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Recent Advances in Magnetization Roasting of Refractory Iron Ores: A

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Recent Advances in Magnetization Roasting of

Refractory Iron Ores: A Technological Review in the
Past Decade

Jianwen Yu, Yuexin Han, Yanjun Li & Peng Gao

To cite this article: Jianwen Yu, Yuexin Han, Yanjun Li & Peng Gao (2019): Recent Advances
in Magnetization Roasting of Refractory Iron Ores: A Technological Review in the Past Decade,
Mineral Processing and Extractive Metallurgy Review

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MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW
https://doi.org/10.1080/08827508.2019.1634565

Recent Advances in Magnetization Roasting of Refractory Iron Ores: A Technological

Review in the Past Decade
a,b
Jianwen Yu , Yuexin Hana, Yanjun Lia, and Peng Gaoa
a
School of Resources and Civil Engineering, Northeastern University, Shenyang, China; bState Key Laboratory of Mineral Processing, Beijing General
Research Institute of Mining & Metallurgy Technology Group, Beijing, China

ABSTRACT KEYWORDS
Improving utilization efficiency of refractory iron ore resources is a common theme for the sustainable Refractory iron ores;
development of the world’s steel and iron industry. Magnetization roasting is considered as an effective magnetization roasting;
and typical method for the beneficiation of refractory iron ores. After magnetization roasting, the weakly shaft furnace; Rotary kiln;
Fluidized bed; Microwave
magnetic iron minerals, including hematite, limonite and siderite, are selectively reduced or oxidized to
ferromagnetic magnetite, which is relatively easier to enrich by magnetic separation after liberation
pretreatments. The primary magnetization roasting methods include shaft furnace roasting, rotary kiln
roasting, fluidized bed roasting, and microwave assisted roasting. This review highlights the develop-
ments in magnetization roasting of difficult to treat iron ores, including shaft furnace roasting, rotary kiln
roasting, fluidized bed roasting, and microwave assisted roasting in the past decade. Fluidized bed
roasting and microwave assisted roasting are considered as the most effective and promising methods,
which is essential to be reviewed. Meanwhile, the effective and future magnetization roasting technol-
ogies are recommended throughout this review.

中文摘要
提高难选铁矿资源的利用率是世界钢铁工业可持续发展的重要主题。磁化焙烧技术被认为是难选铁矿
选矿典型、有效的方法，弱磁性赤铁矿、褐铁矿、菱铁矿等矿物通过磁化焙烧选择性地还原或氧化为
强磁性的磁铁矿，经磨矿解离后可通过磁选得到有效富集。根据反应器结构的不同，磁化焙烧可分为
竖炉焙烧、回转窑焙烧、流化床焙烧和微波焙烧。本综述回顾了近十年难选弱磁性铁矿石磁化焙烧技
术研究进展，主要包括铁矿石竖炉磁化焙烧、回转窑磁化焙烧、流化床磁化焙烧及微波磁化焙烧，其
中流化床磁化焙烧和微波磁化焙烧被认为是效率高和最具发展前景的技术。同时，本综述对磁化焙烧
技术的未来发展趋势进行了展望。

1. Introduction raw ore are fine grained disseminated as well as their nature is
similar to that of gangues. Although the combination process of
The main industrial types of iron-bearing minerals include hema-
gravity concentration, magnetic separation and flotation is adopted,
tite, magnetite, limonite, and siderite. However, they cannot be
limonite and siderite are hard to be separated from gangues, which
used in iron and steel industry without preliminary beneficiation
belongs to typical refractory iron ores (Yin et al. 2010; Thella et al.
due to their low grade. It is important to choose a high-efficiency
2012; Raghukumar et al. 2012).
beneficiation technique for the separation of iron ore according to
From the economic and environmental aspects, magnetic
its mineral composition, and physical properties (Srivastava and
separation is the most effective method to recover iron oxides,
Pathak 2000). Magnetite is a ferromagnetic mineral, and can be
but it requires the modification of magnetic properties of
easily separated from the gangue minerals of magnetite quartzite by
weakly magnetic iron ores. The increase of magnetic suscept-
magnetic separation (Ponomar et al. 2017). However, the deposits
ibility of hematite, siderite, or limonite ores can be achieved
of magnetite iron ore are becoming exhausted. Hematite, limonite,
by phase transformation induced by roasting, including shaft
and siderite are weakly magnetic. Thus, it is hard to produce
furnace roasting, rotary kiln roasting, fluidized bed roasting,
qualified iron concentrate by single magnetic separation. At pre-
and microwave assisted roasting. In other words, the weakly
sent, hematite ores are mainly processed using a combined process
magnetic iron oxides such as hematite [Fe2O3], limonite
of magnetic separation and flotation or gravity separation. The
[FeO(OH) × nH2O], and siderite [FeCO3] can be converted
recovery rate of iron is lower than 80%, however (Luo et al.
into ferromagnetic magnetite [Fe3O4] by chemical reaction.
2016a, 2016b, 2016c; Jena et al. 2015b). For limonite and siderite
Then, iron oxides can be successfully and easily separated
ores, it is difficult to obtain satisfactory separation results by con-
from gangues by magnetic separation. The reaction product
ventional beneficiation methods, including magnetic separation,
magnetite is ferromagnetic, thus this thermally assisted che-
gravity concentration and flotation, due to the iron minerals in
mical conversion process is called magnetization roasting

