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Iron ore is the fourth most common element in the earth’s crust. Iron is essential to steel manufacturing and, por lo tanto, an essential material for global economic development. Hierro es también ampliamente utilizado en la construcción y la fabricación de vehículos. Most iron ore resources are composed of metamorphosed banded iron formations (BIF), en el que el hierro se encuentra comúnmente en forma de óxidos, hydroxides, y, to a lesser extent, carbonates.
The chemical composition of iron ores is apparent to be wide, especially for Fe content and associated gangue minerals. Major iron minerals associated with most iron ores are hematite, Goethita, limonite, and magnetite. Los principales contaminantes en minerales de hierro son SiO2 y Al2O3. The typical silica and alumina-bearing minerals present in iron ores are quartz, caolinita, gibbsita, Diaspore, y corindón. De estos, it is often observed that quartz is the main silica-bearing mineral, and kaolinite and gibbsite are the two main alumina-bearing minerals.
La extracción de mineral de hierro se realiza principalmente a cielo abierto Operaciones mineras, resultando en la generación de relaves significativos. El sistema de producción de mineral de hierro generalmente implica tres etapas: Minería, procesamiento de, and pelletizing activities. Processing ensures that an adequate iron grade and chemistry are achieved prior to the pelletizing stage. El procesamiento incluye el triturado, Clasificación, molienda, and concentration, with the aim of increasing the iron content while reducing the amount of gangue minerals. Each mineral deposit has its own unique characteristics with respect to iron and gangue-bearing minerals, and therefore, it requires a different concentration technique.
Magnetic separation is typically used in high-grade iron ore beneficiation, where the dominant iron minerals are ferro and paramagnetic. Separación magnética húmeda y seca de baja intensidad (Lims) techniques are used to process ores with strong magnetic properties, such as magnetite, while wet high-intensity magnetic separation is used to separate the Fe-bearing minerals with weak magnetic properties, such as hematite, from gangue minerals. Iron ores such as goethite and limonite are commonly found in tailings and do not separate very well by either technique.
La flotación se utiliza para reducir el contenido de impurezas en minerales de hierro de bajo grado. Los minerales de hierro pueden concentrarse ya sea mediante la flotación aniónica directa de óxidos de hierro o la flotación catiónica inversa de sílice; sin embargo, reverse cationic flotation remains the most popular flotation route used in the iron industry. The use of flotation is limited by the cost of reagents, the presence of silica and alumina-rich slimes, and the presence of carbonate minerals. Además, flotation requires wastewater treatment and the use of downstream dewatering for dry final applications.
The use of flotation for the concentration of iron also involves desliming, as floating in the presence of fines results in decreased efficiency and high reagent costs. La desafiación es particularmente crítica para la eliminación de la alúmina, ya que la separación de gibbsite de la hematita o la goethita por cualquier agente activo en la superficie es bastante difícil. Most alumina-bearing minerals occur in the finer size range (<20um), permitiendo su eliminación a través de la desfilación. en general, una alta concentración de multas (<20um) y la alúmina aumenta la dosis de colector catiónico requerida y disminuye la selectividad dramáticamente. Por lo tanto, desliming increases flotation efficiency but results in a large volume of tailings and in loss of iron to the tailings stream.
El procesamiento en seco de mineral de hierro presenta una oportunidad para eliminar costos y generación de relaves húmedos asociados con circuitos de flotación y separación magnética húmeda. STET has evaluated several iron ore tailings and run-of-mine ore samples at bench scale (escala de prefactibilidad). Se observó un movimiento significativo de hierro y silicatos, con ejemplos resaltados en la siguiente tabla.
Los resultados de este estudio demostraron que finos de mineral de hierro de bajo grado pueden actualizarse por medio de separador de correa tribo-electrostático de STET. Basado en la experiencia STET, la recuperación y/o grado del producto mejorará significativamente en el procesamiento a escala piloto, en comparación con el dispositivo de prueba a escala de banco utilizado durante estos ensayos de mineral de hierro.
El STET electrostático en seco Separación fina de mineral de hierro El proceso ofrece muchas ventajas sobre los métodos tradicionales de procesamiento húmedo, como los magnéticos o la flotación, Incluido:
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Referencias:
Iron ore beneficiation involves a series of processes that aim to improve the purity and quality of raw iron ore. These processes include crushing, grinding, separación magnética, flotación, and gravity separation, depending on the mineralogical characteristics of the ore. Each technique is selected based on the ore’s composition and feasibility to extract the maximum amount of iron while minimizing impurities.
Iron ore mining requires specialized equipment to handle the extraction and processing of ore. Common machinery includes ball mills for grinding, crushers for reducing the size of ore, magnetic separators for separating iron particles from impurities, flotation machines for fine particle separation, and conveyors for transport.
Technologies utilized for iron ore beneficiation include advanced techniques such as dry electrostatic separation, flotación, advanced gravity separation, and sensor-based sorting. These technologies aim to efficiently increase the iron content and eliminate contaminants, catering to the growing demand for high-grade iron ore and promoting sustainable mining practices.
The cost of iron ore beneficiation can vary significantly depending on the specific processes and technologies used, the grade of the raw ore, and the desired purity of the final product. It encompasses capital expenditure (GASTOS DE CAPITAL), such as equipment and plant construction, and operational expenditure (OPEX), including labor, energía, y consumibles. It’s essential for companies to evaluate these costs against prospective revenue and market demands to ensure project viability.
