Abstract: The control over delivered iron ore blend characteristics is one of the most important aspects of the mining business. The iron ore price is a function of its composition, which is the outcome of the beneficiation process. So, end-to-end integrated planning of mine operations can reduce risks of penalties on the iron ore price. In a standard iron mining company, the production chain is composed of mining, ore beneficiation, and client supply. When mine planning and client supply decisions are made uncoordinated, the beneficiation plant struggles to deliver the best blend possible. Technological improvements in several fields allowed bridging the gap between departments and boosting integrated decision-making processes. Clusterization and classification algorithms over historical production data generate reasonable previsions for quality and volume of iron ore produced for each pile of run-of-mine (ROM) processed. Mathematical modeling can use those deterministic relations to propose iron ore blends that better-fit specifications within a delivery schedule. Additionally, a model capable of representing the whole production chain can clearly compare the overall impact of different decisions in the process. This study shows how flexibilization combined with a planning optimization model between the mine and the ore beneficiation processes can reduce risks of out of specification deliveries. The model capabilities are illustrated on a hypothetical iron ore mine with magnetic separation process. Finally, this study shows ways of cost reduction or profit increase by optimizing process indicators across the production chain and integrating the different plannings with the sales decisions.
Abstract: In the past, we could increase profit by increasing product prices. But in the new decade, a competitive market does not let us to increase profit with increase prices. Therefore, the only way to increase profit will be reduce costs. A significant percentage of production costs are the maintenance costs, and analysis of these costs could achieve more profit. Most maintenance strategies such as RCM (Reliability-Center-Maintenance), TPM (Total Productivity Maintenance), PM (Preventive Maintenance) etc., are trying to reduce maintenance costs. In this paper, decreasing the maintenance costs of Concentration Plant of Golgohar Company (GEG) was examined by using of MTBF (Mean Time between Failures) and MTTR (Mean Time to Repair) analyses. These analyses showed that instead of buying new machines and increasing costs in order to promote capacity, the improving of MTBF and MTTR indexes would solve capacity problems in the best way and decrease costs.
Abstract: In the past, we could increase profit by increasing product prices. But in the new decade, a competitive market does not let us to increase profit with increased prices. Therefore, the only way to increase profit will be to reduce costs. A significant percentage of production costs are the maintenance costs, and analysis of these costs could achieve more profit. Most maintenance strategies such as RCM (Reliability-Center-Maintenance), TPM (Total Productivity Maintenance), PM (Preventive Maintenance) and etc., are trying to reduce maintenance costs. In this paper, decreasing the maintenance costs of Concentration Plant of Golgohar Iron Ore Mining & Industrial Company (GeG) was examined by using of MTBF (Mean Time Between Failures) and MTTR (Mean Time To Repair) analyses. These analyses showed that instead of buying new machines and increasing costs in order to promote capacity, the improving of MTBF and MTTR indexes would solve capacity problems in the best way and decrease costs.
Abstract: Cluster formation is an essential phenomenon during direct reduction processes at shaft furnaces. Decreasing the reducing temperature to avoid this problem can cause a significant drop in throughput. In order to prevent sticking of pellets, a coating material basically inactive under the reducing conditions prevailing in the shaft furnace, should be applied to cover the outer layer of the pellets. In the present work, steel dust is used as coating material for iron ore pellets to explore dust coating effectiveness and determines the best coating conditions. Steel dust coating is applied for iron ore pellets in various concentrations. Dust slurry concentrations of 5.0-30% were used to have a coated steel dust amount of 1.0-5.0 kg per ton iron ore. Coated pellets with various concentrations were reduced isothermally in weight loss technique with simulated gas mixture to the composition of reducing gases at shaft furnaces. The influences of various coating conditions on the reduction behavior and the morphology were studied. The optimum reduced samples were comparatively applied for sticking index measurement. It was found that the optimized steel dust coating condition that achieve higher reducibility with lower sticking index was 30% steel dust slurry concentration with 3.0 kg steel dust/ton ore.
