot systems, the inventors have found are able to effect a reduction of recirculation load to the autogenous mill 20 from 300-350% to 100-150%, allowing the autogenous mill 20 to operate more efficiently and steadily.
- the secondary crushing circuit includes a cone crusher 22a.
- the secondary crushing circuit may alternatively use a further screen 22b and high-pressure grinding roll (HPGR) 22c to achieve the secondary crushing.
- HPGR 22c is therefore in a feedback loop with the autogenous mill 20. That is, for example, part of the output from the autogenous mill 20 makes its way to the HPGR 22c.
- the circuit may optionally also include a further crushing device, such as bypass cone crusher 22d, for maintaining smooth operation of the grinding and classification module during HPGR 22c shutdown/maintenance, or when the HPGR 22c is operating at or over capacity.
- the secondary crushing circuit may alternatively use a further dry single deck screen 22f, circuit cone crusher 22e, dry double deck screen 22b and high-pressure grinding roll (HPGR) 22c to achieve the secondary crushing.
- the further dry single deck screen 22f is applied to control an upper limit aggregate size fed to the HPGR 22c with the oversize fed the circuit cone crusher 22e.
- the dry double deck screen 22b is employed to control an upper limit aggregate size returning to the autogenous mill 20 with oversize recycling back to HPGR 22c.
- Oversize of the dry single deck screen 22f may alternatively bypass the circuit cone crusher 22e and return back the autogenous mill 20 directly without crushing.
- the secondary crushing circuit is therefore in a feedback loop with the autogenous mill 20.
- the circuit may optionally also include a crushing device, such as bypass cone crusher 22d, for maintaining smooth operation of the grinding and classification module during HPGR 22c shutdown/maintenance, or when the HPGR 22c is operating at or over capacity.
- a crushing device such as bypass cone crusher 22d
- the inventors are not aware of previous use of an HPGR for pebble crushing in iron ore beneficiation systems similar to those described in the second and third embodiments.
- the use of the HPGR 22c in feedback loop with a dry double deck screen 22b has significant advantages in a reduction of energy required for the first grinding and classification module (despite adding further devices to the system), a substantial improvement of the autogenous mill 20 and a reduced wear rate of the crushing surface when compared to traditional methods, such as cone crushing.
- the use of the further dry single deck screen 22f may filter out coarser particles which may be inefficient for crushing in the HPGR 22c, or may damage the grinding roll tyre surface of the HPGR 22c, and may also scalp oversize tramp metals out of the HPGR system, mitigating the damage of the grinding roll tyre surface by the tramp metals.
- the coarser particles of dry single deck screen 22f are reported to the circuit cone crusher 22e which is in feedback loop with the dry single deck screen 22f.
- the coarse particles of the dry single deck screen 22f are alternatively directly returned to the autogenous mill 20 by bypassing the circuit cone crusher 22e, which will be used as grinding media if the ferrous aggregate particle size in stream S1 is small and the autogenous mill power draw is low.
- the HPGR product can be partially recycled to the HPGR feed to maintain enough fines in the feed for HPGR tyre protection, extending the HPGR tyre service life and improving the availability of HPGR. Similar advantages are also applicable for the secondary crushing circuit in the second embodiment.
- the first separation module includes a first separation equipment in the form of a magnetic drum separator 24 to separate the hydrocyclone 23 overflow into a first fine aggregate stream S2, including the magnetic ferrous particles, and a tailings stream T1 .
- the second grinding and classification module receives the first fine aggregate stream S2 as an inlet to a classification equipment, shown in the form of a hydrocyclone 30.
- the overflow from the hydrocyclone 30 is transported to the next module as a second fine aggregate stream S3, while the underflow is recycled to the inlet of a grinding mill, shown in the form of a ball mill 31 . After grinding, this recycle stream is provided back to the hydrocyclone 30 inlet for further classification.
- hydrocyclone 30 may be individually optimised within the module to reduce the recirculation load.
- the hydrocyclone 30 cone angle was optimised from 10 degrees to 13 degrees, which reduced the recirculation load from 600-800% to 200- 500%, significantly improving the ball mill capacity and reducing the energy and water requirements for running the ball mill 31 .
- the second separation module aims to receive and separate the second fine aggregate stream into a concentrated ferrous aggregate stream S4 and further waste tailings streams T2, T3.
- the module includes a magnetic drum separator 40a, to separate out any non-magnetic particles, and a desliming elutriation column 41 to concentrate the concentrated ferrous aggregate stream S4.
