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Iron Ore: Mineralogy, Processing and Environmental Sustainability (Woodhead Publishing Series in Metals and Surface Engineering) PDF

842 Pages·2021·19.172 MB·English
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Iron Ore Woodhead Publishing Series in Metals and Surface Engineering Iron Ore Mineralogy, Processing and Environmental Sustainability SECOND EDITION Edited by Liming Lu CSIRO Mineral Resources, Pullenvale (Brisbane), QLD, Australia Woodhead Publishing is an imprint of Elsevier The Officers’ Mess Business Centre, Royston Road, Duxford, CB22 4QH, United Kingdom 50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States The Boulevard, Langford Lane, Kidlington, OX5 1GB, United Kingdom Copyright © 2022 Elsevier Ltd. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. Details on how to seek permission, further information about the Publisher’s permissions policies and our arrange- ments with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions. This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein). Notices Knowledge and best practice in this field are constantly changing. As new research and experi- ence broaden our understanding, changes in research methods, professional practices, or medi- cal treatment may become necessary. Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility. To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of prod- ucts liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein. British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library Library of Congress Cataloging-in-Publication Data A catalog record for this book is available from the Library of Congress ISBN: 978-0-12-820226-5 For Information on all Woodhead Publishing publications visit our website at https://www.elsevier.com/books-and-journals Publisher: Matthew Deans Acquisitions Editor: Christina Gifford Editorial Project Manager: Charlotte Rowley Production Project Manager: Anitha Sivaraj Cover Designer: Miles Hitchen Cover pictures: designed by Liming Lu, J. R. Manuel Typeset by Aptara, New Delhi, India Contents Contributors xi Preface xiii Preface to the second edition xv Biography xvii 1 Introduction: Overview of the global iron ore industry 1 Ralph J. Holmes, Yifan Lu, Liming Lu 1.1 Introduction 1 1.2 Iron ore mining operations by country 7 1.3 Innovative technologies adopted by iron ore producers 45 1.4 Challenges facing iron ore industry 49 References 55 Part One Characterization and analysis of iron ore 57 2 Mineralogical, chemical, and physical metallurgical characteristics of iron ore 59 J.M.F. Clout, J.R. Manuel 2.1 Introduction 59 2.2 Mineralogy 59 2.3 Chemical composition 87 2.4 Physical properties 90 2.5 Future trends 100 References 103 3 Quantitative XRD analysis and evaluation of iron ore, sinter, and pellets 109 Johan P.R. de Villiers, Liming Lu 3.1 Introduction 109 3.2 XRD mineral quantification 110 3.3 Principal minerals of natural and sintered iron ores 117 3.4 Quantitative XRD analysis of iron ore 117 3.5 Quantitative XRD analysis of iron ore sinter and pellets 122 3.6 Summary 124 References 125 vi Contents 4 Automated optical image analysis of natural and sintered iron ore 127 E. Donskoi, A. Poliakov, J.R. Manuel 4.1 Introduction—overview of optical image analysis technique 127 4.2 Mineralogical characteristics of iron ore and sinter 133 4.3 Automated optical image analysis 139 4.4 Application of automated OIA to natural and sintered iron ore 162 References 175 5 Quantitative analysis of iron ore using SEM-based technologies 179 Igor Željko Tonžetić 5.1 Introduction 179 5.2 Principles of SEM-based technologies 180 5.3 Application of automated SEM-based technologies to ore characterization 190 5.4 Characterization of natural and sintered iron ore using QEMSCAN 195 5.5 Summary 202 5.6 Future trends 204 References 206 6 Characterization of iron ore by visible and infrared reflectance and Raman spectroscopies 209 Erick Ramanaidou, Martin Wells, Ian Lau, Carsten Laukamp 6.1 Introduction 209 6.2 Principles, instrumentations, and applications of reflectance spectroscopy 210 6.3 Principles, instrumentations, and applications of Raman spectroscopy 225 6.4 Future trends 237 References 238 Part Two Extraction, comminution, classification and beneficiation of iron ore 247 7 Iron ore extraction techniques 249 R. Stace 7.1 Introduction 249 7.2 Iron ore mining—an historical UK context 250 7.3 Underground iron ore mining: Kiruna, Sweden 254 7.4 Modern-day surface mining: the Pilbara deposit 259 7.5 Modern day surface mining: iron ore in Minas Gerais Province, Brazil 262 7.6 Conclusions 266 References 267 8 Comminution and classification technologies of iron ore 269 Aleksandar Jankovic 