XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 1147
Gravity-based methods often struggle with fine par-
ticles, but recent advances in gravity separators, such as the
Multi Gravity Separator (MGS), have proven effective for
fine and ultra-fine materials (Singh R et al., 2007). Given
that the liberation size for sub-grade iron ore (SGIO) is
around 100–150 microns, enhanced gravity separation with
MGS is proposed. Aslan (2008, 2009) optimized MGS for
chromite concentration, while Bandopadyaya (2000) dem-
onstrated MGS’s effectiveness for fine particles. Cieck et al.
(2002) used MGS for Turkish fine chromite tailings, and
Rao et al. (2010, 2012) applied it to sub-grade iron ore and
BHQ. Roy (2009) improved concentrate recovery from
fine iron ore using MGS.Response surface methodology is
gaining more importance in modelling and optimisation of
different process in various engineering fields (Gunaraj &
murugan 1999, Ajay et al 2007)).
The objective of this paper is to apply a Box- Behnken
design, Response surface methodology to raise a math-
ematical model to represent the behavior of the system as a
convincing function of process parameters.
MATERIAL AND METHODS
The Sample
The ROM sample of Sub Grade Iron Ore (SGIO) from
Bacheli complex, Bailadila, Chattisgarh, India comprises a
mixture of lump, fines, and friable ore, with fines constitut-
ing up to 36%. The sample size ranges from 150 mm to
less than 1 mm, with lump samples displaying alternating
iron and silica bands. Thorough mixing of the ‘as-received’
sample was followed by drawing representative samples
for size analysis, characterization, Screen Assay Analysis,
evaluation of physical properties, and beneficiation stud-
ies. Chemical analysis was conducted using standard wet
chemical procedures and Induction Coupled Plasma (ICP)
Model JY2000-2 by JOBINYVON. Size analysis and
chemical composition of the ‘as-received’ ROM sample are
presented in Figure 1 and Table 1, respectively.
Mineralogical studies reveal Hematite as the primary
ore mineral and Quartz as the main gangue mineral, with
liberation studies indicating an average particle size for
liberation of approximately 100 microns. A representative
portion of the ‘as received’ ROM sample underwent stage
crushing and grinding to less than 0.15 mm (150 microns).
Subsequently, size analysis (wet) was performed on a portion
of the ground sample, with all size fractions individually
dried, weighed, and chemically analyzed. Table 2 presents
the screen assay analysis of the sample crushed and ground
to 0.150 mm, while Figure 2 illustrates the distribution of
Iron and silica in various size fractions of the product, serv-
ing as the feed for the experimental work.
From Table 2 and Figure 2 it can be observed that Fe is
ranged from 36% to 43% whereas SiO2 ranged from 36%
to 48% in individual size fractions.
Multi Gravity Separator
The Multi Gravity Separator (MGS) supplied by Richard
Mozley Ltd, UK (Presently known as Salter Cyclones) with
a Capacity of 200 kg/hour (model -C900, presently known
0.00
20.00
40.00
60.00
80.00
100.00
120.00
1 10 100 1000 10000 100000 1000000
Size in Microns
Size analysis of 'as received' ROM
Figure 1. Size analysis of ‘as received’ ROM
Table 1. Chemical analysis of ‘as received’ ROM sample
Constituent Fe FeO SiO2 Al2O3 LOI P S TiO2 CaO MgO MnO
Assay %40.80 0.70 40.90 0.24 0.22 0.05 0.01 0.091 0.119 0.110 0.045
Cumulativeweight
%
passi
Gravity-based methods often struggle with fine par-
ticles, but recent advances in gravity separators, such as the
Multi Gravity Separator (MGS), have proven effective for
fine and ultra-fine materials (Singh R et al., 2007). Given
that the liberation size for sub-grade iron ore (SGIO) is
around 100–150 microns, enhanced gravity separation with
MGS is proposed. Aslan (2008, 2009) optimized MGS for
chromite concentration, while Bandopadyaya (2000) dem-
onstrated MGS’s effectiveness for fine particles. Cieck et al.
(2002) used MGS for Turkish fine chromite tailings, and
Rao et al. (2010, 2012) applied it to sub-grade iron ore and
BHQ. Roy (2009) improved concentrate recovery from
fine iron ore using MGS.Response surface methodology is
gaining more importance in modelling and optimisation of
different process in various engineering fields (Gunaraj &
murugan 1999, Ajay et al 2007)).
The objective of this paper is to apply a Box- Behnken
design, Response surface methodology to raise a math-
ematical model to represent the behavior of the system as a
convincing function of process parameters.
MATERIAL AND METHODS
The Sample
The ROM sample of Sub Grade Iron Ore (SGIO) from
Bacheli complex, Bailadila, Chattisgarh, India comprises a
mixture of lump, fines, and friable ore, with fines constitut-
ing up to 36%. The sample size ranges from 150 mm to
less than 1 mm, with lump samples displaying alternating
iron and silica bands. Thorough mixing of the ‘as-received’
sample was followed by drawing representative samples
for size analysis, characterization, Screen Assay Analysis,
evaluation of physical properties, and beneficiation stud-
ies. Chemical analysis was conducted using standard wet
chemical procedures and Induction Coupled Plasma (ICP)
Model JY2000-2 by JOBINYVON. Size analysis and
chemical composition of the ‘as-received’ ROM sample are
presented in Figure 1 and Table 1, respectively.
Mineralogical studies reveal Hematite as the primary
ore mineral and Quartz as the main gangue mineral, with
liberation studies indicating an average particle size for
liberation of approximately 100 microns. A representative
portion of the ‘as received’ ROM sample underwent stage
crushing and grinding to less than 0.15 mm (150 microns).
Subsequently, size analysis (wet) was performed on a portion
of the ground sample, with all size fractions individually
dried, weighed, and chemically analyzed. Table 2 presents
the screen assay analysis of the sample crushed and ground
to 0.150 mm, while Figure 2 illustrates the distribution of
Iron and silica in various size fractions of the product, serv-
ing as the feed for the experimental work.
From Table 2 and Figure 2 it can be observed that Fe is
ranged from 36% to 43% whereas SiO2 ranged from 36%
to 48% in individual size fractions.
Multi Gravity Separator
The Multi Gravity Separator (MGS) supplied by Richard
Mozley Ltd, UK (Presently known as Salter Cyclones) with
a Capacity of 200 kg/hour (model -C900, presently known
0.00
20.00
40.00
60.00
80.00
100.00
120.00
1 10 100 1000 10000 100000 1000000
Size in Microns
Size analysis of 'as received' ROM
Figure 1. Size analysis of ‘as received’ ROM
Table 1. Chemical analysis of ‘as received’ ROM sample
Constituent Fe FeO SiO2 Al2O3 LOI P S TiO2 CaO MgO MnO
Assay %40.80 0.70 40.90 0.24 0.22 0.05 0.01 0.091 0.119 0.110 0.045
Cumulativeweight
%
passi