Abstract: This study investigates the removal of silica, alumina and phosphorus as impurities from Sanje iron ore using wet high-intensity magnetic separation (WHIMS). Sanje iron ore contains low-grade hematite ore found in Nampundwe area of Zambia from which iron is to be used as the feed in the steelmaking process. The chemical composition analysis using X-ray Florence spectrometer showed that Sanje low-grade ore contains 48.90 mass% of hematite (Fe2O3) with 34.18 mass% as an iron grade. The ore also contains silica (SiO2) and alumina (Al2O3) of 31.10 mass% and 7.65 mass% respectively. The mineralogical analysis using X-ray diffraction spectrometer showed hematite and silica as the major mineral components of the ore while magnetite and alumina exist as minor mineral components. Mineral particle distribution analysis was done using scanning electron microscope with an X-ray energy dispersion spectrometry (SEM-EDS) and images showed that the average mineral size distribution of alumina-silicate gangue particles is in order of 100 μm and exists as iron-bearing interlocked particles. Magnetic separation was done using series L model 4 Magnetic Separator. The effect of various magnetic separation parameters such as magnetic flux density, particle size, and pulp density of the feed was studied during magnetic separation experiments. The ore with average particle size of 25 µm and pulp density of 2.5% was concentrated using pulp flow of 7 L/min. The results showed that 10 T was optimal magnetic flux density which enhanced the recovery of 93.08% of iron with 53.22 mass% grade. The gangue mineral particles containing 12 mass% silica and 3.94 mass% alumna remained in the concentrate, therefore the concentrate was further treated in the second stage WHIMS using the same parameters from the first stage. The second stage process recovered 83.41% of iron with 67.07 mass% grade. Silica was reduced to 2.14 mass% and alumina to 1.30 mass%. Accordingly, phosphorus was also reduced to 0.02 mass%. Therefore, the two stage magnetic separation process was established using these results.
Abstract: The iron content of the ore used is crucial for the productivity and coke consumption rate in blast furnace pig iron production. Therefore, most iron ore deposits are processed in beneficiation plants to increase the iron content and remove impurities. In several comminution stages, the particle size of the ore is reduced to ensure that the iron oxides are physically liberated from the gangue. Subsequently, physical separation processes are applied to concentrate the iron ore. The fine-grained ore concentrates produced need to be transported, stored, and processed. For smooth operation of these processes, the flow properties of the material are crucial. The flowability of powders depends on several properties of the material: grain size, grain size distribution, grain shape, and moisture content of the material. The flowability of powders can be measured using ring shear testers. In this study, the influence of the moisture content on the flowability for the Krivoy Rog magnetite iron ore concentrate was investigated. Dry iron ore concentrate was mixed with varying amounts of water to produce samples with a moisture content in the range of 0.2 to 12.2%. The flowability of the samples was investigated using a Schulze ring shear tester. At all measured values of the normal stress (1.0 kPa – 20 kPa), the flowability decreased significantly from dry ore to a moisture content of approximately 3-5%. At higher moisture contents, the flowability was nearly constant, while at the maximum moisture content the flowability improved for high values of the normal stress only. The results also showed an improving flowability with increasing consolidation stress for all moisture content levels investigated. The wall friction angle of the dust with carbon steel (S235JR), and an ultra-high molecule low-pressure polyethylene (Robalon) was also investigated. The wall friction angle increased significantly from dry ore to a moisture content of approximately 3%. For higher moisture content levels, the wall friction angles were nearly constant. Generally, the wall friction angle was approximately 4° lower at the higher wall normal stress.
Abstract: Starches are widely used as depressant in froth flotation operations in Brazil due to their efficiency, increasing the selectivity in the inverse flotation of quartz depressing iron ore. Starches market have been growing and improving in recent years, leading to better products attending the requirements of the mineral industry. The major source of starch used for iron ore is corn starch, which needs to be gelatinized with sodium hydroxide (NaOH) prior to use. This stage has a direct impact on industrials costs, once the lowest consumption of NaOH in gelatinization provides better control of the pH in the froth flotation and reduces the amount of electrolytes present in the pulp. In order to evaluate the gelatinization degree of different starches and flour were subjected to the addiction of NaOH and temperature variation experiments. Samples of starch (corn, cassava, HIPIX 100, HIPIX 101 and HIPIX 102 commercialized by Ingredion) and flour (cassava and potato) were tested. The starch samples were characterized through Scanning Electronic Microscopy and the amylose content were determined through spectrometry, swelling and solubility tests. The gelatinization was carried out through titration with NaOH, keeping the solution temperature constant at 40 oC. At the end of the tests, the optimal amount of NaOH consumed to gelatinize the starch or flour from different botanical sources was established and a correlation between the content of amylopectin in the starch and the starch/NaOH ratio needed for its gelatinization.
