1956 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
REFERENCES
[1] J. Pal, ‘Innovative Development on Agglomeration
of Iron Ore Fines and Iron Oxide Wastes’,
Mineral Processing and Extractive Metallurgy
Review, vol. 40, no. 4, pp. 248–264, 2019, doi:
10.1080/08827508.2018.1518222.
[2] N. A. El-Hussiny and M. E. H. Shalabi, ‘A self-
reduced intermediate product from iron and steel
plants waste materials using a briquetting process’,
Powder Technol, vol. 205, no. 1–3, pp. 217–223,
2011, doi: 10.1016/j.powtec.2010.09.017.
[3] J. Xu, N. Wang, M. Chen, and H. Yu, ‘Recycling
of Blast Furnace Flue Dust with In-flight
Reduction Technology: Reduction Behavior
and Kinetic Analysis’, in Minerals, Metals and
Materials Series, Springer, 2020, pp. 365–376. doi:
10.1007/978-3-030-36830-2_35.
[4] A. Yehia and F. H. El-Rahiem, ‘Recovery and utili-
zation of iron and carbon values from blast furnace
flue dust’, Transactions of the Institutions of Mining
and Metallurgy, Section C: Mineral Processing and
Extractive Metallurgy, vol. 114, no. 4, pp. 184–189,
2005, doi: 10.1179/037195505X28519.
[5] B. Das, S. Prakash, P. S. R. Reddy, S. K. Biswal, B.
K. Mohapatra, and V. N. Misra, ‘Effective utiliza-
tion of blast furnace flue dust of integrated steel
plants’, The European Journal of Mineral Processinf and
Environmental Protection, vol. 2, no. 2, pp. 61–68,
2002, [Online]. Available: http://www.ejmpep.com
/das_et al.pdf.
[6] V. Ri et al., ‘) ORWDWLRQ FKDUDFWHU-
LVWLFV RI KLJK DVK R [LGLVHG, QGLDQ’,
pp. 1–10.
[7] X. Gui, Y. Xing, T. Wang, Y. Cao, Z. Miao, and M. Xu,
‘Intensification mechanism of oxidized coal flotation
by using oxygen-containing collector α-furanacrylic
acid’, Powder Technol, vol. 305, pp. 109–116, 2017,
doi: 10.1016/j.powtec.2016.09.058.
[8] M. S. Jena, S. K. Biswal, and M. V. Rudramuniyappa,
‘Study on flotation characteristics of oxidised Indian
high ash sub-bituminous coal’, Int J Miner Process,
vol. 87, no. 1–2, pp. 42–50, 2008, doi: 10.1016/j.
minpro.2008.01.004.
[9] W. Xia, J. Yang, and C. Liang, ‘A short review of
improvement in flotation of low rank/oxidized coals
by pretreatments’, Powder Technol, vol. 237, pp. 1–8,
2013, doi: 10.1016/j.powtec.2013.01.017.
[10] J. Wang, Y. He, Y. Yang, W. Xie, and X. Ling, ‘Research
on quantifying the hydrophilicity of leached coals
by FTIR spectroscopy’, Physicochemical Problems of
Mineral Processing, vol. 53, no. 1, pp. 227–239, 2017,
doi: 10.5277/ppmp170119.
[11] B. Das, S. Prakash, P. S. R. Reddy, and V. N.
Misra, ‘An overview of utilization of slag and
sludge from steel industries’, Resour Conserv Recycl,
vol. 50, no. 1, pp. 40–57, 2007, doi: 10.1016/j.
resconrec.2006.05.008.
[12] S. S. Rath, D. S. Rao, S. K. Tripathy, and S. K.
Biswal, ‘Characterization vis-á-vis utilization of blast
furnace flue dust in the roast reduction of banded
iron ore’, Process Safety and Environmental Protection,
vol. 117, pp. 232–244, 2018, doi: 10.1016/j.
psep.2018.05.007.
[13] D. Xiong, L. Lu, and R. J. Holmes, ‘Developments
in the physical separation of iron ore: Magnetic
separation’, Iron Ore: Mineralogy, Processing and
Environmental Sustainability, pp. 283–307, 2015,
doi: 10.1016/B978-1-78242-156-6.00009-5.
[14] S. K. Tripathy, P. K. Banerjee, N. Suresh, Y. R.
Murthy, and V. Singh, ‘Dry High-Intensity Magnetic
Separation In Mineral Industry—A Review Of Present
Status And Future Prospects’, Mineral Processing and
Extractive Metallurgy Review, vol. 38, no. 6, pp. 339–
365, 2017, doi: 10.1080/08827508.2017.1323743.
[15] M. Dworzanowski, ‘Maximizing the recovery of fine
iron ore using magnetic separation’, J South Afr Inst
Min Metall, vol. 112, no. 3, pp. 197–202, 2012.
[16] Y. Shao, T. J. Veasey, and N. A. Rowson, ‘Wet high
intensity magnetic separation of iron minerals’,
Magnetic and Electrical Separation, vol. 8, no. 1,
pp. 41–51, 1996, doi: 10.1155/1996/34321.
[17] D. N. Shibaeva, A. A. Kompanchenko, and S. V.
Tereschenko, ‘Analysis of the effect of dry magnetic
separation on the process of ferruginous quartzites
disintegration’, Minerals, vol. 11, no. 8, pp. 1–15,
2021, doi: 10.3390/min11080797.