CONTACT Yuexin Han dongdafulong@mail.neu.edu.cn School of Resources and Civil Engineering, Northeastern University, Shenyang 110819, China
Color versions of one or more of the figures in the article can be found online at www.tandfonline.com/gmpr.
© 2019 Taylor & Francis Group, LLC
2 J. YU ET AL.
(Priestley 1957; Iwasaki and Prasad 1989; Uwadiale 1992; Ren
and Yu 2005). Magnetization roasting increases the magnetic
difference between iron oxides and gangues, thus improving
the separability of iron ores. Despite the energy consumption
associated with roasting, the magnetization roasting can be
advantageous as magnetic separation is simpler and more
selective than other separation techniques (e.g. flotation).
Furthermore, the friability of the roasted ore is increased,
which is beneficial to reduce the cost of downstream grinding
(Zhu et al. 2010; Huang et al. 2010).
The study of iron ore magnetization roasting started in the
1900s and has been for more than 100 years. According to the
type of roasting reactor, magnetization roasting can be
divided into shaft furnace roasting, rotary kiln roasting, flui-
dized bed roasting, and microwave assisted roasting. In recent
years, the fluidized magnetization roasting technologies have
become research hotspots due to its outstanding advantages of
high heat and mass transfer efficiency, and the microwave
energy assisted ones are considered as the new research fields
in iron ore magnetization roasting. These two aspects should
be highlighted to achieve a better and further progress into
magnetization roasting of iron ores.
2. Literature review
2.1. Shaft furnace roasting
The shaft furnace that roasts hematite ore for mineral proces-
sing is a large-scale industrial kiln, which can be categorized
as thermal equipment. It is used to turn weak-magnetic
mineral ore into strong-magnetic ore through a technical
process named magnetization roasting. The magnetization
roasting process of hematite or specularite ore inside the
shaft furnace can be divided into four phases, namely, the ore-
feeding, ore preheating, heating, reduction, cooling and dis-
charge, As shown in Figure 1 (Yan et al. 2012; Lu et al. 2015).
The raw hematite or specularite ores fall into the furnace
through an ore-store slot and a square funnel at its top. In
the preheating zone, the temperature of the ores is first
Ore feeding
Funnel
Pre-heating
zone
Gas/air Heating
mixture zone
Combustion
chamber
Reduction
zone
Water-
sealed pool
Reducing gas
Belt-conveyer
Figure 1. Process and material flows diagram of shaft furnace roasting process.
raised to 100 ~ 150°C by contacting the ascending hot gas.
In the heating zone, heating air and heating gas are mixed
to burn in combustion chambers, where the temperature is
generally controlled in the range from 1050°C to 1150°C.
The heat from the combustion chamber can raise the tem-
perature of the falling ore to 700–850°C through heat con-
vection, radiation, and conduction. In the reduction zone,
the heated ores, containing the useful ingredient Fe2O3,
contacts with room temperature reducing gas, and is
reduced by CO or H2 to the product Fe3O4 (magnetite) at
approximately 570°C, as shown in Equations (1) and (2).
Meanwhile, the Gibbs free energy of these reactions are very
negative at the temperature of 843 K (570°C), indicating
these reactions are easy to take place. Cooling and dischar-
ging is the final stage where the roasted ores are cooled by
pouring them into a water-sealed pool. Then, the deoxidized
ores are discharged out of the furnace to grinding and
magnetic separation workshop by two belt-conveyer
machines (Yan et al. 2008; Chai et al. 2011).
FeCO3 þFe2 O3 ¼ Fe3 O4 þCO2 ;Δr Gθ ¼ 51; 618  178:49T; J mol1
(1)
3Fe2 O3 þH2 ¼ 2Fe3 O4 þH2 O;Δr Gθ ¼ 459:2  22:0T; J mol1 (2)
In the early 1926, an industrial scale production of iron ore
magnetization roasting with shaft furnace in Anshan area of
China was established. Shaft furnace roasting-magnetic
separation was the major beneficiation method for processing
refractory hematite and specularite ores. So far, only JISCO
continue to use 44 shaft furnaces (model: 100 m3) to roast
refractory specular hematite ores (TFe 35%) using blast fur-
nace gas (containing 29 vol.% CO and 3 vol.% H2) as reduc-
tant. After shaft furnace roasting, an iron concentrate
containing 59.7% Fe with an iron recovery of 77.6% is
achieved by magnetic separation (Zhang 2015).
However, numerous practical applications indicate that
the shaft furnace can only handle the massive ore with
a granularity of 15 mm~75 mm to ensure the permeability
of the shaft furnace. The production capacity of a shaft
furnace is approximately 25t/h, and the duration time of
ore in the shaft furnace is up to 6 ~ 10 hours. The most
fatal drawback is that the deoxidized ore is chemically
heterogeneous, which is the main reason for the low iron
recovery rate in the shaft furnace roasting process. For
example, when the useful ingredient Fe2O3 within coarse
particle (such as 75 mm) is reduced to Fe3O4, the ingredi-
ent Fe2O3 within relatively fine particle (such as 15 mm) is
easily over-reduced to weakly magnetic FeO; when the
ingredient Fe2O3 within fine particle (15 mm) is success-
fully reduced to Fe3O4, while the Fe2O3 within coarse
particle (75 mm) is reduced to Fe3O4 in part, showing
a bad impact on iron recovery. Hence, the shaft furnace
roasting process is gradually replaced by the combined
process of magnetic separation followed by gravity concen-
tration or flotation with the development and application of
high gradient magnetic separators.

