Processing Studies on Iron Ore Tailings Sample For Pelletisation Plant From Barbil Region, Orissa

Abstract

An iron ore tails sample from Barbil region, Orissa state was received for evolving a process, to produce pellet grade concentrates. The sample consisted of mostly brown coloured fines with little hard – compact chips. It contained mainly hematite with subordinate amounts of clay. Amphibole, quartz, gibbsite and magnetite were found in minor to trace amounts. Hematite aggregates are liberated fairly at 50 mesh size.. The sample analysed 56.09% Fe(T), 8.52% SiO2,5.86 %Al2O3 and 4.74% LOI. The recommended process flow sheet comprises of [1] Rod mill grinding of sample to 95% - 50 mesh, d80 200 microns with little slimes.[2] Tabling of ground pulp with Diester diagonal deck table, re-passing I middling to get II table concentrate in addition to I table concentrate yielding a primary gravity concentrate.[3] Wet high intensity magnetic separation of table II middling, table tails & slimes at ~7000 gauss to get secondary magnetic concentrate after re-grinding of table rejects to -100 mesh followed by natural thickening. [4] Grinding of the final composite concentrate in ball mill to - 200 mesh [5] Thickening of ground final concentrate and Final tails [6] Larox pressure filtration on ground thickened concentrate pulp. The process yielded concentrate assaying 63.65% Fe(T), 3.25% SiO2,2.15%Al2O3, 2.78% LOI, 8.2% moisture, - 200 mesh size, d80 30 microns, and specific surface area of 2076 Cm2/ gram with 76.5 % Fe recovery yield at 67.5 wt.% yield. Feasibility study is recommended as the proposed project appears to be viable and sustainable.