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A New Method For Gravity Separation Vibrating Tabl PDF
A New Method For Gravity Separation Vibrating Tabl PDF
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All content following this page was uploaded by Ergin GÜLCAN on 08 January 2019.
Hacettepe University, Mining Engineering Department, Mineral Processing Division, 06800, Beytepe, Ankara, Turkey
Keywords: This paper discusses recently developed gravity concentration equipment, namely vibrating table, and reports
Vibrating table detailed descriptions of the equipment in terms of principles of design and their effects on operational para-
Gravity concentration meters. Vibrating table originally combines the known physical phenomena of a teetered bed, resistance to water
Hydrosizer flow, vibration, and density differences. The resulting effect of these combined forces can also be manipulated by
Hydrocyclone
integrated settings of feed rate, solid %, plate inclination, and water rate. Following the detailed description of
Shaking table
Chromite ore
the equipment, mineral separation tests with two different chromite ores obtained from industrial applications
were performed in order to investigate the performance of the laboratory scale vibrating table. While former
chromite ore had low grade with complex mineralogy and inadequate liberation, the latter had high grade
consisting of liberated lumpy chromite particles. Experimental studies were focused on investigating the effect of
plate inclination, removal of slimes, ore type, size classification, and particle size on separation performance.
Within the tests performed with −600 µm, −800 µm, and −1000 µm high grade chromite ores under certain
conditions, it was observed that increase in particle size results in a dramatic increase in recovery, while % grade
decreases slightly. In another test with high grade chromite ore, sustainable product qualities were achieved up
to a recovery of 93.22% in comparison with the 66.08% achieved with a conventional shaking table, within and
approx. 47–48% final grade level. Additionally, product grades and recoveries up to 50.20%–58.36% with de-
slimed −400 µm low grade chromite feed and 53.68%–67.45% with deslimed −200 µm low grade chromite
feed were obtained, respectively.
1. Introduction [21,22]), air table separators (coal [23,24]), dense medium separators
such as dense medium cyclone (coal and minerals [25,26]), spiral
In its simplest definition, gravity concentration is a class of methods concentrators (chromite, sand, coal, iron, etc. [27–29]), shaking tables
which take advantage of the density differences among mineral parti- (chromite, gold, rare earth minerals [30–33]), and multi-gravity se-
cles [1–3]. As a result, particles of which densities are different from parators (chromite, coal, graphite, rare earth minerals [34–37]). Among
each other have their own relative movement against the forces of the the afore mentioned methods and equipment, shaking tables are one of
gravity depending on the factors such as viscosity of the environment, the oldest yet the most effective appliances allowing to process a wide
resistance to the motion in viscous environment, density, weight, par- range of minerals and coal having various particle size ranges from
ticle size, and shape or a relevant combination of them [4]. Although 15 mm down to 10–15 µm [38,5,31]. Capacity of a shaking table is in
interest in gravity concentration dates back to Homer's Odyssey ac- the range between 0.5 tons per hour and approx. 1.5–2 tons per hour
cording to Wills’ [5], cultivating for modern methods and technologies depending on the particle size processed. Therefore, it is usually a
for the need of better recovery and production continued [6–8]. standard in the industry to install tens of shaking tables in series or
After decades of research and development, various number of parallel in order to process excessive tonnages, especially in chromite
gravity concentration equipment and application have been reviewed processing. Hence, new problems arise due to the required space for
successfully. Some of the most popular examples and successful appli- installation, equipment control difficulties accompanied by increase of
cations are the ones with jigs or centrifugal jigs (gold bearing sulfide the number of installations, and need for more automated flowsheets.
minerals, tin, mineral sands, chromite, iron, coal, etc. [9–12]), cen- Besides the wide range of use, easiness, and effectiveness of gravity
trifugal gravity concentrators such as Knelson and Falcon (gold, copper, concentration without the need for any chemical intervention, low
platinum, chromite ore, coal, etc. [13–17]), teetered bed separators capacities of the equipment and increasing demand for better produc-
(coal, chromite, manganese, etc., [18–20]), FGX dry separators (coal tion always made it the last resort to be considered when all other
⁎
Corresponding author.
