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Gavin Diener, Director, Allied Mineral Laboratories Pty Ltd (AML) delivered this presentation at the 2013 FE Tech Conference. The event focussed on the economics of processing and the beneficiation of iron ore. In light of the slowdown in demand for iron ore and pricing decreases, the need to process more efficiently and cost effectively is a challenge. The conference examined on how we can achieve greater value from the iron ore supply chain, with topics addressing optimisation and streamlining processes, applying improved technologies, understanding the ore body and how to properly characterise it, knowing the steel makers needs. For more information please visit the conference website: http://www.informa.com.au/fe-tech
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ALLIED MINERAL LABORATORIES ALLIED MINERAL LABORATORIES
FINE IRON ORE
BENEFICIATION
GAVIN DIENER
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 2
Content
• Introduction
• Characterisation
– What do you need to know before you start?
• Equipment selection
– Matching the flowsheet with the material
– Optimised flowsheet design
• Testwork program
– Characterisation
– Laboratory scale
– Pilot scale
• Conclusion
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 3
What do you need to know before you start?
• Particle size distribution
• Typically between 45 micron and 1 mm
• Relative distribution of Fe and gangue elements
• Heavy liquid separation
• SG of 2.9-3.3
• Mineralogy / Microscopy
• Liberation
• Mineral assemblage
• Magnetic separation profile
Characterisation
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 4
0%
10%
20%
30%
40%
50%
60%
70%
80%
0% 10% 20% 30% 40% 50% 60% 70%
SiO
2 g
rad
e in
fee
d (
%)
Fe grade in feed (%)
Ore 1
Ore 2
Ore 3
Ore 5
Ore 6
Ore 4
Ore characterisation
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 5
Equipment selection
Center
To Cons To Tails
High SG Low SG
Spirals
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 6
Equipment selection
To Underflow
To Overflow
High SG Low SG
Upcurrent classification
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 7
Equipment selection
High SG Low SG
0
10
20
30
40
50
60
70
80
90
100
10 100 1000
% M
as
s p
as
sin
g
Particle size (micron)
O/F
U/F
Upcurrent classification
To Underflow
To Overflow
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 8
0
10
20
30
40
50
60
70
80
90
100-1
06u
m
+1
06-1
25 u
m
+1
25-1
50 u
m
+1
50-2
12 u
m
+2
12-2
50 u
m
+2
50-3
00 u
m
+3
00 u
m
Pro
po
rtio
n r
ep
ort
ing
to
un
derf
low
Mass
Upcurrent classification
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 9
0
10
20
30
40
50
60
70
80
90
100-1
06u
m
+1
06-1
25 u
m
+1
25-1
50 u
m
+1
50-2
12 u
m
+2
12-2
50 u
m
+2
50-3
00 u
m
+3
00 u
m
Pro
po
rtio
n r
ep
ort
ing
to
un
derf
low
Mass
Fe
SiO2
Upcurrent classification
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 10
Flowsheet design
Underflow
Overflow
Flowsheet options
• Spirals only
• Classifier only
• Classifier with underflow spirals
• Classifier with overflow spirals
• Classifier with both sets of spirals
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 11
Equipment selection
To Underflow
To Overflow
Center
To Cons To Tails
Center
To Cons To Tails
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 12
0%
10%
20%
30%
40%
50%
60%
70%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Cu
mu
lati
ve
Fe g
rad
e (
%)
Cumulative yield to concentrate (%)
U/F 1
O/F 1
Spiral results
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 13
0%
10%
20%
30%
40%
50%
60%
70%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Cu
mu
lati
ve
Fe g
rad
e (
%)
Cumulative yield to concentrate (%)
U/F 1
O/F 1
O/F 2
Spiral results
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 14
Testwork programs
Characterisation
Particle size distribution
Mineralogy
Heavy liquid separation
Sample sizes < 1 kg
Laboratory scale testwork
Laboratory gravity
separation
Air tables and wet tables
Sample sizes
5 to 20 kg
Pilot scale testwork
Pilot scale classification
Plant scale spiral
separators
Sample sizes
> 100 kg
NOVEMBER 2013 FE TECH 2013 - FINE IRON ORE BENEFICIATION
GAVIN DIENER ALLIED MINERAL LABORATORIES
Slide 15
• Understand the ore
• Consider the appropriate flowsheet
• Consider the optimised testwork plan
• Gravity separation on fine iron ore has produced exceptional results
Conclusion
ALLIED MINERAL LABORATORIES
THANK YOU