Previous Page Next Page

Extracted Text (may have errors)

1956 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
REFERENCES
[1] J. Pal, ‘Innovative Development on Agglomeration
of Iron Ore Fines and Iron Oxide Wastes’,
Mineral Processing and Extractive Metallurgy
Review, vol. 40, no. 4, pp. 248–264, 2019, doi:
10.1080/08827508.2018.1518222.
[2] N. A. El-Hussiny and M. E. H. Shalabi, ‘A self-
reduced intermediate product from iron and steel
plants waste materials using a briquetting process’,
Powder Technol, vol. 205, no. 1–3, pp. 217–223,
2011, doi: 10.1016/j.powtec.2010.09.017.
[3] J. Xu, N. Wang, M. Chen, and H. Yu, ‘Recycling
of Blast Furnace Flue Dust with In-flight
Reduction Technology: Reduction Behavior
and Kinetic Analysis’, in Minerals, Metals and
Materials Series, Springer, 2020, pp. 365–376. doi:
10.1007/978-3-030-36830-2_35.
[4] A. Yehia and F. H. El-Rahiem, ‘Recovery and utili-
zation of iron and carbon values from blast furnace
flue dust’, Transactions of the Institutions of Mining
and Metallurgy, Section C: Mineral Processing and
Extractive Metallurgy, vol. 114, no. 4, pp. 184–189,
2005, doi: 10.1179/037195505X28519.
[5] B. Das, S. Prakash, P. S. R. Reddy, S. K. Biswal, B.
K. Mohapatra, and V. N. Misra, ‘Effective utiliza-
tion of blast furnace flue dust of integrated steel
plants’, The European Journal of Mineral Processinf and
Environmental Protection, vol. 2, no. 2, pp. 61–68,
2002, [Online]. Available: http://www.ejmpep.com
/das_et al.pdf.
[6] V. Ri et al., ‘) ORWDWLRQ FKDUDFWHU-
LVWLFV RI KLJK DVK R [LGLVHG, QGLDQ’,
pp. 1–10.
[7] X. Gui, Y. Xing, T. Wang, Y. Cao, Z. Miao, and M. Xu,
‘Intensification mechanism of oxidized coal flotation
by using oxygen-containing collector α-furanacrylic
acid’, Powder Technol, vol. 305, pp. 109–116, 2017,
doi: 10.1016/j.powtec.2016.09.058.
[8] M. S. Jena, S. K. Biswal, and M. V. Rudramuniyappa,
‘Study on flotation characteristics of oxidised Indian
high ash sub-bituminous coal’, Int J Miner Process,
vol. 87, no. 1–2, pp. 42–50, 2008, doi: 10.1016/j.
minpro.2008.01.004.
