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

842 Pages·2021·19.172 MB·English

by  Liming Lu (editor)

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
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ISBN: 978-0-12-820226-5
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Cover pictures: designed by Liming Lu,
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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