Abstract: A significant percentage of production costs is the maintenance costs, and analysis of maintenance costs could to achieve greater productivity and competitiveness. With this is mind, the maintenance of machines and installations is considered as an essential part of organizational functions and applying effective strategies causes significant added value in manufacturing activities. Organizations are trying to achieve performance levels on a global scale with emphasis on creating competitive advantage by different methods consist of RCM (Reliability-Center-Maintenance), TPM (Total Productivity Maintenance) etc. In this study, increasing the capacity of Concentration Plant of Golgohar Iron Ore Mining & Industrial Company (GEG) was examined by using of reliability and maintainability analyses. The results of this research showed that instead of increasing the number of machines (in order to solve the bottleneck problems), the improving of reliability and maintainability would solve bottleneck problems in the best way. It should be mention that in the abovementioned study, the data set of Concentration Plant of GEG as a case study, was applied and analyzed.
Abstract: Boiler coals with low fixed carbon and higher ash content have always challenged the metallurgists to develop a suitable method for their utilization. In the present study, an attempt is made to establish an energy effective method for the reduction of iron ore fines in the form of nuggets by using ‘Syngas’. By devolatisation (expulsion of volatile matter by applying heat) of boiler coal, gaseous product (enriched with reducing agents like CO, CO2, H2, and CH4 gases) is generated. Iron ore nuggets are reduced by this syngas. For that reason, there is no direct contact between iron ore nuggets and coal ash. It helps to control the minimization of the sulphur intake of the reduced nuggets. A laboratory scale devolatisation furnace designed with reduction facility is evaluated after in-depth studies and exhaustive experimentations including thermo-gravimetric (TG-DTA) analysis to find out the volatile fraction present in boiler grade coal, gas chromatography (GC) to find out syngas composition in different temperature and furnace temperature gradient measurements to minimize the furnace cost by applying one heating coil. The nuggets are reduced in the devolatisation furnace at three different temperatures and three different times. The pre-reduced nuggets are subjected to analytical weight loss calculations to evaluate the extent of reduction. The phase and surface morphology analysis of pre-reduced samples are characterized using X-ray diffractometry (XRD), energy dispersive x-ray spectrometry (EDX), scanning electron microscopy (SEM), carbon sulphur analyzer and chemical analysis method. Degree of metallization of the reduced nuggets is 78.9% by using boiler grade coal. The pre-reduced nuggets with lesser sulphur content could be used in the blast furnace as raw materials or coolant which would reduce the high quality of coke rate of the furnace due to its pre-reduced character. These can be used in Basic Oxygen Furnace (BOF) as coolant also.
Abstract: The rapid depletion of high-grade iron ore (Fe2O3) has gained attention on the use of other sources of iron ore. Titaniferous magnetite ore (TMO) is a special type of magnetite ore having high titania content (23.23% TiO2 present in this case). Due to high TiO2 content and high density, TMO cannot be treated by the conventional smelting reduction. In this present work, the TMO has been collected from high-grade metamorphic terrain of the Precambrian Chotanagpur gneissic complex situated in the eastern part of India (Shaltora area, Bankura district, West Bengal) and the hematite ore has been collected from Visakhapatnam Steel Plant (VSP), Visakhapatnam. At VSP, iron ore is received from Bailadila mines, Chattisgarh of M/s. National Mineral Development Corporation. The preliminary characterization of TMO and hematite ore (HMO) has been investigated by WDXRF, XRD and FESEM analyses. Similarly, good quality of coal (mainly coking coal) is also getting depleted fast. The basic purpose of this work is to find how lean grade coal can be utilised along with TMO for smelting to produce pig iron. Lean grade coal has been characterised by using TG/DTA, proximate and ultimate analyses. The boiler grade coal has been found to contain 28.08% of fixed carbon and 28.31% of volatile matter. TMO fines (below 75 μm) and HMO fines (below 75 μm) have been separately agglomerated with lean grade coal fines (below 75 μm) in the form of briquettes using binders like bentonite and molasses. These green briquettes are dried first in oven at 423 K for 30 min and then reduced isothermally in tube furnace over the temperature range of 1323 K, 1373 K and 1423 K for 30 min & 60 min. After reduction, the reduced briquettes are characterized by XRD and FESEM analyses. The best reduced TMO and HMO samples are taken and blended in three different weight percentage ratios of 1:4, 1:8 and 1:12 of TMO:HMO. The chemical analysis of three blended samples is carried out and degree of metallisation of iron is found to contain 89.38%, 92.12% and 93.12%, respectively. These three blended samples are briquetted using binder like bentonite and lime. Thereafter these blended briquettes are separately smelted in raising hearth furnace at 1773 K for 30 min. The pig iron formed is characterized using XRD, microscopic analysis. It can be concluded that 90% yield of pig iron can be achieved when the blend ratio of TMO:HMO is 1:4.5. This means for 90% yield, the maximum TMO that could be used in the blend is about 18%.
