Enrichment of Low Grade Iron Ore for Better Resource Utilisation

"Total iron ore reserves in India, as reported by the Indian Bureau of mines, are 23.6 billion tons. Hematite iron ore reserves constitute about 45 % of the total reserve. If we go by the National Steel Policy-2005 projections, India’s supply of hematite iron ore would not last more than 40 years. Laboratory investigations were carried out for the development of a process flow sheet for treating low grade as well as Banded Hematite Quartzite (BHQ) iron ore. The purpose of these investigations was to aim for better resource utilization.Beneficiation studies were conducted on samples of low grade and siliceous iron ore from the Dalli mines, a captive mine of the Bhilai Steel Plant and BHQ ore from Southern states of India. The process flowsheet, developed for upgrading of low grade iron ore, incorporates wet screening of the ore at 0.5 mm, followed by grinding of the +0.5 mm fraction to below 0.5 mm. The whole –0.5 mm fraction, after grinding, was treated in a conventional hydro-cyclone and stub cyclone followed by treatment in Wet High Intensity Magnetic Separator (WHIMS). This resulted in a concentrate product having >66% Fe content from a feed containing 55.5% Fe with an iron recovery of 48 %. The process flowsheet developed for treating BHQ ore in the laboratory resulted in an increase in iron grade in the concentrate from 43.4 to 61.3 Fe % with a yield of 51.7 % .INTRODUCTIONThe classification of Indian iron ore resources have been made compatible with United Nations Framework Classification (UNFC), which is more scientific and has been adopted in most countries in the world. Iron ore reserves and resources estimated using the UNFC classification system, as of April 01,2000 are about 12,906 million tons of hematite ore and 10,628 million tons of magnetite ore. The Indian Bureau of Mines (IBM) has given a breakdown of these reserves by designation as either lumps or fines of hematite iron ore (Table 1). The percentage of the reserves reported lumps and fines are 42 and 34% of the total reserves respectively. High grade iron ore is less than 10% of the total reserve."