Aeration induced moisture reduction of iron ore

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1 Paper Number: 8 Aeration induced moisture reduction of iron ore S Caldwell, K Williams 2, J Guo 3 and W Chen 4 Masters Candidate, TUNRA Bulk Solids Research, Newcastle Institute for Energy and Resources, The General Manager - Research, TUNRA Bulk Solids Research, Newcastle Institute for Energy and Resources, The Research Engineer, TUNRA Bulk Solids Research, Newcastle Institute for Energy and Resources, The 4. Research Engineer, TUNRA Bulk Solids Research, Newcastle Institute for Energy and Resources, The Mineral and ore mining is increasingly occurring near or below the water table. This has led to a higher rate of handling problems associated with increased moisture and increased adhesion which lead to higher rate of blockage events within the materials handling chain. Typically these ores and minerals and known as Wet and Sticky Materials. Currently there is very limited knowledge and/or methodologies that allow for the design of efficient materials handling systems when it comes to handling these wet and sticky materials. However, there is one major parameter which significantly affects handleability of a wet and sticky ore, namely its moisture content. Flow property testing has shown that when moisture is reduced, the adhesive properties of the ore are also significantly reduced, thereby increasing ore flowability. The research embodied in this paper investigated the moisture reduction change and rate through a loose packed bed of iron ore using dry, low heat airflows of varying temperature. The test system varied the temperature from 30 o C to 80 o C using a cylindrical packed-bed aeration rig. A correlation between energy use, adhesion reduction and flowability with respect to moisture change within the ore body was investigated. From this research, identification of improved moisture reduction approaches is envisaged.

2 Paper Number: 09 Recent development and application of SLon VPHGMS magnetic separators in iron ore and ilmenite processing industry X Dahe SLon Magnetic Separator Ltd, Shahe Industrial Park, Jiangxi Province, China SLon vertical ring and pulsating high gradient magnetic separators possess the advantages of high efficiency and high reliability in beneficiating fine weakly magnetic minerals. In recent years, the models of SLon-2250, SLon-2500, SLon-3000 SLon-3500 and SLon-4000 have been developed. SLon-2250 applied in Yuan Jia Cun Iron Ore Processing Plant: The plant annually treats 22 million tons of oxidized iron ore with a high intensity magnetic separation and reverse flotation flowsheet. n 204, 6 units of SLon-2250 magnetic separators were applied and iron recovery raised 67 %. SLon-2500 applied in Hai Nan Iron Mine: In 203, the mine built a iron ore processing line which annually treats 2 million tons of refractory oxidized iron ore with a high intensity magnetic separation and centrifugal separation flowsheet. SLon-2500 magnetic separators were applied. The results of the flowsheet are: Feed grade 39.5%Fe, Iron concentrate grade 620%Fe, iron recovery 626%. SLon-3000 applied in Tai He Iron Mine to recover ilmenite: The mine annually treats 7 million tons of iron ore. The ore contains magnetite and ilmenite. The flowsheet first recovers magnetite as iron concentrate, and then 7 units of SLon-3000 magnetic separators are applied to recover ilmenite. The ilmenite processing line annually produces 0.45 million tons of high quality ilmenite concentrate (47.5%TiO2). SLon-4000 applied in Pan Zhi Hua Iron and Steel Company to recover ilmenite: The ore contains magnetite and ilmenite. The iron ore processing plant of the company annually treats million tons of iron ore and gets 5 million tons of iron concentrate and 0.5 million tons ilmenite concentrate. However, the abandoned 7 million tons of tails still contains about 6.5%TiO In 202, 2 units of SLon-4000 magnetic separators were applied to recover ilmenite from the abandoned tails. The added flowsheet annually recovers 0.8 million tons of high quality ilmenite concentrate (47.0%TiO2). Keywords SLon magnetic separator, oxidized iron ore, magnetite, ilmenite.