Abstract: Clustering phenomenon of pellets was observed frequently in shaft processes operating at higher temperatures. Clustering is a result of the growth of fibrous iron precipitates (iron whiskers) that become hooked to each other and finally become crystallized during the initial stages of metallization. If the pellet clustering is pronounced, sometimes leads to blocking inside the furnace and forced shutdown takes place. This work clarifies further the relation between metallic iron whisker growth and iron ore mineralogy. Various pellet sizes (6 – 12.0 & +12.0 mm) from three different ores (A, B & C) were (completely and partially) reduced at 985 oC with H2/CO gas mixture using thermos-gravimetric technique. It was found that reducibility increases by decreasing the iron ore pellet’s size. Ore (A) has the highest reducibility than ore (B) and ore (C). Increasing the iron ore pellet’s size leads to increase the probability of metallic iron whisker formation. Ore (A) has the highest tendency for metallic iron whisker formation than ore (B) and ore (C). The reduction reactions for all iron ores A, B and C are mainly controlled by diffusion reaction mechanism.
Abstract: In present study, a large deposit of oolitic iron ore of
Late Carboniferous-Permotriassic-Lower Jurassic age was discovered
in Wadi Halfa and Argein areas, North Sudan. It seems that the iron
ore mineralization exists in the west and east bank of the River Nile
of the study area that are found on the Egyptian-Sudanese border.
The Carboniferous-Lower Jurassic age strata were covered by 67
sections and each section has been examined and carefully described.
The iron-ore in Wadi Halfa occurs as oolitic ironstone and contained
two horizons: (A) horizon and (B) horizon. Only horizon (A) was
observed in southern Argein area. The texture of the ore is variable
depending on the volume of the component. In thin sections, the
average of the ooids was ranged between 90%-80%. The matrix
varies between 10%-20% by volume and detritus quartz in other
component my reach up to 30% by volume in sandy massive ore.
Ooids size ranges from 0.2mm-1.00 mm on average in very coarse
ooids may attend up to 1 mm in size. The matrix around the ooids is
dominated by iron hydroxide, carbonate, fine, and amorphous silica.
The probable ore reserve estimate of 1.234 billion at a head grade of
41.29% Fe for the Wadi Halfa Oolitic Ironstone Formation. The iron
ore shows higher content of phosphorus ranges from 6.15% to 0.16%,
with mean 1.45%. The new technology Hatch–Ironstone Chloride
Segregation (HICS) can be used to produce commercial-quality of
iron and reduce phosphorus and silica to acceptable levels for steel
industry. The presence of infrastructures in addition to the presence
of massive quantities of iron ore would make exploitation
economically.
Abstract: The paper deals with possibilities of interpretation of
iron ore reducibility tests. It presents a mathematical model
developed at Centre ENET, VŠB – Technical University of Ostrava,
Czech Republic for an evaluation of metallurgical material of blast
furnace feedstock such as iron ore, sinter or pellets. According to the
data from the test, the model predicts its usage in blast furnace
technology and its effects on production parameters of shaft
aggregate. At the beginning, the paper sums up the general concept
and experience in mathematical modelling of iron ore reduction. It
presents basic equation for the calculation and the main parts of the
developed model. In the experimental part, there is an example of
usage of the mathematical model. The paper describes the usage of
data for some predictive calculation. There are presented material,
method of carried test of iron ore reducibility. Then there are
graphically interpreted effects of used material on carbon
consumption, rate of direct reduction and the whole reduction
process.
Abstract: Numerous amounts of metallurgical dusts and sludge containing iron as well as some other valuable elements such as Zn, Pb and C are annually produced in the steelmaking industry. These alternative iron ore resources (fines) with unsatisfying physical and metallurgical properties are difficult to recycle. However, agglomerating these fines to be further used as a feed stock for existing iron and steelmaking processes is practiced successfully at several plants but for limited extent.
In the present study, briquettes of integrated steelmaking industry waste materials (namely, BF-dust and sludge, BOF-dust and sludge) were used as feed stock to produce direct reduced iron (DRI). Physical and metallurgical properties of produced briquettes were investigated by means of TGA/DTA/QMS in combination with XRD. Swelling, softening and melting behavior were also studied using heating microscope.