E-mail address: ergingulcan@hacettepe.edu.tr (E. Gülcan).
https://doi.org/10.1016/j.seppur.2018.09.074
Received 18 April 2018; Received in revised form 11 September 2018; Accepted 25 September 2018
Available online 26 September 2018
1383-5866/ © 2018 Elsevier B.V. All rights reserved.
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134
methods fail. Therefore, search for enhanced gravity concentration solid percent. Sample particles17 are contained in a teetered bed12, within
methods are all in progress either by investigating the better versions of of which volume the denser particles14 move downwards at relatively
current setups or attempting to invent totally new perspectives based on higher velocities in comparison with lighter particles13. Consequently,
gravity differences in order to achieve possible alterations in % grade the submerged dense particles14 are transported horizontally upward
and recovery of final products [1,2,5,7]. from the teetered bed through the serrated surface of the groove10 of the
The purpose of this study is to investigate the performance of a inclined chute1 by linear vibration. Vibration frequency9 is controlled by a
recently developed gravity concentration system, namely “vibrating unit9 which can be adjusted depending on the sample characteristics.
table” [39], and highlight the effect of operational parameters in al- Meanwhile, the light particles13 and those above the layer of the teetered
tering the product qualities. Therefore, configured new system was bed drag to the tailing stream by the water3&4 through the inclination
revealed in detail and exemplary chromite processing studies had been direction, and they are separated. Water within the process is supplied
performed. Within the experimental studies, vibrating table perfor- via wash water4 (WW) and teetering water (TW) jets3. While WW4 cleans
mance was investigated at various particle sizes under different the concentrate from by-passing lighter particles13, TW3 helps form the
equipment specific parameters. For this purpose, either vibrating table fluidized bed where the actual separation takes place. TW rate3, and
was integrated into some basic mineral processing flowsheets or used WW flow4 are the most important operational parameters which are
solely. Effect of size classification and desliming prior to the operation adjusted by a water rate adjustment unit, and solenoid valve control
was also investigated. Finally, performance of a vibrating table in unit7, respectively.
comparison with the shaking table had been tested under similar con- Additionally, the water level of the teetered bed is also critical.
ditions. Following the data collection, product qualities of each test and Denser particles14 are drawn away from the bed, travel horizontally
their possible impact on overall performance was investigated. upwards on the serrated surface of the groove10, and leave the system
through product discharge16. Inclination of the chute is set via a tilt ad-
2. Equipment descriptions justment bar11 placed under the chute, which also effects water level cut
point18 of the teetered bed. Meanwhile, lighter particles13 having lower
The recently developed gravity concentration system namely “vi- specific gravity tend to layer on the top of the denser particles14.
brating table” shown in Fig. 1 allows the particles to be separated from Consequently, with the effect of drag force of the water flow, lighter
each other due to density differences [39]. A heterogeneous mixture of particles13 leave the system from tail discharge15. It is important to note
particles is fed to the inclined chute1 either dry or wet with a substantial that, gravity powered separation process is started after a steady state
fluidized bed is formed. Therefore, after reaching the steady state,
10 3 properties of the bed forming material are constant unless there is a
8
15 change in the operational parameters.
1. Inclined chute
7
1 The inclined chute1 is vibrated via one or two magnetic vibration
2. Magnetic vibration unit
3. Teetering water jet device(s) depending on the width of the chute. This unit provides
4 2 9 4. Wash water jet single-directional vibrations. The chute can be manufactured to have a
5 5. Vertical steel plate
11 6. Main frame width of 20 cm to 100 cm and a length of 50 cm to 150 cm. The chute is
7. Solenoid valve control unit fixed to the magnetic vibration unit2 which is a ready-to-use system with
6
8. Solenoid valve amplitude and frequency control. The unit is mounted on a horizontal
9. Vibrator frequency control unit
10. Serrated groove surface steel plate5 whose inclination is adjustable. The steel plate5 is mounted
11. Tilt adjustment bar on the main frame6 (a table with four legs) to fix the device in place
17 1 14 4 12. Teethered bed
(Fig. 1).
