Iron Making Processes

(MY-210)

Lecture # 3
Engr. Aqeel Ahmed Shah
Assistant Professor
MYD, NED University
Department of Metallurgical Engineering,
1
NED University of Engineering and Technology
 Objectives:

• To get the maximum liberated ore

• To get minimum cum optimum size

These objectives can be met by Beneficiation.

Department of Metallurgical Engineering,

2
NED University of Engineering and Technology
 Beneficiation
Beneficiation/mineral processing/mineral dressing A chain of processes
aimed to get the maximum liberated ore from the associated impurities.

Includes:

 Crushing
 Primary (Jaw/Gyratory)
 Secondry (Roll/Hammer)

 Grinding (Ball/rod/autogenous)
 Classification (Hydro/Air)
 Screening (Static/ Moving/ Vibrating)
 Magnetic Separation
 Drying

Department of Metallurgical Engineering,

3
NED University of Engineering and Technology
 Comminution

• Crushing
• Grinding

Department of Metallurgical Engineering,

4
NED University of Engineering and Technology
5
Jaw crusher

6
Gyratory crusher

7
Secondary Crushing

8
Roll mill

9
Cone crusher

10
Hammer mill

11
 Grinding
GRINDING:-
Breaking down of relatively COARSE CRUSHED ore to ULTIMATE FINENESS.

The fineness of the ground product depends on the subsequent mineral beneficiation
operations .

Theoretically, PARTICLES SHOULD BE BROKEN DOWN TILL EVERY PARTICLE IS FULLY

MINERAL
( VALUABLE ) OR GANGUE.

For this, fracture should be along boundaries ( detachment ) between valuables and
gangue.
It is not possible in practice.

Hence, grinding should produce finer particles for satisfactory CONCENTRATION.

LIBERATION of the mineral is to reduce the size of the particle till – Optimum liberated
size

Department of Metallurgical Engineering,

12
NED University of Engineering and Technology
 Tumbling Mills

• Ball mill
• Pebble mill
• Autogeneous mill

Department of Metallurgical Engineering,

13
NED University of Engineering and Technology
Ball mill

14
15
TUMBLING MILL - GRINDING MEDIA

Grinding occurs during tumbling action of the mill.

The media used –

Steel balls of varying sizes – 25 – 125 mm dia.

They are made of Hadfield ( Mn ) steel, Cr steels, Cr-Mo steels.

WC ( Tungsten Carbide ) / ceramic balls are also used – Costly but long life.

Large pieces of ore are used as grinding medium in Autogenous grinding.

16
TUMBLING MILL LINERS.

• Lined with replaceable liners

made of alloy steel, rubber or
ceramic materials.

• They may be smooth, ship-slap ,

wave or wedge bar type.

• Liners help in lifting the load as

the mill revolves , to minimise the
slip between layers of the
grinding media and to minimise
wear of the mill shell.

Department of Metallurgical Engineering,

17
NED University of Engineering and Technology
18
 Department of Metallurgical Engineering,
19
NED University of Engineering and Technology
20
Rod mill

21
 Autogenous mill
 The working principle of the self-grinding machine is basically the
same as the ball mill, the biggest difference is that the sag grinding
machine uses the crushed material inside the cylinder as the grinding
medium, the material constantly impacts and grinding to gradually
pulverize. Sometimes, in order to improve the processing capacity
of the mill, a small amount of steel balls be added appropriately,
usually occupying 2-3% of the volume of the mill

22
23