XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 2673
it is vital to also acknowledge how they impact each other.
Actions taken in grinding or deslime can have huge impacts
on the flotation or filtration processes, some of which are
improvements, some of which can be managed, and some
of which are complete dealbreakers for otherwise good
optimization efforts.
Three case studies are presented in which phenomena
common to the entire process both hindered and advanced
optimization efforts in the plant. The sensitivity of the sur-
face chemistry of iron ore processing means that the addi-
tion of surface-active reagents like dispersants in one stage
has considerable impact on everything downstream.
The addition of grinding aids killed the froth flotation
during the plant trial, and as a result grinding aids were not
used at any iron ore processing plant in the United States
or around the world. Work is finally beginning to be under-
taken to overcome this issue.
At the same time, the goals of each step sometimes
align in surprisingly helpful ways, such as when an attempt
to improve pelletization performance by attempting to
remove calcium and magnesium with CO2 resulted in con-
siderable improvements in filtering performance instead.
This appears again when introducing dispersants to the
pelletization process improved pellet strength and reduced
pellet dustiness.
There are only so many opportunities available in each
individual section. In the modern plant, it is no longer suf-
ficient to consider these sections individually. It is vital to
look at how each section affects the whole process.
REFERENCES
Anameric, B., and Kawatra, S.K., 2006. Laboratory study
related to the production and properties of pig iron
nuggets, Mining, Metallurgy &Exploration, 23:52–56.
Anameric, B., Rundman, K.B., and Kawatra, S.K., 2006.
Carburization effects on pig iron nugget making,
Mining, Metallurgy &Exploration, 23:139–150.
Archambo, M., and Kawatra, S.K., 2021. Red mud:
Fundamentals and new avenues for utilization,
Mineral Processing and Extractive Metallurgy Review,
42(7):427–450.
Carlson, J.J. and Kawatra, S.K., 2011. Effects of CO2 on
the zeta potential of hematite. International Journal of
Mineral Processing, 98(1–2):8–14.
Carlson, J.J., and Kawatra, S.K., 2013. Factors Affecting
Zeta Potential of Iron Oxides, Mineral Processing and
Extractive Metallurgy Review, 34(5):269–303.
Chipakwe, V., Semsari, P., Karlkvist, T., Rosenkranz, J., and
Chelgani, S.C., 2020. A critical review on the mecha-
nisms of chemical additives used in grinding and their
effects on the downstream processes. J. Mater. Res.
Technol. 9:8148–8162.
Chipakwe, V., Karlkvist, T., Rosenkranz, J., and Chelgani,
S.C., 2022. Beneficial effects of a polysaccharide-based
grinding aid on magnetite flotation: a green approach.
Scientific Reports, 12:6502.
Chipakwe, V., Karlkvist, T., Rosenkranz, J., and Chelgani,
S.C., 2023. Exploring the effect of a polyacrylic acid-
based grinding aid on magnetite-quartz flotation
separation. Separation and Purification Technology,
305:122530.
Copeland, C.R., Eisele, T.C., and Kawatra, S.K., 2009.
Suppression of airborne particulates in iron ore pro-
cessing facilities. International Journal of Mineral
Processing, 93(3–4):232–238.
Da Cruz, D.G., Gonçalves, P.S.M., Lelis, D.F., and Lima,
R.M.F., 2021. Effect of Ca2+ and Mg2+ ions on the
reverse cationic flotation of itabiritic iron ore. HOLOS,
37(3):1–11.
De Moraes, S.L., de Lima, J.R.B., and Neto, J.B.F., 2013.
Influence of dispersants on the rheological and colloi-
dal properties of iron ore ultrafine particles and their
effect on the pelletizing process – A review. Journal of
Materials Research and Technology, 2(4):386–391.
Eisele, T.C., Kawatra, S.K., and Ripke, S.J., 2005. Water
chemistry effects in iron ore concentrate agglomera-
tion feed, Mineral Processing and Extractive Metallurgy
Review, 26(3–4):295–305.
Green, R.E., and Colombo, A.F., 1984. Dispersion-selective
flocculation-desliming characteristics of oxidized taco-
nites, US Department of the Interior, Bureau of Mines,
8867.
Haselhuhn, H.J., Swanson, K.P., and Kawatra, S.K.,
2012a. The effects of CO2 sparging on the floccula-
tion and filtration rate of concentrated hematite
slurries. International Journal of Mineral Processing,
112:107–109.
Haselhuhn, H.J., Carlson, J.J., and Kawatra, S.K., 2012b.
Water chemistry analysis of an industrial selective floc-
culation dispersion hematite ore concentrator plant.
International Journal of Mineral Processing, 102:99–106.
Haselhuhn, H.J. and Kawatra, S.K., 2015. Role of water
chemistry in the selective flocculation and disper-
sion of iron ore. Minerals &Metallurgical Processing,
32(2):69–77.
it is vital to also acknowledge how they impact each other.