18 13. Lighter particles
15 13 14. Denser particles The groove10 on the inclined chute1 can be made of stainless steel,
16
15. Tail discharge painted normal steel, fiberglass, etc., a sufficiently hard and durable
16. Product discharge
12 17 16 17. Sample particles (ore)
material. The serrated groove surface10 may be smooth, rough or saw-
3 18. Water level cut point toothed as the sandpaper surface. The surface of the groove10 can be
2 made as desired by coating.
Side view 15
Side perspective view 3. Experimental studies
(a)
3.1. Sample characterization
125
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134
Table 1
Brief roundup of experimental procedures.
Feed sample description Equipment Classification Operation intricacies
−400 µm low grade ore Vibrating table not applied 9°, 7°, and 5° plate inclinations applied
−400 µm low grade ore Vibrating table deslimed with hydrocyclone 9°, 7°, and 5° plate inclinations applied
−200 µm low grade ore Vibrating table not applied 4°, 3°, and 2° plate inclination applied
−200 µm low grade ore Vibrating table deslimed with hydrocyclone 4°, 3°, and 2° plate inclination applied
−1000 µm high grade ore Vibrating table not applied Lowest liberation
−800 µm high grade ore Vibrating table not applied Moderate liberation
−600 µm high grade ore Vibrating table not applied Highest liberation
−1000 µm high grade ore Shaking table classified with hydrosizer 1st reservoir was fed
−1000 µm high grade ore Shaking table classified with hydrosizer Combined 2nd, 3rd, and 4th reservoirs were fed
−1000 µm high grade ore Vibrating table classified with hydrosizer 1st reservoir was fed
−1000 µm high grade ore Vibrating table classified with hydrosizer Combined 2nd, 3rd, and 4th reservoirs were fed
−600 µm high grade ore Vibrating table deslimed with hydrocyclone −600 + 75 µm of U/F was fed after screening
−600 µm high grade ore Vibrating table deslimed with hydrocyclone −600 + 212 µm of U/F was fed after screening
−600 µm high grade ore Vibrating table deslimed with hydrocyclone −212 + 75 µm of U/F was fed after screening
Vibrating table
Tail
(a) (b)
Specific gravity (SG) of the as-received sample was measured as 2.69 approx. 33–38%, 24.30%, 4.63%, 13.38%, and 18.33%, respectively.
with a pycnometer of which top particle size was 14.47 mm Chromite liberation of high grade ore was starting below 1000 μm and
(f80 = 12.3 mm). Fe2+Cr2O4, Fe2O3, SiO2, CaCO3, Mg2SiO4 (lizardite), reaching up to approx. 75–80% below 425 μm. Majority of the chromite
and Mg(OH)2 contents of the low grade chromite ore were determined (Cr2O3) was reported as free and liberated from the host minerals
by chemical analysis as 5.04–5.25%, 0.209%, 0.205%, 1.24%, 86.46%, providing a more convenient angle for concentration methodology
and 5.48%, respectively. Previous studies and visual observations design. Therefore, lump particles in the original sample batch were
showed that chromite liberation of this particular ore was starting initially classified into two different grade batch by hand-picking.
below 600 μm [40] and reaches up to approx. 80% below 212 μm. Hence, two distinct groups of sample batches having approx. 32–33%
Accordingly, sample preparation efforts were focused on crushing the and 37–38% chromite content were obtained, respectively. Due to the
original sample down to 400 µm (f80 = 348 μm) and 200 µm high liberation tendency and % chromite grade, each sample group was
(f80 = 151 μm), respectively. ground below 1 mm (f80 = 825 μm for the former and f80 = 812 μm for
X-ray Diffraction (XRD) analysis had also been performed with the the latter). For more detailed examination, additional size reduction
main batch to determine primary minerals along with the chromite had been performed with high grade chromite ore batches depending
[40]. Chromite ore showed reasonable peaks related with the contents on the application.
observed in chemical analysis. In the analysis of the XRD patterns, Li-
zardite (Mg3Si2O5.OH), Brusit (Mg.OH) and chromite (Fe+2Cr2O4) 3.2. Methodology overview
minerals were primarily determined.
