What are the processes of iron ore beneficiation?
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The process of iron ore beneficiation involves several steps to enhance its quality and remove impurities. Here are the common processes used for iron ore beneficiation:
1.Crushing and Grinding: The ore is first crushed into smaller pieces by primary crushers. It is then ground to a fine powder in a ball mill or a semi-autogenous grinding (SAG) mill. This step helps in liberating the iron ore from the gangue minerals.
2.Magnetic Separation: Magnetic separators are used to separate the magnetic minerals from the non-magnetic ones. In this process, the finely ground ore is passed over a magnetic drum or high-intensity magnetic separator. The magnetic minerals, such as magnetite, are attracted to the magnetic field and separated from the non-magnetic minerals.
3.Gravity Separation: Gravity separation techniques are used to separate the dense iron ore particles from the lighter gangue minerals. This can be achieved using methods such as dense media separation or jigging. In dense media separation, a suspension of fine magnetite or ferrosilicon is used as a medium to separate the iron ore particles based on their density.
4.Froth Flotation: Froth flotation is a widely used method for the beneficiation of iron ores. In this process, the finely ground ore is mixed with water and a reagent, and air is blown through the mixture. The reagent selectively attaches to the surface of the desired minerals, forming a froth that is skimmed off. This helps in separating the valuable iron minerals from the gangue minerals.
5.Dewatering: After the beneficiation process, the iron ore concentrate is often subjected to dewatering to remove excess water. This is typically done using thickeners or filters to reduce the moisture content of the concentrate.
6.Pelletization: In some cases, the beneficiated iron ore is further processed into pellets. Pelletization involves forming small balls or pellets by agglomerating the iron ore fines with a binder, such as bentonite, and additives. The pellets are then hardened by heating them to high temperatures in a furnace. Pelletization improves the handling and transportation of iron ore, making it suitable for use in blast furnaces.
These are the general processes involved in the beneficiation of iron ore. The specific processes and techniques used can vary depending on the characteristics of the ore and the desired product specifications.