2.2. Rotary kiln roasting
The rotary kiln generally processes the iron ores with
a granularity of less than 25 mm, and the iron ore magentiza-
tion roasting process in a rotary kiln can be illustrated in
Figure 2.
With the slow rotation (0.4 ~ 1.0 r/m) of the rotary kiln,
the hematite or specularite within iron ores are first heated in
countercurrent with the hot off-gas from the burner, and then
reduced to magnetite by reducing gas CO, which is generated
from the Boudouard reaction. Namely, when solid reducing
agents (such as coal) were used, CO2 generated in the reduc-
tion reactions subsequently reacted with the solid carbon to
produce more CO (Flavio 1992). The related reduction reac-
tions were presented in Eqs. (1) and (3). According to Eq. (3),
the Boudouard reaction is an endothermic reaction, which
means increasing temperature enables the Boudouard reac-
tion to occur as fast as possible, thus causing a high CO partial
pressure and an accelerated magnetic reduction of hematite or
specularite. Therefore, the roasting temperature in a rotary
kiln is usually up to 750 ~ 1000°C.
C þ CO2 ¼ 2CO;Δr Gn ¼ þ166; 550  171:0T; Jmol1
The JISCO once built an industrial rotary kiln (model:
ϕ3.6 m × 50 m) with a throughput of 32 t/h to roast a specular
hematite ore (TFe 37.8%) with a granularity of less than
10 mm. After roasting at 700 ~ 800°C, an iron concentrate
containing 58.2% Fe with an iron recovery of 84.5% is
obtained by magnetic separation (Zhu and Li 2014).
However, due to the high energy consumption and produc-
tion costs, it has been discontinued.
Xue et al. used a large-scale ϕ4 m × 60 m rotary kiln to deal
with a limonite ore from Xinjiang, China. Ore roasted at
optimal roasting conditions of 750°C, processing capacity of
50 t/h and a coal/ore mass ratio of 6% was subjected to low
intensity magnetic separation resulting in an iron grade of 62%
and a recovery of 90% starting from a feed containing 40.7%
Fe. Therefore, an industrial processing line with an annual
throughput of 2 million tons limonite ore was built and put
into production for the first time in 2010 (Xue et al. 2011).
Dust collector
Gas outlet
Solid inlet
Figure 2. Magnetization roasting process of iron ores in the rotary kiln.
MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW 3
Wang et al. also used a large-scale (ϕ4 m × 60 m) rotary kiln to
treat a limonite ore from Yunnan, China. The results showed
that the limonite was almost completely reduced to magnetite
by 8% coal at roasting temperature of 850°C for 80 min with
a suitable processing amount of 45 t/h. Under the optimized
conditions, a magnetic concentrate containing 58.4% iron with
an iron recovery of 93.9% was produced (Wang et al. 2012).
Xiao and Zhang carried out a pilot-scale (ϕ0.8 m × 9 m) rotary
kiln magnetization roasting of an oolitic hematite ore (TFe
39.4%) from Sichuan, China. After magnetic reduction roasting
at 1000°C for 45 min with 8% coal, low-intensity magnetic
separation gives a magnetic concentrate of 65.9% Fe with
78.9% Fe recovery (Xiao and Zhang 2012). In another study,
Luo et al. carried out a pilot-scale roasting of Daxigou siderite
ore (containing 26.8% Fe) in a ϕ1.3 m × 24 m rotary kiln.
Under roasting temperature of 750°C and roasting time of
80 min in a neutral atmosphere, the roasted ore was ground
to 95.6% passing 0.045 mm, and then separated by magnetic
tube at a field intensity of 120 kA/m, the iron grade and
recovery of magnetic iron concentrate was 59.8% and 86.4%,
respectively (Luo et al. 2006).
(3) In fact, people often use the laboratory muffle furnace to
simulate the industrial rotary kiln roasting effect. Peng et al.
studied the phase transformation and magnetic separation of
an oolitic hematite ore using pulverized coal as reductant in
a muffle furnace. The results showed that the hematite could
be converted to magnetite successfully, and an iron concen-
trate of 55.6% Fe with a recovery of 83.8% was obtained after
magnetic separation of roasted ore at 800°C for 120 min with
20% coal (Peng et al. 2017). Faris et al. explored the factors
influencing goethite to magnetite conversion during magnetic
reduction roasting of an iron-rich rare earth ore using coal as
a reductant. The optimal roasting conditions were determined
as a roasting temperature of 600–650°C with the addition of
10 ~ 20% coal in the mixture and a roasting time of 90 min,
resulting in complete conversion of goethite to magnetite
(Faris et al. 2017). Rath et al. studied the magnetic reduction
roasting of an iron ore assaying 51.6% Fe using activated
charcoal as reductant. The results showed that the hematite
and goethite minerals were converted to the magnetite phase
Chimney
Induced draft fan
Gas inlet
Rotating Burner
Solid outlet
4 J. YU ET AL.
after roasting at 950°C for a roasting duration of 53 min, and
a reductant concentration of 3%, and an iron concentrate
assaying 64% Fe with a recovery of 76% was achieved (Rath
et al. 2014). Jena et al. used the process of magnetic reduction
roasting followed by magnetic separation to treat a titano-
magnetite ore (TFe 52.4%). After reduction roasting of the ore
at 850 C followed by magnetic separation, a concentrate with
65.7% Fe content at a yield of 61.2% with 78.0% Fe recovery
was obtained (Jena et al. 2015a). Yu et al. used a process of
magnetic reduction roasting followed by magnetic separation
to separate and recover iron from a low-grade carbonate-
bearing iron ore, and the hematite and siderite within the
ore were almost completely converted into magnetite by 8%
coal at roasting temperature of 800°C for 8 min. Therefore,