Mineralogical analysis showed that the main mineral in the ore is Following the sample preparation via subsequent crushing and
forsterite, which is a magnesium silicate mineral, and it is present in a grinding, various chromite processing flowsheets either to apply solely
very high amount such as 86%. Other major minerals are brucite and using vibrating table or in combination with other gravity type equip-
chromite. Both minerals are found in approximately 5–5.5% of the ore. ment were designed based on the properties of the sample batch. Brief
The percentages of Cr and Fe in chromite were 46.46% and 24.94%, summary of the experimental methodology is given in Table 1. Initially,
respectively. Forsterite and brucite have lower density values than vibrating table tests were performed with −400 µm and −200 µm low
chromite concentration, which presumably provides an advantage in grade chromite samples under varying plate inclinations of 9°, 7°, and
gravity enrichment. 5° for the former and 4°, 3°, and 2° for the latter particle sizes (Fig. 2a).
About 15% of chromite is bonded with other minerals. Additionally, Following, same plate inclinations were applied to process -400 µm and
13.46% of this amount is originated from forsterite mineral. Forsterite −200 µm low grade chromite samples right after removing the slimes
is more free than chromite, with a total of approx. 2% locked with other with hydrocyclone (Fig. 2b). TW was kept constant in order to keep the
minerals including chromite. solid ratio of the feed around 30% by weight. WW was also set constant
to 0.75 L per minute (for a 20 cm chute opening) of water for a clear
3.1.2. Characterization of the high grade chromite ore observation of recovery changes related with the change in plate in-
High grade chromite ore delivered to the laboratory was below clination.
300 mm in size, having a significant number of lumpy and high quality In the experimental work with two distinct high grade chromite
chromite particles within. Cr2O3, Fe2O3, SiO2, Al2O3, and MgO contents samples, while the former one with approx. 32–33% chromite was di-
of the high grade chromite ore were determined by chemical analysis as rectly fed to the vibrating table in three distinct size fractions (namely
126
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134
Hydrosizer
Feed Slime
To Cleaner and
Scavenger steps
Chromite
Product to Cleaner product
Vibrating table
Scavenger
(a)
Hydrosizer
Feed Slime
Shaking table
1st product
2nd product Tail Shaking table
Midling
1st product
2nd product Tail
Midling
(b)
Fig. 3. Schematic view of the −1000 µm high grade chromite sample tests in which feed samples were primarily classified via hydrosizer (a: vibrating table tests, b:
shaking table tests).
−1000, −800, and −600 µm) (Fig. 2a), latter with approx. 37–38% to the 1st stage vibrating table tail which enabled a convenient com-
chromite content was first classified with hydrosizer. 1st reservoir and a parison with shaking table (Fig. 3a). Nevertheless, combined products
combination of 2nd, 3rd, and 4th reservoirs of hydrosizer were sepa- were also compared in terms of grade and recovery values attained.
rately fed to the both vibrating table (Fig. 3a) and shaking table Finally, −600 µm high grade (approx. 37–38%) chromite sample
(Fig. 3b) in order to conduct a reasonable comparison between sibling was fed to the hydrocyclone for the removal of the fines
instruments. In the tests applied to hydrosizer products, two different (d50 = −75 µm) and clayey content (Fig. 4). After representatively
quality product were collected through the surface ending line of the sampling from the underflow (U/F) stream of the hydrocyclone,
shaking table along with a middling product which is usually re- -600 + 75 µm product was wet classified with a 212 µm screen forming
processed (Fig. 3b). Considering that the vibrating table outputs consist two narrowly sized fractions namely −600 + 212 µm and
of a concentrate and a tailing, an additional cleaner stage was applied −212 + 75 µm samples. Then, −600 + 75 µm, −600 + 212 µm, and
127
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134
Table 2
Low grade chromite sample vibrating table test parameters and product qualities.