[9] W. Xia, J. Yang, and C. Liang, ‘A short review of
improvement in flotation of low rank/oxidized coals
by pretreatments’, Powder Technol, vol. 237, pp. 1–8,
2013, doi: 10.1016/j.powtec.2013.01.017.
[10] J. Wang, Y. He, Y. Yang, W. Xie, and X. Ling, ‘Research
on quantifying the hydrophilicity of leached coals
by FTIR spectroscopy’, Physicochemical Problems of
Mineral Processing, vol. 53, no. 1, pp. 227–239, 2017,
doi: 10.5277/ppmp170119.
[11] B. Das, S. Prakash, P. S. R. Reddy, and V. N.
Misra, ‘An overview of utilization of slag and
sludge from steel industries’, Resour Conserv Recycl,
vol. 50, no. 1, pp. 40–57, 2007, doi: 10.1016/j.
resconrec.2006.05.008.
[12] S. S. Rath, D. S. Rao, S. K. Tripathy, and S. K.
Biswal, ‘Characterization vis-á-vis utilization of blast
furnace flue dust in the roast reduction of banded
iron ore’, Process Safety and Environmental Protection,
vol. 117, pp. 232–244, 2018, doi: 10.1016/j.
psep.2018.05.007.
[13] D. Xiong, L. Lu, and R. J. Holmes, ‘Developments
in the physical separation of iron ore: Magnetic
separation’, Iron Ore: Mineralogy, Processing and
Environmental Sustainability, pp. 283–307, 2015,
doi: 10.1016/B978-1-78242-156-6.00009-5.
[14] S. K. Tripathy, P. K. Banerjee, N. Suresh, Y. R.
Murthy, and V. Singh, ‘Dry High-Intensity Magnetic
Separation In Mineral Industry—A Review Of Present
Status And Future Prospects’, Mineral Processing and
Extractive Metallurgy Review, vol. 38, no. 6, pp. 339–
365, 2017, doi: 10.1080/08827508.2017.1323743.
[15] M. Dworzanowski, ‘Maximizing the recovery of fine
iron ore using magnetic separation’, J South Afr Inst
Min Metall, vol. 112, no. 3, pp. 197–202, 2012.
[16] Y. Shao, T. J. Veasey, and N. A. Rowson, ‘Wet high
intensity magnetic separation of iron minerals’,
Magnetic and Electrical Separation, vol. 8, no. 1,
pp. 41–51, 1996, doi: 10.1155/1996/34321.
[17] D. N. Shibaeva, A. A. Kompanchenko, and S. V.
Tereschenko, ‘Analysis of the effect of dry magnetic
separation on the process of ferruginous quartzites
disintegration’, Minerals, vol. 11, no. 8, pp. 1–15,
2021, doi: 10.3390/min11080797.