3 Paper Number: 70 The autonomous rail conveyor (ARC) significantly reduces ore haulage costs T Graham Director, MinSep (Pty) Ltd, Mount Claremont, WA 600 The invention of the traditional belt and idler conveyor system is attributed to Thomas Robins in 89 This basic concept, ubiquitous on most mining operations, has not changed markedly in 25 years, and still suffers from five forms of energy losses. Firstly, indentation rolling losses, a consequence of the indentation a roller inflicts on the belt, consume 60% of all energy. Secondly, bulk solid flexure resistance, resulting from material interaction and movement, absorbs 20%. The remaining energy is lost by idler rotating resistance (5%), belt flexure resistance (5%) and secondary resistances (0%). Traditional conveyor systems are continuous as opposed to batch systems, implying both positive and negative features: On one hand the systems have high availability (they are available if they are running), but, on the other hand, the utilisation of availability is often low, for example when a conveyor is running empty, which reduces the system OEE (Overall Effective Efficiency). Many attempts have been made to mitigate both energy losses and low OEE issues, including many rail based systems. The key drawbacks are higher capital cost, lower flexibility and lower availability. A recent conceptual development known as the Autonomous Rail Conveyor (ARC) promises to address both the issues of energy loss and poor availability, and provide increased flexibility by being relocatable. The ARC uses a series of carriages running on relocatable light rail. Each carriage has two wheels driven by an integrated variable speed geared motor and brake system, and is connected to the next carriage by a hitch system. Power is provided by a generator (located in a dedicated carriage) and interconnected daisy chain plug in cables. Centralised redundant control is provided at a preferred point. Although the system is batch in nature, the number of carriages and trains is flexible, meaning that the system is effectively continuous.

4 Paper Number: 03 Real time slurry elemental analyser for iron ore beneficiation plant control A Stabile, G Noble 2 and E Portes 3 Product Manager Thermo Fisher Scientific Lead PGNAA Calibration Physicist / Research Physicist - Thermo Fisher Scientific Project Manager - Thermo Fisher Scientific Iron Ore beneficiation plants are facing economic pressures to treat more challenging ore types, improve efficiency, and improve product quality. Better control and stability of the plant process in the face of increasing feed ore variability has been a goal for many of the operations facing these challenges. Prompt Gamma Neutron Activation Analysis (PGNAA) technology has proven to be a successful measurement technique within an Iron ore beneficiation plant. PGNAA was first developed in the early 980 s for the measurement of the elemental composition of bulk materials. Today, PGNAA technology is applied for elemental analysis within the iron ore industry on both bulk materials and slurries. Traditional composite sampling throughout the wet iron ore beneficiation process provides a delayed measurement of average properties but does not capture the true variability of the process in real-time. As such this is a limiting factor towards stabilisation and optimization of the process. A PGNAA analyser provides real-time slurry elemental analysis of Feed, Concentrate and Tails streams within the processing plant. The analytical data from the analyser can be exploited with a control strategy to correct and stabilize the plant on a much shorter time scale, delivering significant economic benefits and greater operational flexibility. The economic benefits include more stable product quality and a reduction in composite sampling and laboratory costs. Some example results will be presented from the Vale Vargem Grande iron ore beneficiation plants, which are utilising a six stream multiplexed Thermo Scientific PGNAA Slurry Analyser.

5 Paper Number: 45 Chutes to thrill! T Tan, R Ruiz 2 and G Wellwood 3 Senior Engineer, Jenike & Johanson, Belmont, WA 604 Australia Project Engineer, Jenike & Johanson, BRASIL General Manager, Jenike & Johanson, Belmont, WA 604 Australia The productivity of most iron ore operations is largely dictated by the performance of their materials handling systems. Within these systems lives the humble transfer chute used to change the elevation and/or direction of the flowing bulk material. They have no moving parts and can appear trite in the context of the mechanical complexity that surround them, however the physics involved is quite complex. Unlike the transfer chutes themselves, the performance demands on them are not static. To improve productivity and reduce unit costs, mine operators are continually striving to increase throughput. Add to this the changing physical properties of the ore over the life of the mine and it is not hard to understand why transfer chutes are often the bottleneck. The situation has changed dramatically over recent years with the emergence of more wet and sticky ore (WSO); a trend that is set to continue. Incremental methods to accommodate these increased demands are nearly exhausted so how can transfer chute performance be improved within the financial and physical constraints of existing operations? It s time to step back and see where science can be used to advantage and this paper outlines development of SMART chutes; the next generation of design capable of accommodating future performance demands. While the physics of transfer chute performance is complex, adhesion is the dominant phenomenon. The application of bulk solids science has identified options to deal with adhesion and using a Lean Start-Up approach, a number of minimum viable products have been devised to test the associated leap of faith assumptions. This exercise has revealed a number of viable options for increasing the operating window of transfer chutes within the constraints and details together with the proposed pathway to accelerated commercial implementation are presented.

Resource Efficient Mining Processes of Tomorrow

Metso Process Technology & Innovation (PTI) Resource Efficient Mining Processes of Tomorrow R&D Project Authors: K Duffy W Valery A Jankovic P Holtham www.metso.com General PTI presentation 2014 2015 A