1. Beneficiation of High Alumina Iron-ore Slimes
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Manish Kumar Jha
Chemical Engineering
IIT Kanpur
Guided by:
John Samuel Thella
Raw Material Group, R & D
01/12

2. Objective Iron Ore (ROM) -40+10 mm 1.9 % Al2O3 -10+0.15 mm 2.7 % Al2O3
Blast furnace mm
1.9 % Al2O3
Sinter Plant mm
2.7 % Al2O3
Tailing pond
-0.15 mm
~10 % Al2O3
Iron Ore (ROM)
Pellet Feed Fines
VAP
02/12

3. Less Energy in Regrinding
Motivation 1
Higher Mine Output 2
Less Energy in Regrinding 3
Ecological Benefits
This way we can be winners twice over.
03/12

4. Feed Analysis
Size-wise Distribution
Particle Size (µm)
04/12

5. Modus Operandi Overflow High Alumina Slimes Tailings Concentrate
Underflow
05/12

6. Hydrocyclone Separator
Overflow
Overflow
Iron Slimes
Underflow
Centrifugal
Viscous
Feed
Underflow
06/12

7. 15 experiments conducted, using 3 factor – 3 level Box-Behnken DOE.
Parameters involved:
15 experiments conducted, using 3 factor – 3 level Box-Behnken DOE.
Pressure ( kg/cm2)
Percent solid (%)
Spigot diameter (mm)
1.4 10
3.2
2.1 15
4.5
2.5 20
6.4
Fe(t)%
SiO2%
Al2O3%
Wt %
Best results:
62.63
1.83
2.68
54.9
62.79
1.88
2.73
60.3
61.47
1.89
2.78
59.4
07/12

8. Result Analysis Alumina Rejection: Surface plot
Alumina Rejection: Pareto Chart
08/12

9. Froth Flotation
(Tailings) Fe
Al2O3
Concentrate
09/12

10. Depressant dose (g/Kg)
Parameters involved pH
Collector dose (g/Kg)
Depressant dose (g/Kg) 8
0.5
0.25 9 1 10
1.5
Fe(t)%
SiO2%
Al2O3%
Wt %
Best results known yet:
64.64
1.56
2.58
64.4
62.69
1.47
3.64 --
59.16
1.76
3.74
49.7
10/12

11. Conclusions
Best result that we got till now is, alumina reduction from:
6.12 to 2.68 percent (Hydro-cyclone).
4.31 to 2.58 percent (Froth Flotation).
It is expected to get alumina concentration below 2 percent if we use the best setup together.
11/12

12. Thank You
12/12