a magnetic concentrate containing 65.4% Fe with an iron
recovery of 92.7% was produced at a magnetic field of
0.12 T (Yu et al. 2017a). In another study, the process of
magnetic reduction roasting followed by magnetic separation
was also used to recycle iron from an iron ore tailing. After
roasting at 800°C with 1% coal for 30 min, a magnetic con-
centrate assaying 61.3% Fe with a recovery rate of 88.2% was
obtained by magnetic separation (Yu et al. 2017b). Lei et al.
found that it was an effective method to recover iron from
a lead-zinc tailing by magnetic reduction roasting and mag-
netic separation. Most of iron in the roasted lead-zinc tailing
was transformed from Fe2O3 to Fe3O4 with 7% coal at 720°C.
Thus, the iron recovery reached 82.2%, and the iron content
in the magnetic concentrate reached 62.1% (Li et al. 2010).
Rath et al. explored the process of simultaneous roast-
reduction and magnetic separation of blast furnace flue dust
(Fe 32%) and a low-grade banded iron ore (Fe 47.2%) without
using any extra reductant, and yielded an iron ore concentrate
of 63% Fe at an iron recovery of 68% under statistically
optimized conditions such as temperature: 850°C, time:
90 min and blast furnace flue dust to ore ratio: 0.4 (Rath
et al. 2018). Sun et al. proposed a green magnetization roast-
ing process by using siderite (FeCO3) as the reductant. The
influences of the siderite dosage, roasting temperature and
roasting time on the magnetization roasting process were
investigated. The optimal roasting conditions were deter-
mined to be a siderite dosage of 40% with a roasting tempera-
ture of 700°C and a roasting time of 10.0 min. Under optimal
conditions, an iron concentrate with 66.7% Fe content and
98.05% recovery was obtained by magnetic separation. In
another study, Ponomar et al. also prepared pure magnetite
powder from the mixture of natural siderite and hematite by
heating in air. Both siderite and hematite transformed into
magnetite, and the maximum saturation magnetization was
70 Am2/kg for a mixture in 1:1 ratio of hematite to siderite
obtained after heating at 600°C for 10 min, which agrees with
Sun’s findings (Lei et al. 2017). In order to provide a better
theoretical foundation for utilization of Xinjiang siderite
resources in China, Luo et al studied its thermal decomposi-
tion behavior in neutral and oxidizing atmospheres. They
found that siderite has self-magnetization characteristics
under controlled conditions, and the phase transformation
process in weak oxidizing atmosphere follows the steps as:
FeCO3→Fe3O4→γ-Fe2O3 at 550°C, and FeCO3→FeO+Fe3O4
→Fe3O4→γ-Fe2O3→α-Fe2O3 at 800°C (Luo et al., 2016d). In
inert atmosphere, the decomposition pathway is FeCO3→Fe3
O4 below 733°C and FeCO3→FeO+Fe3O4 above 733°C. Also,
Chun et al found that simultaneously roasting and magnetic
separation was an effective way to treat hematite and siderite
ores without adding any reductant. When the mixture with
a mass ratio of siderite to hematite of 80:20 roasted at 850°C
for 20 min, an iron concentrate assaying 61.6% Fe with
a recovery of 91.1% was produced after magnetic separation
(Chun et al. 2015). The thermal decomposition of siderite are
quite complex and depends on the roasting atmosphere. The
final product, generally, is hematite (Fe2O3) in an oxidizing
atmosphere (O2 or air), magnetite (Fe3O4) in a CO2 atmo-
sphere, and magnetite and wustite (FeO) in an inert atmo-
sphere (Chang and Ahmad ; Dhupe and Gokarn 1990). In an
inert atmosphere, wustite is first formed during the decom-
position of siderite, and finally transforms to magnetite
(Kissinger et al. 1956; Sun et al. 2019). The reactions can be
presented as the following:
FeCO3 ¼ FeO þ CO2 ;Δr Gθ ¼ þ74; 893  180:77T; J mol1
(4)
3FeO þ CO2 ¼ Fe3 O4 þCO;Δr Gθ ¼ 106; 164 þ 120:48T; J mol1
(5)
Because wustite is an intermediate phase, thus the decompo-
sition of siderite (FeCO3) in an inert atmosphere can be
described in Eq. (6):
3FeCO3 ¼ Fe3 O4 þCO þ 2CO2 ;Δr Gθ ¼ 206; 985  494:37T; J mol1
(6)
During the simultaneously roasting of siderite and hematite in
an inert atmosphere, siderite transforms to magnetite along
with producing CO (see Eq. (6)) and hematite needs CO to
reduce into magnetite (see Eq. (1)). Therefore, simultaneously
roasting is an economical process to treat low grade hematite
and siderite ores, and also reduce the emission of CO2 because
no reductant is added. In addition, the co-roasting reaction of
hematite and siderite is summarized as Eq. (7). The Gibbs free
energy of this reaction is negative at temperatures above
290 K, indicating the reaction is easy to take place.
FeCO3 þFe2 O3 ¼ Fe3 O4 þCO2 ;Δr Gθ ¼ 51; 618  178:49T; J mol1
(7)
In some cases, some biomass instead of coke or coal were used
as reductant during magnetization roasting of refractory iron
ores. Wu et al. used pine sawdust as reducing agent, and
investigated the effects of reduction temperature, reaction
time and dosage of pine sawdust on the magnetism of the
goethite ore in a muffle furnace. The magnetic susceptibility
could be enhanced 30 times than the raw goethite ore when it
roasted at 550°C for 30 min with 20% pine sawdust, and the
ferromagnetic percentage is more than 96%, achieving a good
magnetization (Wu et al. 2012). Zhang et al. used a biomass
containing 13.4% fixed carbon as reducing agent to roast
a low-grade limonite ore (TFe 33.58%) from Baotou in
a muffle furnace, and found that limonite is first dehydrated
to α-Fe2O3 at high temperature, and then it is reduced to Fe3
 MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW 5