Test notation Feed top size, µm Desliming Plate inclination Vibration frequency Mass pull, % Cr2O3 in product, % Cr/Fe in product
128
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134
100 100
90 Mass pull, % Weight 90 Mass pull, % Weight
Cr O , % Cr O , %
80 Cr O Recovery, % 80
Cr O Recovery, %
70 70
60 60
50 50
%
%
40 40
30 30
20 20
10 10
0 0
4 6 8 10 1 2 3 4 5
Plate inclination, ° Plate inclination, °
(a) (b)
100 100
90 Mass pull, % Weight Mass pull, % Weight
90
Cr O , % Cr O , %
80 Cr O Recovery, % 80
Cr O Recovery, %
70 70
60 60
50 50
%
%
40 40
30 30
20 20
10 10
0 0
4 6 8 10 1 2 3 4 5
Plate inclination, ° Plate inclination, °
(c) (d)
Fig. 5. % grade and % recovery comparison of the low grade chromite sample vibrating table test products (a: 400 µm, b: 200 µm, c: 400 µm deslimed, d: 200 µm
deslimed).
Table 3
Vibrating table test results of −1000 µm, −800 µm, and −600 µm high grade chromite (approx. 32–33%) samples.
8° plate inclination −1000 µm feed −800 µm feed −600 µm feed
Weight% Cr2O3% Cr2O3 Recovery% Weight% Cr2O3% Cr2O3 Recovery% Weight% Cr2O3% Cr2O3 Recovery%
1st stage Cr2O3 product 47.02 36.42 51.46 37.28 39.88 44.44 37.22 44.86 49.46
2nd stage Cr2O3 product 25.17 39.88 30.16 15.21 45.68 20.77 5.28 46.74 7.31
Combined chromite product 72.19 37.63 81.63 52.49 41.56 65.20 42.50 45.09 56.77
Bed forming material 12.31 16.22 6.00 23.62 20.35 14.37 12.64 21.44 8.03
Tailing 15.50 26.55 12.37 23.89 28.61 20.43 44.86 26.49 35.20
Feed 100.00 33.28 100.00 100.00 33.46 100.00 100.00 33.76 100.00
other operating parameters constant. 1st and 2nd stage cleaning con- higher WW rate increased the % grade of final product of coarse size
centrates obtained under two different WW rates were combined fraction (−1000 µm) slightly without any significant decrease in %
forming a single chromite product. Results of the separation tests were recovery of final product in comparison with 0.5 lpm WW rate.
given in Table 3. Separation performances of three distinct particle sizes The WW jet pipe of the equipment extends along the bed and stands
calculated considering combined products were presented in Fig. 6a. perpendicular to the flow. The diameter of WW pipe is less than 0.5 mm
Additionally, the effect of WW rate on % chromite recoveries and % with holes drilled along at every 0.5–1 cm width, thus the water can be
chromite grades of final products were given in Fig. 6b and c, respec- sprayed smoothly. The rate of WW should be set according to plate
tively. In Fig. 6a, effect of particle size on Cr2O3 grade and recovery inclination and feed particle size. WW is an important separation
were discussed on the basis of combined 1st and 2nd stage products. parameter and should be provided intermittently, ideally with an
Results showed that sufficient liberation at −600 µm particle size opening and closing time interval in between 0.5 s and 20 s resulting
provoked a slightly higher grade. On the other hand, loses were also with a WW rate of 0.5 and 1.25 lpm, respectively. When processing
higher resulting with the lack of the resistance to the WW and low G- finer particle sizes, lower WW rates result in higher % grade and %
force action. With −1000 µm feed, grade of final product decreased recoveries in final products, and vice versa while processing coarser
down to 37.63% Cr2O3, while chromite recovery in the final product sizes due to the increasing mass of the individual chromite grains.
was increased up to 81.63% within a single stage operation. In Fig. 6b
and c, effect of increasing solely the WW rate was presented while
keeping plate inclination (8°) and feed rate (0.15 t/h) constant (for a 4.1.3. Effect of TW (teetering water), feed rate and solid % on separation
20 cm chute opening) for given particle sizes. Results showed that performance
under WW rate of 1 lpm, although chromite recovery was significantly Chute of the laboratory scale experimental setup manufactured with
lower at finer sizes in comparison with 0.5 lpm WW rate, % chromite the dimensions of 20 cm in width × 5 cm in height × 50 cm in length.