Abstract: The ice rink floor is the largest heat exchanger in an ice rink. The important part of the floor consists of concrete, and the thermophysical properties of this concrete have strong influence on the energy usage of the ice rink. The thermal conductivity of concrete can be increased by using iron ore as ballast. In this study, the Transient Plane Source (TPS) method showed an increase up to 58.2% of thermal conductivity comparing the improved concrete to standard concrete. Moreover, two alternative ice rink floor designs are suggested to incorporate the improved concrete. A 2D simulation was developed to investigate the temperature distribution in the conventional and the suggested designs. The results show that the suggested designs reduce the temperature difference between the ice surface and the brine by 1-4˚C, when comparing with convectional designs at equal heat flux. This primarily leads to an increased coefficient of performance (COP) in the primary refrigeration cycle and secondly to a decrease in the secondary refrigerant pumping power. The suggested designs have great potential to reduce the energy usage of ice rinks. Depending on the load scenario in the ice rink, the saving potential lies in the range of 3-10% of the refrigeration system energy usage. This calculation is based on steady state conditions and the potential with improved dynamic behavior is expected to increase the potential saving.
Abstract: Based upon generalized analysis of modern know-how in the sphere of processing, concentration and purification of iron-ore raw materials (IORM), in particular, the most widespread ferrioxide-silicate materials (FOSM), containing impurities of phosphorus and other elements compounds, noted special role of nanotechnological initiatives in improvement of such processes. Considered ideas of role of nanoparticles in processes of FOSM carbonization with subsequent direct reduction of ferric oxides contained in them to metal phase, as well as in processes of alkali treatment and separation of powered iron from phosphorus compounds. Using the obtained results the wasteless method of solid-phase processing, concentration and purification of IORM and FOSM from compounds of phosphorus, silicon and other impurities was developed and it excels known methods of direct iron reduction from iron ores and metallurgical slimes.
Abstract: Isobaric and cooling zone of iron ore reactor have been
simulated. In this paper, heat and mass transfer equation are
formulated to perform the temperature and concentration of gas and
solid phase respectively. Temperature profile for isobaric zone is
simulated on the range temperature of 873-1163K while cooling zone
is simulated on the range temperature of 733-1139K. The simulation
results have a good agreement with the plant data. Total carbon
formation in the isobaric zone is only 30% of total carbon contained in
the sponge iron product. The formation of Fe3C in isobaric zone
reduces metallization degree up to 0.58% whereas reduction of
metallization degree in cooling zone up to 1.139%. The decreasing of
sponge iron temperature in the isobaric and cooling zone is around 300
K and 600 K respectively.
Abstract: Usually, the solid-fuel flow of an iron ore sinter plant
consists of different types of the solid-fuels, which differ from each
other. Information about the composition of the solid-fuel flow
usually comes every 8-24 hours. It can be clearly seen that this
information cannot be used to control the sintering process in real
time. Due to this, we propose an expert system which uses indirect
measurements from the process in order to obtain the composition of
the solid-fuel flow by solving an optimization task. Then this
information can be used to control the sintering process. The
proposed technique can be successfully used to improve sinter
quality and reduce the amount of solid-fuel used by the process.
Abstract: Iron ore and coal are the two major important raw
materials being used in Iron making industries. Usually ore fines
containing around 5% Alumina are rejected due to higher proportion
of alumina. Therefore, a technology or process which may reduce
the alumina content by 2% by beneficiation process will be highly
attractive . In addition fine coals with ash content is used nearly 12%
is directly injected in blast furnace. Fast fluidization is a technology
by using dry beneficiation of coal and iron ore can be done. During
the fluidization process the iron ore band coal is fluidized at high
velocity in the riser of a fast fluidized bed, the heavier and coarse
particles is generally settled at the bottom in a dense zone of the riser
while the finer and lighter particle are entrained to the top dilute zone
and then via a cyclone is fed back to the bottom of the riser column.
Most of the alumina and low ash fine size coals being lighter are
expected to move up to the riser and by a natural beneficiation of
ores is expected to take place in the riser. Therefore in this study an
attempt has been made for dry beneficiation of iron ore and coal in a
fluidized bed and its hydrodynamic characterization.
Abstract: In this article we present a change point detection algorithm based on the continuous wavelet transform. At the beginning of the article we describe a necessary transformation of a signal which has to be made for the purpose of change detection. Then case study related to iron ore sinter production which can be solved using our proposed technique is discussed. After that we describe a probabilistic algorithm which can be used to find changes using our transformed signal. It is shown that our algorithm works well with the presence of some noise and abnormal random bursts.