Actions taken in grinding or deslime can have huge impacts
on the flotation or filtration processes, some of which are
improvements, some of which can be managed, and some
of which are complete dealbreakers for otherwise good
optimization efforts.
Three case studies are presented in which phenomena
common to the entire process both hindered and advanced
optimization efforts in the plant. The sensitivity of the sur-
face chemistry of iron ore processing means that the addi-
tion of surface-active reagents like dispersants in one stage
has considerable impact on everything downstream.
The addition of grinding aids killed the froth flotation
during the plant trial, and as a result grinding aids were not
used at any iron ore processing plant in the United States
or around the world. Work is finally beginning to be under-
taken to overcome this issue.
At the same time, the goals of each step sometimes
align in surprisingly helpful ways, such as when an attempt
to improve pelletization performance by attempting to
remove calcium and magnesium with CO2 resulted in con-
siderable improvements in filtering performance instead.
This appears again when introducing dispersants to the
pelletization process improved pellet strength and reduced
pellet dustiness.
There are only so many opportunities available in each
individual section. In the modern plant, it is no longer suf-
ficient to consider these sections individually. It is vital to
look at how each section affects the whole process.
REFERENCES
Anameric, B., and Kawatra, S.K., 2006. Laboratory study
related to the production and properties of pig iron
nuggets, Mining, Metallurgy &Exploration, 23:52–56.
Anameric, B., Rundman, K.B., and Kawatra, S.K., 2006.
Carburization effects on pig iron nugget making,
Mining, Metallurgy &Exploration, 23:139–150.
Archambo, M., and Kawatra, S.K., 2021. Red mud:
Fundamentals and new avenues for utilization,
Mineral Processing and Extractive Metallurgy Review,
42(7):427–450.
Carlson, J.J. and Kawatra, S.K., 2011. Effects of CO2 on
the zeta potential of hematite. International Journal of
Mineral Processing, 98(1–2):8–14.
Carlson, J.J., and Kawatra, S.K., 2013. Factors Affecting
Zeta Potential of Iron Oxides, Mineral Processing and
Extractive Metallurgy Review, 34(5):269–303.
Chipakwe, V., Semsari, P., Karlkvist, T., Rosenkranz, J., and
Chelgani, S.C., 2020. A critical review on the mecha-
nisms of chemical additives used in grinding and their
effects on the downstream processes. J. Mater. Res.
Technol. 9:8148–8162.
Chipakwe, V., Karlkvist, T., Rosenkranz, J., and Chelgani,
S.C., 2022. Beneficial effects of a polysaccharide-based
grinding aid on magnetite flotation: a green approach.
Scientific Reports, 12:6502.
Chipakwe, V., Karlkvist, T., Rosenkranz, J., and Chelgani,
S.C., 2023. Exploring the effect of a polyacrylic acid-
based grinding aid on magnetite-quartz flotation
separation. Separation and Purification Technology,
305:122530.
Copeland, C.R., Eisele, T.C., and Kawatra, S.K., 2009.
Suppression of airborne particulates in iron ore pro-
cessing facilities. International Journal of Mineral
Processing, 93(3–4):232–238.
Da Cruz, D.G., Gonçalves, P.S.M., Lelis, D.F., and Lima,
R.M.F., 2021. Effect of Ca2+ and Mg2+ ions on the
reverse cationic flotation of itabiritic iron ore. HOLOS,
37(3):1–11.
De Moraes, S.L., de Lima, J.R.B., and Neto, J.B.F., 2013.
Influence of dispersants on the rheological and colloi-
dal properties of iron ore ultrafine particles and their
effect on the pelletizing process – A review. Journal of
Materials Research and Technology, 2(4):386–391.
Eisele, T.C., Kawatra, S.K., and Ripke, S.J., 2005. Water
chemistry effects in iron ore concentrate agglomera-
tion feed, Mineral Processing and Extractive Metallurgy
Review, 26(3–4):295–305.
Green, R.E., and Colombo, A.F., 1984. Dispersion-selective
flocculation-desliming characteristics of oxidized taco-
nites, US Department of the Interior, Bureau of Mines,
8867.
Haselhuhn, H.J., Swanson, K.P., and Kawatra, S.K.,
2012a. The effects of CO2 sparging on the floccula-
tion and filtration rate of concentrated hematite
slurries. International Journal of Mineral Processing,
112:107–109.
Haselhuhn, H.J., Carlson, J.J., and Kawatra, S.K., 2012b.
Water chemistry analysis of an industrial selective floc-
culation dispersion hematite ore concentrator plant.
International Journal of Mineral Processing, 102:99–106.
Haselhuhn, H.J. and Kawatra, S.K., 2015. Role of water
chemistry in the selective flocculation and disper-
sion of iron ore. Minerals &Metallurgical Processing,
32(2):69–77.