Optimization of the Hematite Concentration Stage at the Chadormalu Complex: A Case Study on High-Gradient Magnetic Separation and Flotation

This study explores a laboratory scale study on the optimization of the concentration stage for hematite ore at the Chadormalu Iron Ore Complex by integrating high-gradient magnetic separation (HGMS) and flotation techniques. Hematite ore types in this mine are frequently associated with silicates, phosphates, and rarely sulfide bearing gangue, presenting challenges in producing concentrates suitable for steelmaking. Lab-scale studies systematically assessed the potential of HGMS to separate coarse gangue minerals and remove non-magnetic impurities. The HGMS process at the optimized condition (dR۰:۱۵۰ μm, Solid percent: ۳۰%, and Magnetic field with an intensity of ۰.۸ Tesla) produced a preliminary concentrate with an iron grade of ۶۱.۲% and a recovery rate of ۸۰.۷%, effectively reducing silicate and phosphate impurities. To further enhance concentrate quality, flotation was applied, utilizing sodium silicate as a dispersant, starch as a depressant, and sodium oleate as a collector under optimized solid percent and pH conditions. The flotation stage increased the iron grade to ۶۸.۵%, while significantly lowering silica and phosphate contents to ۱.۸% and ۰.۱%, respectively, achieving an overall hematite recovery of ۹۲.۳%. This research highlights the effectiveness of combining HGMS and flotation in overcoming the limitations of individual methods, resulting in high-grade hematite concentrates with minimal impurities. These results demonstrate the potential for implementing this optimized approach in industrial operations at Chadormalu, offering a sustainable and economically viable solution for upgrading hematite ores.

کلیدواژه ها:

High-Gradient Magnetic Separation (HGMS) ، Flotation ، Hematite Concentration ، Chadormalu Iron Ore Complex ، Mineral Processing Optimization