O4 by biomass. The optimal saturation magnetization reached Ore powder

60.13 emu/g after roasting at 550°C for 30 min with 15% Off-gas
biomass, resulting in a magnetic concentrate of 58% Fe with
a recovery of 72% (Zhang et al. 2017). Cyclone
Compared to the shaft furnace, the roasting and separation
performance of ore in rotary kiln are better. However, the
average energy consumption associated with rotary kiln roast-
ing is up to 60 kg standard coal per ton of raw ore, which is Cyclone
Draft fan
42% higher than that of shaft furnace roasting (Xue et al.
2011). What’s worse, the kiln coating induced by the forma- Dust collector
tion of some low-melting substances such as fayalite during
roasting process will affect the yield of iron resource. Very
Cyclone
currently, the longest good running period for a rotary kiln is
only 30 ~ 75 days. Thus, the high roasting energy consump-
Solid flow
tion and the clinker ring forming are still the main problems Cyclone
that need to be solved for magnetization roasting in rotary Gas flow
kiln.

Reactor

2.3. Fluidized bed roasting

In the fluidized bed furnace, the solid material to be roasted is Coal/air
shaken up by an upward current of gas which maintains the Roasted ore
Burner
individual particles in suspension. Precise adjustment of the
velocity of the gas to the grain size and the specific weight of Figure 3. Sketch of the flash magnetization roasting process.
the material to be roasted makes it possible to generate
a floating mixture of gas and solids which behave almost
like a liquid. The process is reported to have the following Table 1. Magnetic separation results of typical refractory iron ores after flash
magnetization roasting.
advantages over the other roasting techniques: ease of control
Ore type Product Weight % Fe % Recovery %
due to absence of moving parts within the reactor, homoge-
Limonite ore from Jiangxi Concentrate 61.9 60.3 94.3
neity of discharge products, ability to handle fine particles (＜ Tailing 38.1 5.9 5.7
0.8 mm) and high efficiency of heat transfer and mass transfer Roasted ore 100 39.6 100
(Uwadiale 1992). Since the 1950s, fluidized roasting has been Siderite ore from Shanxi Concentrate 40 56.8 84
Tailing 60 7.2 16
widely studied in the field of iron ore magnetization roasting. Roasted ore 100 27.1 100
Currently, fluidized magnetization roasting is the most pro- Siderite ore from Kunming Concentrate 59.6 57.1 90.7
Tailing 40.4 8.6 9.3
mising approach for handling refractory weakly magnetic iron Roasted ore 100 37.5 100
ores, and has become a research hotspot in recent years. Oolitic hematite ore from Hubei Concentrate 64.4 56.5 82.2
Tailing 35.6 22.1 17.8
Yu et al. invented a new process of flash magnetization Roasted ore 100 44.3 100
roasting for refractory iron ores (＜0.5 mm). This technique Limonite ore from Hubei Concentrate 50.9 60.7 94.5
featured high reduction temperature (750 ~ 950°C), low CO Tailing 49.1 3.7 5.5
Roasted ore 100 32.7 100
concentration (0 ~ 5 vol.%) and short roasting time (0 ~ 60 s).
As shown in Figure 3, the iron ore powder was preheated in
countercurrent with the hot off-gas from the reactor via three
cyclone stages. The hot combustion gas (about 750 ~ 950°C), beneficiation methods including magnetic separation, gravi-
containing 0 ~ 5 vol.% CO produced by the combustion of metric separation and flotation.
coal, converted hematite, limonite or siderite within the ore Zhang et al. conducted a semi-industrial test on flash
into magnetite quickly, and the retention time of ore powder magnetization roasting of a siderite tailing (TFe 15.1%) from
in the reactor was estimated to 5 ~ 60 s (Yu and Chen 2010; Daxigou Iron Mine. After roasting at 740°C with 1.0 vol.%
Yu and Qi 2011; Liu et al. 2017; Chen et al. 2017). However, oxygen, the iron grade of ore can be upgraded to 53.3% with
both the heating and the reduction of the ore were simulta- a recovery of 70.5% after magnetic separation (Zhang 2011).
neously performed in the reactor. Hence, the reductive atmo- Yao et al. carried out a pilot-scale flash magnetization roasting
sphere in the reactor was hard to be controlled. What’s worse, test for the beneficiation of a cyanide tailing (TFe 27.3%), and
iron ore fines are prone to sintering at high temperatures found that the magnetic concentrate could be increased to
(750 ~ 950°C), resulting in crusting on the inner wall of the 55.6% with a Fe recovery rate of 81.9% after roasting at 800°C