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1957
Enhancing Ultrafine Iron Ore Particle Recovery with
Extended Height Magnetic Matrices
Fernanda Hoffmann, José Ribeiro
Gaustec Magnetismo
Claudio Ribeiro
Gaustec America LLC
ABSTRACT: This study focuses on enhancing the recovery of ultrafine iron ore particles, typically measuring
below 45µm, to mitigate their disposal in tailings dams. Efficient recovery of these small particles necessitates
extended exposure to a magnetic field. Experimental trials were conducted using matrices of different heights,
ranging from 220 mm to 880 mm. Findings highlight that a matrix height of 440 mm offers the most cost-
effective solution, yielding 2.5 times increase in mass recovery while improving the concentrate grades, when
compared to the standard 220 mm matrices. Notably, these matrices can be seamlessly retrofitted into existing
magnetic separators with minimal modifications.
INTRODUCTION
Ultrafine particles, smaller than 45µm, have been a chal-
lenge in the mineral processing sector for several decades.
Particularly in iron mining, these particles are removed
from the beneficiation circuit and deposited directly into
tailings dams along with the ore processing rejects because
existing concentration methods are inefficient for these par-
ticle sizes (Gonçalves 2023). In other words, these particles
do not undergo any concentration stage, even though they
may contain recoverable iron content.
However, this method of discarding ultrafine particles
has been under review for some years. Due to the challenges
of environmental licensing, companies have been striving
to minimize the amount of material dumped into tailings
dams. Consequently, mining companies have increasingly
sought innovations with the aim of reducing waste genera-
tion (Silva et al., 2023).
Ultrafine particles are typically generated in the grind-
ing stage, as it is necessary at this stage to reduce the ore to
very fine granulometries to achieve the necessary liberation
degree between iron ore and quartz (silica) (Figueira, Luz
and Almeida 2010), enabling iron concentration.
It is important to highlight that these ultrafine parti-
cles, currently discarded because they are not fully recover-
able by current methods, typically have granulometry and
liberation degree suitable for pellet feed production, below
0.150mm (PUC-RJ). Concentrating these particles repre-
sents a significant opportunity to improve the utilization of
mineral resources in a project.
One of the most traditional methods for recover-
ing iron ore is high-intensity magnetic separation. In this
methodology, the exposure time of particles to the mag-
netic field directly influences their recovery, especially for
very fine granulometries.
Therefore, one feasible proposal to increase the recov-
ery of these materials is to extend the exposure time of par-
ticles by increasing the height of the magnetic matrices, the
element where magnetic concentration occurs.

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Extracted Text (may have errors)

1957
Enhancing Ultrafine Iron Ore Particle Recovery with
Extended Height Magnetic Matrices
Fernanda Hoffmann, José Ribeiro
Gaustec Magnetismo
Claudio Ribeiro
Gaustec America LLC
ABSTRACT: This study focuses on enhancing the recovery of ultrafine iron ore particles, typically measuring
below 45µm, to mitigate their disposal in tailings dams. Efficient recovery of these small particles necessitates
extended exposure to a magnetic field. Experimental trials were conducted using matrices of different heights,
ranging from 220 mm to 880 mm. Findings highlight that a matrix height of 440 mm offers the most cost-
effective solution, yielding 2.5 times increase in mass recovery while improving the concentrate grades, when
compared to the standard 220 mm matrices. Notably, these matrices can be seamlessly retrofitted into existing
magnetic separators with minimal modifications.
INTRODUCTION
Ultrafine particles, smaller than 45µm, have been a chal-
lenge in the mineral processing sector for several decades.
Particularly in iron mining, these particles are removed
from the beneficiation circuit and deposited directly into
tailings dams along with the ore processing rejects because
existing concentration methods are inefficient for these par-
ticle sizes (Gonçalves 2023). In other words, these particles
do not undergo any concentration stage, even though they
may contain recoverable iron content.
However, this method of discarding ultrafine particles
has been under review for some years. Due to the challenges
of environmental licensing, companies have been striving
to minimize the amount of material dumped into tailings
dams. Consequently, mining companies have increasingly
sought innovations with the aim of reducing waste genera-
tion (Silva et al., 2023).
Ultrafine particles are typically generated in the grind-
ing stage, as it is necessary at this stage to reduce the ore to
very fine granulometries to achieve the necessary liberation
degree between iron ore and quartz (silica) (Figueira, Luz
and Almeida 2010), enabling iron concentration.
It is important to highlight that these ultrafine parti-
cles, currently discarded because they are not fully recover-
able by current methods, typically have granulometry and
liberation degree suitable for pellet feed production, below
0.150mm (PUC-RJ). Concentrating these particles repre-
sents a significant opportunity to improve the utilization of
mineral resources in a project.
One of the most traditional methods for recover-
ing iron ore is high-intensity magnetic separation. In this
methodology, the exposure time of particles to the mag-
netic field directly influences their recovery, especially for
very fine granulometries.
Therefore, one feasible proposal to increase the recov-
ery of these materials is to extend the exposure time of par-
ticles by increasing the height of the magnetic matrices, the
element where magnetic concentration occurs.

XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 1955
composition. The sample contains 33.64% iron
and 16.84% carbon by weight. Additionally, it has
a significant presence of gangue impurities, with
silica and alumina combined constituting around
20% of the sample.
2. Physical beneficiation techniques have been
employed to treat the blast furnace flue dust, focus-
ing on achieving particle liberation. This involves
processes to separate and enhance the concentra-
tion of valuable minerals in the sample.
3. Through experimentation, it has been determined
that a particle size of –25 microns is the most suit-
able for efficiently separating iron and carbon min-
erals. This size range enhances the effectiveness of
the beneficiation process.
4. Non-liberated particles in the coarser fraction
result in the loss of carbonaceous material during
froth flotation and ferruginous material during
magnetic separation.
5. By optimising various parameters, the study
achieved appreciable recovery rates. Specifically,
carbon recovery reached 77.6%, with a carbon
content of 52.0%, while iron recovery reached
86.6%, with iron content at 45.0% Fe(T).
6. The carbonaceous component generated during
the froth flotation study is identified as a valuable
material. It is suggested that this material can be
effectively utilised as a reductant in relevant indus-
trial processes.
7. The magnetic products obtained from the ben-
eficiation process are identified as potential feed-
stock. These can be employed in cold bonded
pelletization or composite pelletization processes,
indicating their suitability for further downstream
applications.
8. The microstructural investigations reveal the par-
ticle liberation behaviour and association of miner-
als with locked and unlocked particles.
9. The study advises against further reduction in par-
ticle size through grinding. This caution is based on
the understanding that a finer size could adversely
affect the agglomeration process of the material.
Maintaining a certain particle size is crucial for
ensuring the optimal performance of subsequent
processes.
Figure 21. Stereo microscopic images (a): (–75 +63 micron) (b): (–63 +45 micron) (c): (–45 +38 micron) (d): (–38 +25
micron) (e): (-25 micron)

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Extracted Text (may have errors)

XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 1955
composition. The sample contains 33.64% iron
and 16.84% carbon by weight. Additionally, it has
a significant presence of gangue impurities, with
silica and alumina combined constituting around
20% of the sample.
2. Physical beneficiation techniques have been
employed to treat the blast furnace flue dust, focus-
ing on achieving particle liberation. This involves
processes to separate and enhance the concentra-
tion of valuable minerals in the sample.
3. Through experimentation, it has been determined
that a particle size of –25 microns is the most suit-
able for efficiently separating iron and carbon min-
erals. This size range enhances the effectiveness of
the beneficiation process.
4. Non-liberated particles in the coarser fraction
result in the loss of carbonaceous material during
froth flotation and ferruginous material during
magnetic separation.
5. By optimising various parameters, the study
achieved appreciable recovery rates. Specifically,
carbon recovery reached 77.6%, with a carbon
content of 52.0%, while iron recovery reached
86.6%, with iron content at 45.0% Fe(T).
6. The carbonaceous component generated during
the froth flotation study is identified as a valuable
material. It is suggested that this material can be
effectively utilised as a reductant in relevant indus-
trial processes.
7. The magnetic products obtained from the ben-
eficiation process are identified as potential feed-
stock. These can be employed in cold bonded
pelletization or composite pelletization processes,
indicating their suitability for further downstream
applications.
8. The microstructural investigations reveal the par-
ticle liberation behaviour and association of miner-
als with locked and unlocked particles.
9. The study advises against further reduction in par-
ticle size through grinding. This caution is based on
the understanding that a finer size could adversely
affect the agglomeration process of the material.
Maintaining a certain particle size is crucial for
ensuring the optimal performance of subsequent
processes.
Figure 21. Stereo microscopic images (a): (–75 +63 micron) (b): (–63 +45 micron) (c): (–45 +38 micron) (d): (–38 +25
micron) (e): (-25 micron)