International Journal of Engineering Research

R. Suhasini ¹, Ashish Kumar Mallick ¹, N. Vasumathi ¹, T. V. Vijaya Kumar ¹, S. Subba Rao ¹, S. Prabhakar ¹, G. Bhaskar Raju ¹, S. Shiva Kumar ²

Affiliations
1 CSIR-National Metallurgical Laboratory Madras Centre, CSIR Madras Complex, Taramani, Chennai - 600 113, IN
2 Somu Organo Chem Pvt. Ltd., Bengaluru - 560 076, IN

Abstract

Reverse cationic column flotation technology is gaining traction in iron ore processing industry for recovering iron values from iron ore slimes/tailings. Development and selection of appropriate collector suitable to the material to be processed plays vital role in the development of the process/technology. Three cationic collectors which are vegetable oil based, biodegradable and environmental friendly were tested for their efficacy in reducing alumina and silica and improve iron content in the tailings of an operating iron ore washing plant. Selectivity index as defined by Douglas was used as response parameter to measure the efficiency of separation while comparing the performance of these collectors during flotation tests. Sokem 522C proved to be better in comparison to Sokem 701 and Sokem 702 with the highest selectivity index of 20.87. The concentrate generated analyzed 63.30% Fe, 2.20% SiO₂ and 2.52% Al₂O₃ with 69.00% weight recovery and 79.21% Fe recovery from the tailings containing 55.14% Fe, 17.34%SiO₂ and 4.04% Al₂O₃. The concentrate generated is suitable for pellet making due to its attractive granulometry and acceptable levels of alumina content (≤ 2.50%) in it. The tailings generated in this process could be utilised for cement manufacturing and tiles or pavement blocks making. The process developed is ‘zero waste’ while mitigating the environmental issues related to managing tailings in iron ore processing plants.

Keywords

Iron Ore, Ultra Fines, Cationic Collector, Tailings Pond, Column Flotation.

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T. V. Vijaya Kumar ¹, S. J. Gopalkrishna ²

Affiliations
1 CSIR National Metallurgical Laboratory Madras Centre, CSIR Madras Complex, Taramani, Chennai-600113, IN
2 Department of Mineral Processing, Vijayanagara Sri Krishnadevaraya University Post Graduate Centre, Nandihalli, Sandur-583119, Karnataka, IN

Abstract

Reverse flotation process was optimized by an experimental programme based on statistical analysis for reduction of silica and alumina levels from screw classifier overflow so as to enrich iron values. Flotation of alumina and silica bearing minerals with Sokem 521C and starch as collector and depressant respectively was studied to estimate their optimum levels at different particle sizes. A two-level three factor design of experiments showed that particle size is insignificant in the ranges of study. Tests on an orthogonal design of the hexagonal type were then carried out to determine the effects of the other two variables, on the response, Selectivity Index (SI), a measure of separation efficiency of iron values from alumina and silica. Regression equations were developed as models and response contours were plotted. Maximum response (SI of 2.25) has been optimized at 0.306 kg/t of amine collector, 1.0043 kg/t of starch at a particle size of 40 μm.

Keywords

Reverse Flotation, Iron Ore, Alumina, Silica, Selectivity Index, Statistical Analysis.

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N. Vasumathi ¹, T. V. Vijaya Kumar ¹, S. Subba Rao ¹, S. Prabhakar ¹, G. Bhaskar Raju ¹, S. Shiva Kumar ², Uma Raman ²

Affiliations
1 CSIR-National Metallurgical Laboratory, Madras Centre, CSIR Madras Complex, Taramani, Chennai 600113, IN
2 Somu Organo Chem Pvt. Ltd., Bangalore 560076, IN

Abstract

Conventionally, diesel in combination with a frother is used widely in flotation of coal fines. With the continuous price escalation of petroleum products and their negative impact on environment, attempts are made to formulate an eco-friendly single reagent to replace diesel-frother system without affecting the flotation performance. Laboratory flotation tests are carried out, on a coking coal sample from eastern India, that analyzes 25.67% ash and 53.97% fixed carbon using a series of reagents developed. Among them, the performance of Sokem 590C derived from a vegetable oil was found to be encouraging. Concentrate assaying 11.77% ash and 66.40% fixed carbon was obtained with a yield of 56.57%. Moreover, the reagent is biodegradable and eco friendly. Based on favorable kinetics and encouraging test results, plant trials were conducted at a coal preparation plant and the superiority of this reagent was demonstrated.

Keywords

Coal Flotation, Diesel, Frother, Single Reagent, Biodegradable Collector.

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