reactor and failure to produce normally. with 1.0 vol.% carbon monoxide (Yao 2012). In another study,
Table 1 shows the magnetic separation results of some Boehm et al. used a device shown in Figure 4 to investigate
typical refractory iron ores after flash magnetization roasting. mineral selective magnetizing flash roasting of siderite ore. It
For these ores, the iron grade only can be upgraded to was found that flash roasting in a weak oxidizing atmosphere
40 ~ 50% with a recovery of 50 ~ 60% by conventional (12 vol.% O2) was tested successfully for the improved low
6 J. YU ET AL.
Feed
< =0.8mm
FM
+
Magnetics
Iron oxides
Non-magnetics
Ankerite,
Quartz,...
Calcined product
Figure 4. Schematic of the calcination system by means of cyclone preheater and calcination loop followed by low intensity magnetic separation.
intensity magnetic separation of siderite from ankerite and
other gangue minerals within the ore, and a dry magnetic
concentrate bearing 56% Fe with a recovery of 80% was
obtained after roasting (Boehm et al. 2014).
Zhu and Li developed a multistage circulating fluidized bed
magnetization roasting process for the beneficiation of weakly
magnetic iron ores. This technique featured low roasting
temperature (about 450°C), and multilevel fluidized reduction
roasting. They performed a pilot-scale multi-level fluidized
magnetization roasting test for the beneficiation of
a Yunnan limonite ore with 33% Fe. After roasting and
magnetic separation, the iron grade of ore can be upgraded
to 57% with a recovery rate of 95%. Furthermore, the roasting
energy consumption was only 36 kg standard coal per ton of
raw ore (Zhu and Li 2014). Zhou et al. investigated the
magnetization performance of an oolitic iron ore (TFe
44.6%) from Yunnan via a laboratory fluidized bed reactor,
and found that the magnetic concentrate could only be
increased to 55% with a Fe recovery rate of 70% after direct
fluidized bed roasting. While, with a pre-calcination process
prior to magnetization roasting, an iron concentrate with
60.2% Fe with a recovery of 85.9% was successfully produced
(Zhou et al. 2009). Yu et al. performed a magnetization roast-
ing experiment via a laboratory-batch scale fluidized reactor
for the beneficiation of an Anshan-type hematite ore (TFe
41.6%). The ore powder (70% passing 0.074 mm) roasted at
650°C with 3.2 m3/h H2 and 4.8 m3/h N2 for 15 s, resulting in
a magnetic concentrate assaying 65.4% Fe with a recovery of
88.1% at a magnetic field of 80 kA/m (Yu et al., 2018). Zhao
et al. studied the beneficiation of siderite fines containing high
Off-gas
Hot combustion gas
levels of carbonates using a combined fluidized-bed magnetiz-
ing roasting process. The siderite was almost completely con-
verted into magnetite under the optimum conditions of
preheating at 550°C for 30 s followed by magnetic reduction
roasting at 550°C for 60 s at 0.5 m/s gas fluidization velocity
in a 13.3% CO + 6.7% H2 + 80% N2 atmosphere. Thus, a high-
grade magnetic concentrate containing 62.6% iron grade with
an iron recovery of 89.2% was achieved (Zhao et al. 2019). Li
and Zhu investigated the separability of a low-grade hematite
ore from Tangshan via laboratory-scale fluidized bed magne-
tizing roasting. The best separation results occurred when the
applied magnetic field was 120 kA/m and the particle size was
−0.048 mm, with the iron grade of the concentrate being
62.5% and the recovery rate being 91.1% (Li and Zhu 2012).
Li et al. investigated the phase transformation of an oolitic
hematite ore during fluidized reduction roasting, and found
that hematite within the ore was almost completely reduced to
magnetite by H2 at 650°C. Higher temperature could lead to
over-reduction of magnetite, forming weakly magnetic wus-
tite. Hence, the highest iron content of 58.7% and iron recov-
ery of 84.0% were achieved by magnetic separation at the
roasting temperature of 650°C (Li et al. 2015). Li et al. treated
the iron ore tailing of the Anshan mining area with labora-
tory-scale fluidized magnetizing roasting and low-intensity
magnetic separation. The results indicated that an iron con-
centrate with an iron grade of 65.3% and a recovery of 85.8%
could be produced under the conditions of gas-flow rate of
8 m3/h, H2 concentration of 50%, and fluidized magnetizing
roasting at 600°C for 20 s. The hematite and limonite within
the tailing were transformed into magnetite during the

