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Beneficiation process for Ore Extraction

Theme: Others

Expected Pilot Duration - 3 Months

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Challenge Summary

Currently there is no available Beneficiation (improving economic value of ore) solution for reducing Mn & Phos from Iron Ore. The lack of beneficiation process within the mine is resulting in poor ore quality and loss of iron extraction percentage.

Challenge Scenario

When the ore is extracted from the mines it is not excavated in the purest form which can be processed. There will be resulting gangue minerals (Mn at 3%) along with the ore concentrate which needs to be refined. This process generates two by-products, which include high grade ore and waste streams. The beneficiation can be done either physically or chemically to attain the best quality output. Currently physical crushing and grinding is done for transportation purposes but not in the context of beneficiation. The main challenge is to remove the Mn & Phos from the Iron Ore with the help of beneficiation tech in Mine itself before it is sold to the end customers for Iron & Steel Making.

Profile of the end users

Coal Oven Team

Quality Control Team (Head Quality): Responsible for maintaining the amount of Manganese & Phosphorus that helps in increased quality of Iron in the ore. Currently the quality is optimised through blending with low mn & phos ore within the mine.

Solution Requirements

Beneficiation technology to reduce the Mn & Phos.

Should be able to synchronize within the existing process

Yield loss or recovery loss during the process should justify the techno economics and make business sense

Integration: Should be easy to install in existing conveyors and processes

Time Consumption: The Beneficiation process must not stall the existing timeline of the process

Physical & Personal Risk : In case of chemical beneficiation, there should be no harmful impact to the miners and employees

Expected Outcomes

1. Quantified Metrics & Outcomes:
Operational KPIs/Metrics Current Value Expected Target Value
Beneficiation solution for reducing Manganese & Phosphate from Iron Ore 3% Manganese 0.15% Phosphorus Manganese < 1% Phosphorus < 0.1%
2. Qualified Outcomes:
Operational KPI/Metrics Current State Expected Target State
Quality Iron Ore Good Best Grade Iron
3. ESG Impact:
ESG Metric Expected Value/State
NA NA

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