grades were higher due to obtaining a cleaner product. Similarly, Due to the design principle, effective separation takes place in teetered
zone and flowing water film carry low density particles through tail
129
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134
100 performed with −1000 µm high grade chromite sample under constant
feed rate of 0.25 t/h at varying TW rates. Plate inclinations of 11° and 5°
80 were applied for each test separately. Following, solid % measurements
were carried out with the remaining material in chute and results were
60 presented in Table 4. It was observed that, although plate inclination
and TW have primary importance, solid % within chute does not
%
130
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134
Table 4 optimum for a vibrating table operation due to the experimental results.
Change in separation solid % due to TW rate, WW rate, and feed rate. On the other hand, although the quantity of water used in the feed pulp
Feed rate, kg/h* TW rate, lpm* Plate inclination,° Measured solid %** varies, shaking table’s normal feed dilution in comparison with the
vibrating table were reported as 20–25% solids by weight for ores, and
24 8 11 11.69 33–40% solids for coal [2,5].
24 2 11 23.80
Shaking tables are used in a variety of applications, and depending
24 8 5 37.84
24 2 5 51.40
on the application an industrial shaking table is approx. 2–5 m long and
50 8 11 18.03 1–3 m wide. Hence, single shaking table occupies a large area and most
50 2 11 35.33 operations require tens of tables in order to handle excessive tonnages.
50 8 5 49.35 In contrary, although an industrial scale vibrating table operation has
50 2 5 58.26
not been undertaken yet, installation space required for vibrating table
* Values calculated for laboratory scale vibrating table with a 20 cm chute is predicted to be significantly less than shaking table according to the
opening. experimental results.
** 2.7 g/cm3 bulk density value for the chromite ore sample was used within Within aforementioned experimental crosscheck between shaking
calculations. table and vibrating table, it was observed that vibrating table either
caught up or outperformed the performance of the shaking table under
Table 5 the given conditions. Considering the factors such as capacity, space
Hydrosizer test results of −1000 µm high grade chromite (approx. 37–38%) required for installation, etc., vibrating table was proved to be a strong
samples. alternative to conventional shaking tables when sibling operations were
−1000 µm feed to hyrdosizer considered.
Table 6
High grade chromite (approx. 37–38%) sample shaking table test results applied to classified products obtained from hydrosizer reservoirs.
Feed from hydrosizer 1st reservoir hydrosizer 2nd + 3rd + 4th reservoirs
1st stage chromite product 20.53 49.00 23.99 13.12 49.68 17.22
2nd stage chromite product 37.03 47.66 42.09 32.54 48.79 41.96
Middling 41.14 33.79 33.16 46.39 29.08 35.66
Tailing 1.31 24.45 0.76 7.96 24.54 5.16
Feed 100.00 41.92 100.00 100.00 37.83 100.00
1st + 2nd stage chromite product 57.55 48.13 66.08 45.65 49.04 59.18
131
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134
Table 7
High grade chromite (approx. 37–38%) sample vibrating table test results applied to classified products obtained from hydrosizer reservoirs.
Feed from hydrosizer 1st reservoir hydrosizer 2nd + 3rd + 4th reservoirs
0 20 40 60 80 100
Cr O Recovery, % Cr O , %
(a)
0 10 20 30 40 50 60 70
Cr O Recovery, % Cr O , %
(b)
Fig. 8. Comparison of the high grade chromite (approx. 37–38%) sample shaking table and vibrating table test results applied to classified products obtained from
hydrosizer reservoirs (a, 1st reservoir; b, combination of 2nd, 3rd, and 4th reservoirs) (ST, shaking table; VT, vibrating table).
132
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134
Table 9
High grade chromite (approx. 37–38%) sample vibrating table test results applied to classified products obtained from hydrocyclone underflow.
Feed from Hydrocyclone U/F -600 + 75 Hydrocyclone U/F -600 + 212 Hydrocyclone U/F -212 + 75
Weight% Cr2O3% Cr2O3 Recovery% Weight% Cr2O3% Cr2O3 Recovery% Weight% Cr2O3% Cr2O3 Recovery%
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