fluidized magnetizing roasting process, thus it could be easily
separated from gangues by magnetic separation (Li et al.
2019).
An innovative suspension (fluidized) roasting process for
magnetizing of refractory iron ores based on the technical
route of preheating followed by heat-retaining reduction and
re-oxidization was created by Prof. Han and his academic
team (Gao et al. 2018; Yu et al. 2018a, 2018b). As shown in
Figure 5, The iron ore powder (＜0.8 mm) was preheated by
the hot off-gas originally from the burner, and then entered
into the pneumatic carrier through a cyclone. The hot gases
(about 700 ~ 900°C) produced by the combustion of natural
gas simultaneously heated and transported the iron ore pow-
der to the gas-solid separator (the second cyclone) where the
siderite (FeCO3) and limonite (Fe2O3·nH2O) within the ore
were thermally oxidized or decomposed to hematite (Fe2O3).
The heated hematite within the ore fell into the reactor and
reacted with room temperature reducing gas CO or H2 to
form magnetite in the range of 450 ~ 600°C. After magnetic
reduction roasting, the mixed gas transported the iron ore
powder to the cooler where partial artificial magnetite (Fe3O4)
was re-oxidized to ferromagnetic maghemite (γ-Fe2O3) by air
in the range of 200 ~ 350°C. Meanwhile, the preheated air
with residual CO or H2 entered into the heating furnace and
burnt for heating ore. Finally, the iron oxides within the
roasted ore could be successfully be recovered by magnetic
separation after liberating from gangue minerals.
Dust collector
Ore powder
Cyclone
Screw feeder
Off-gas
Cyclone
Induced draft fan pneumatic carrier Fluidized reactor
Gas inlet CO/H2+N2
Burner
Cooler
Ball mill
Magnetic
Roasted ore
separator
Tailing
Concentrate
Figure 5. Sketch of suspension magnetization roasting followed by magnetic
separation apparatus and general procedure.
MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW 7
Yu et al. used a pilot-scale suspension (fluidized) roasting
system with a throughput of 150 kg/h to enhance magnetic
properties of a carbonate-bearing hematite ore from
Donganshan Sintering Plant, and found that the hematite
was almost completely reduced to magnetite by a gas mixture
of 4 m3/h CO and 1 Nm3/h N2 at a roasting temperature of
540°C. Therefore, a high grade concentrate containing 66.8%
Fe with a recovery rate of 91.2% was produced after magnetic
separation (Yu et al. 2018a). Also, they used the same roasting
conditions to treat an iron ore tailing, and obtained
a magnetic concentrate assaying 61.4 wt% Fe with a recovery
rate of 81.8% (Yu et al. 2018b). Furthermore, some other
difficult to treat iron ores were subjected to pilot-scale sus-
pension magnetization roasting followed by low-intensity
magnetic separation studies, and the beneficiation perfor-
mance are shown in Table 2. For these ores, the iron grade
can be upgraded to more than 60%, and iron recovery is
greater than 85% by suspension magnetization roasting fol-
lowed by low-intensity magnetic separation (SMR-
LIMS) (Yu et al. 2018c).
Zhang et al. carried out a pilot-scale suspension magnetization
roasting for beneficiation of refractory iron ore from Jingtieshan
Mine. The results showed that with the appropriate roasting
conditions – a roasting temperature of 520°C, CO flow rate of
4.0 m3/h, N2 flow rate of 2.0 m3/h, and feeding rate of 100 kg/h –
an iron concentrate with a total iron grade of 60.1% and iron
recovery of 90.1% could be obtained. Compared to the traditional
process of shaft furnace magnetization roasting followed by mag-
netic separation, the novel technique developed here could
improve the TFe and iron recovery of the iron concentrate by
12 ~ 14% and 17 ~ 22%, respectively. During the suspension
magnetization roasting process, hematite and siderite were suc-
cessfully transformed into magnetite or maghemite, which
enhanced the magnetism of the iron minerals (Zhang et al.
2019). This innovative suspension magnetization roasting tech-
nology has been applied in Jiuquan Iron& Steel (Group)
Corporation (JISCO), and an industrial production line of
1.65 million t/a for beneficiation of specularite ore was built (see
Figure 6), which provided a demonstration for the efficient use of
refractory iron ore resources. At present, it is in the stage of
industrial production debugging.
2.4. Microwave assisted roasting
Microwave roasting is a new field of magnetization roasting
research. It is unique and different from conventional heating.
Microwave is a non-ionizing form of electromagnetic wave
with frequency ranging from 300 MHz to 300 GH, which can
be absorbed by dielectrics (Song et al. 2014). Thus, microwave
radiation roasting is also referred to as dielectric heating. The
interaction of dielectric minerals (such as siderite, hematite,
limonite and pyrite) with microwave radiation results in
dielectric minerals heating due to the ionic conduction and
dipolar rotation in dielectric minerals induced by alternating
microwave electromagnetic field. Compared with conven-
tional roasting techniques (shaft furnace roasting, rotary kiln
roasting et al.), microwave radiation roasting is unique and
offers a number of advantages such as rapid heating, non-
contact heating, material-selective heating, volumetric heating
8 J. YU ET AL.
Table 2. Beneficiation performance of some difficult to treat iron ores using pilot-scale suspension magnetization roasting followed by magnetic separation.
Existing process
Ore type TFe/%
Jingtieshan specularite ore 59 ~ 60
Shilu hematite ore 62.5
Tonkolili limonite ore 56
Figure 6. Industrial suspension magnetization roasting system with a throughput of 1.65 million t/a for beneficiation of specularite ore in JISCO.
and non-pollution (Clark et al. 2000). Furthermore, findings
of recent investigations revealed that microwave assisted heat-
ing had a significant influence on the magnetic properties of
iron ores, such as hematite, pyrite, ilmenite, and siderite.
Omran et al. carried out a comparative study between
untreated and microwave roasted oolitic hematite ores. It
was found that fractional Fe3+ within hematite were reduced
to Fe2+ in the form of magnetite after microwave irradiation,
which was confirmed by high resolution XPS and XRD ana-
lyses. In addition, the reducing agent for the transformation of
hematite into magnetite might be chamosite due to its char-
acteristic XRD diffraction peaks disappeared after microwave
heating, and the saturation magnetism of ore was increased
from 0.50 to 2.48 emu/g after microwave irradiation (Omran
et al. 2014, 2015).
Barani et al. studied the effect of microwave roasting on the
magnetic properties of an iron ore sample consisted of 64%
magnetite, 34% hematite and 1% quartz. The results demon-
strated that an over long period of roasting in microwave field
had a negative influence on magnetic properties of ores and
an irradiation time of 60 s was enough for the magnetization
of the ore. Moreover, the increase of magnetic susceptibility
could be attributed to transformation of weakly magnetic
hematite into ferromagnetic maghemite induced by micro-
wave radiation (Barani et al. 2011).
Znamenáčková et al. investigated the influence of micro-
wave radiation on phase transformation of siderite. With the
prolonging of microwave radiation, siderite was initially
SMR-LIMS Increased by
Recovery/% TFe/% Recovery/% TFe/% Recovery/%
76 ~ 78 60.5 91.36 0.5 13 ~ 15
60 ~ 65 65.58 85.56 3 20 ~ 25
– 64 ~ 65 95 ~ 98 8~9 95 ~ 98
decomposed to magnetite, then to wustite, and finally to
metallic iron, which was confirmed by X-ray diffraction ana-
lysis and local microanalysis. Therefore, the selective conver-
sion of siderite to magnetite can be achieved by controlling
the microwave radiation time. Meanwhile, the results showed
that a magnetic concentrate containing 45.6% Fe with
a recovery rate of 97.6% was produced after microwave roast-
ing followed by magnetic separation (Znamenáčková et al.
2005).
Wu et al. investigated the phase transformation and mag-
netic properties of a limonite ore assaying 40.1% Fe via
microwave roasting with alkali lignin additive, and found
that goethite and hematite within the ore could be selectively
reduced to magnetite by alkali lignin in the following
sequence during microwave roasting process: FeOOH/α-Fe2
O3→γ-Fe2O3→Fe3O4, achieving effective magnetization of
the limonite ore (Wu et al. 2017).
Rath et al. compared the effects of microwave-assisted
roasting and conventional roasting on magnetic separation
of a complex Indian hematite ore with 57% Fe. The results
demonstrated that the furnace roasting route yielded an mag-
netic iron concentrate of 63 ~ 64% Fe at 88 ~ 90% weight
recovery, while the microwave roasting yielded 62 ~ 63% Fe at
84 ~ 85% weight recovery. However, the microwave roasting
had a tremendous potential to produce an equally good
roasted product in a shorter period of time accompanied by
a lesser formation of undesired products like fayalite as com-
pared to the conventional roasting (Rath et al. 2016).
 MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW 9