- the module includes two desliming elutriation columns 40b, 41 connected in series to concentrate the concentrated ferrous aggregate stream S4.
- the use of a desliming elutriation column was found to be beneficial over using only traditional drum magnetic separators in improving separation efficiency, leading to less grinding required for a similar grade aggregate product or higher concentrate grade at a similar grind size.
- the desliming elutriation column is very effective in diverting high silica slime, non-magnetic material and poorly locked ferrous particles to the tailings steams T2, T3. This is particularly advantageous for refining magnetite ore due to the difficulties in separating silica from ferrous particles in the ore. This results in a higher quality concentrated ferrous aggregate stream S4, which requires a reduced number of steps to further purify to a metallic iron product.
- the dewatering module aims to receive the concentrated ferrous aggregate stream S4 and remove moisture from it to produce an iron concentrate S5, as shown in Figure 11 .
- this is achieved through the use of a concentrate thickener 50 and a filter press 52.
- a filtrate thickener 51 may be utilised in series with the concentrate thickener 50 to further dewater the stream prior to pressing in filter press 52 when the density of the ferrous aggregate stream to the filter press 52 is suitably low.
- the modular system may also include a tailings thickening stage to further dewater the tailings streams T1 , T2, T3 such that they may be suitable disposed of. In the illustrated embodiments, this is achieved through tailings thickeners 60, 61 such that the tailings may be disposed of in the tailings dam 62.
- Example systems
- Example systems of the first and third embodiments of the invention were modelled and tested in accordance with an aggregate magnetite ore input having a particle size between about 0-1 .2m:
- Each embodiment was optimised toward a target grade of 65% Fe in the aggregate stream after the second separation module, and less than 10% w/w moisture after the filter press in the dewatering module.
- the third embodiment has additional installed power for each individual unit of equipment, the inventors found that the use of the HPGR was significantly more energy efficient than the cone crusher in the first embodiment and the aggregate size recycling to the first grinding mill after the secondary crushing was much coarser for the first embodiment. Moreover, the first embodiment had a higher recirculation rate for secondary crushing, further increasing its energy requirements and reducing the rate of aggregate throughput of the module compared to the third embodiment.
- the inventors have found the use of an HPGR in the first grinding and classification module to be significantly beneficial in reducing the unit energy consumption in the first grinding and classification module, and increasing the aggregate throughput in the first grinding mill.
- the use of desliming elutriation column(s) in the separation modules beneficial in separating unwanted impurities and increasing the iron content of the concentrated ferrous aggregate stream, as well as reducing the overall energy consumption.
- the modular system is also beneficial in that each module may be isolated and individually optimised, which would additionally increase efficiency in each subsequent module.
- the modular system with two stages of grinding and classification and separation is a shorter process in comparison with other ferrous ore beneficiating systems, with less equipment maintenance and sufficient operation flexibility to accommodate ferrous ore feed property variation and to achieve target iron concentrate quality.
- the terms ‘comprises’, ‘comprising’, ‘includes’, ‘including’, or similar terms are intended to mean a non-exclusive inclusion, such that a method, system or apparatus that comprises a list of elements does not include those elements solely, but may well include other elements not listed.
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- Geochemistry & Mineralogy (AREA)
- Environmental & Geological Engineering (AREA)
- Manufacturing & Machinery (AREA)
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Abstract
Description
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Priority Applications (1)
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AU2022388082A AU2022388082A1 (en) | 2021-11-11 | 2022-11-11 | Modular system and method for beneficiating a ferrous ore |
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AU2021903610A AU2021903610A0 (en) | 2021-11-11 | Modular System and Method for Beneficiating a Ferrous Ore | |
AU2021903610 | 2021-11-11 |
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PCT/AU2022/051344 WO2023081971A1 (en) | 2021-11-11 | 2022-11-11 | Modular system and method for beneficiating a ferrous ore |
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CN103691538A (en) * | 2014-01-10 | 2014-04-02 | 重钢西昌矿业有限公司 | Ore grinding and classifying system and method |
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BASHE LUZUKO: "Optimisation of the classical semi-autogenous and ball milling circuit using the attainable region technique", MASTER'S THESIS, UNIVERSITY OF SOUTH AFRICA, 1 October 2019 (2019-10-01), XP093067777, Retrieved from the Internet <URL:https://uir.unisa.ac.za/bitstream/handle/10500/26693/dissertation_bashe_l.pdf?sequence=1&isAllowed=y> [retrieved on 20230726] * |
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