8.1 Introduction 269 8.2 Iron ore crushing and screening 270 8.3 Iron ore grinding and classification 282 Contents vii 8.4 Future trends in iron ore comminution and classification 291 References 306 9 Physical separation of iron ore: magnetic separation 309 Dahe Xiong, Liming Lu, Ralph J. Holmes 9.1 Introduction 309 9.2 Principle of magnetic separation 309 9.3 Magnetic separators 312 9.4 Typical flow sheets for upgrading low-grade iron ores 317 9.5 Challenges and recent advances in upgrading low-grade iron ores using magnetic separation 330 9.6 Summary 332 References 332 10 Non-magnetic physical separation of hematitic/goethitic iron ore 333 E. Maré, T. Gerrans, C. Crisafio, M.J. Hartmann, J.P. Oosthuizen, S. Bensley 10.1 Physical processing for enhancing chemical properties 333 10.2 Dense medium separation 335 10.3 Jigging 345 10.4 Upflow classification 351 10.5 Spiraling 359 10.6 Dry physical separation technologies aimed at enhancing chemical properties 371 References 372 11 Physiochemical separation of iron ore 375 Warren J. Bruckard, Leanne K. Smith, Graeme W. Heyes, Graham J. Sparrow 11.1 Introduction 375 11.2 Mineral properties 375 11.3 Iron ore flotation 379 11.4 Key challenges and future directions 390 References 392 12 Chemical separation of iron ore 397 Graham J. Sparrow, Liming Lu, Roy R. Lovel, Michael J. Fisher-White 12.1 Introduction 397 12.2 Phosphorus removal from iron ores 399 12.3 Removal of silicon, aluminum, and sulfur minerals 412 12.4 Summary and future trends 415 References 417 13 Thermal beneficiation of refractory iron ore 421 Hongliang Han, Liming Lu 13.1 Introduction 421 13.2 Magnetizing roasting and magnetic separation process 421 13.3 Deep reduction and magnetic separation process 438 13.4 Summary 450 References 452 viii Contents 14 Application of biotechnology in iron ore beneficiation 457 Suzanne M. Rea, Naomi J. Boxall, Rebecca B. Dwyer, Warren J. Bruckard 14.1 Introduction 457 14.2 Microbial adhesion to mineral surfaces 459 14.3 Bioleaching for phosphorus removal from iron ores 465 14.4 Biobeneficiation of sulfide ores 468 14.5 Biobeneficiation of iron ore 471 14.6 Future trends 477 Acknowledgments 479 References 479 Part Three Iron ore agglomeration and ironmaking technologies 487 15 Iron ore sintering 489 Liming Lu, Osamu Ishiyama, Takahide Higuchi, Masaru Matsumura, Kenichi Higuchi 15.1 Introduction 489 15.2 Effect of iron ore characteristics on sintering 494 15.3 Evaluation of iron ore for the sintering process 509 15.4 Recent developments in iron ore sintering 516 15.5 Conclusions 532 Acknowledgments 533 References 533 16 Iron ore pelletization 539 Deqing Zhu, Jian Pan, Liming Lu, Ralph J. Holmes 16.1 Introduction 539 16.2 Specification requirements of pellet feed 545 16.3 Green ball formation and properties 546 16.4 Induration of green pellets 563 16.5 Quality requirements for fired pellets 573 16.6 Conclusions 573 References 574 17 Blast furnace ironmaking and its ferrous burden quality requirements 579 Liming Lu, Yifan Lu 17.1 Introduction to ironmaking technologies 579 17.2 Blast furnace ironmaking fundamentals—zones and reactions in the blast furnace 579 17.3 Quality requirements 586 17.4 Physical testing of blast furnace Fe-bearing materials 589 17.5 Summary 601 References 601 Contents ix 18 Alternative ironmaking processes and their ferrous burden quality requirements 605 Liming Lu, Jian Pan, Deqing Zhu 18.1 Introduction 605 18.2 Direct reduction 606 18.3 Smelting reduction 614 18.4 Summary 623 References 623 Part Four Environmental sustainability and low emission technologies 627 19 Sintering emissions and mitigation technologies 629 Liming Lu, Tze Chean Ooi, Xianchun Li 19.1 Introduction 629 19.2 CO emissions and their mitigation 631 X 19.3 SO emissions and their mitigation 637 X 19.4 NO emissions and their mitigation 640 X 19.5 Dioxin emissions and their mitigation 643 19.6 Dust emissions and their reduction 651 19.7 Utilization of biomass materials in iron ore sintering 653 19.8 Conclusions 658 References 658 20 Utilization of biomass as an alternative fuel in iron and steel making 665 Elsayed Mousa, Hesham Ahmed 20.1 Introduction 665 20.2 Potentials of biomass utilization in iron and steel industry 666 20.3 Biomass in steelmaking 683 20.4 Conclusions 685 Acknowledgment 686 References 686 21 Life cycle assessment of iron ore mining and processing 691 Nawshad Haque 21.1 Introduction 691 21.2 Iron ore mining and processing 695 21.3 Loading and haulage 697 21.4 Application of LCA to iron ore mining and processing 698 21.5 Using LCA to reduce energy and greenhouse gas impacts 705 21.6 Conclusions 708 21.7 Sources of further information and advice 708 References 709

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