Table 4. Salient features of different magnetic reduction roasting process. Based on the above analysis and discussion, the merits and
Roasting reactor Industrial scale Ore size/ Iron Energy demerits of the furnaces discussed are shown in Table 3, and
type level mm recovery consumption the salient features of different magnetization roasting pro-
Shaft furnace 25t/h 15 ~ 75 ~70% ~46 kgce/t cesses are summarized in Table 4. Compared with other
Rotary kiln 45t/h 0 ~ 25 ~75% ~60 kgce/t
Fluidized bed 200t/h 0 ~ 0.8 ＞85% ~36 kgce/t magnetization roasting methods, the fluidized bed magnetiza-
Microwave oven Laboratory scale - - - tion roasting may be the most effective and promising
approach for the beneficiation of refractory iron ores due to
its lower energy consumption, higher iron recovery and larger
processing scale.
Several researchers have investigated the effect of microwave
heating on phase change and magnetic separation of pyrite
(Uslu et al. 2003; Waters et al. 2007; Xing et al. 2017).
According to the reported results, the microwave treated pyrite 3. Conclusions
was firstly converted to ferromagnetic pyrrhotite, and then to Magnetization roasting methods include shaft furnace
troilite under a nitrogen atmosphere. With the prolonging of roasting, rotary kiln roasting, fluidized bed roasting, and
microwave radiation time, the pyrite was initially transformed microwave assisted roasting. Shaft furnace roasting is gra-
to ferromagnetic pyrrhotite, then to anti-ferromagnetic hema- dually eliminated due to its high energy consumption and
tite (α-Fe2O3), and finally to ferromagnetic maghemite (γ-Fe2 low industrial processing capacity, and the primary pro-
O3) in air. Thus, the performance of magnetic separation in blem for rotary kiln roasting is the kiln coating which
removing mineral pyrite from coal was improved due to the affects the yield of iron resource and its industrial applica-
magnetic enhancement of pyrite induced by microwave tion. Suspension (fluidized) magnetization roasting is
radiation. recognized as the most effective and promising technology
Although none of these alternative microwaves assisted due to its high reaction efficiency, low energy consumption
roasting techniques have been implemented successfully on and large processing capacity. Moreover, an industrial pro-
a semi-industrial or industrial scale, it is the need of the hour duction line with a throughput of 1.65 million t/a for
to conduct extensive laboratory scale research and make these beneficiation of a specularite ore has been built.
processes feasible for practical applications. As a new area of Microwave assisted roasting is a potential alternative tech-
research in iron ore processing, microwave heating is unique nology for magnetizing iron ores. However, it is currently
and different from conventional heating. Its excellent advan- limited to laboratory research and has no industrial appli-
tages are rapid and selective heating, environmentally friendly cation. Forwarding microwave assisted magnetization roast-
application, and high efficiency. Much more attention should ing methods into industrial applications needs long way
be payed to the microwave assisted roasting research for and time to achieve.
a better and further progress into iron ore magnetization. In Furthermore, using biomass, H2 or siderite as a reducing
particular, the problem of engineering amplification of micro- agent in the magnetic reduction roasting of iron ores is
wave magnetization roasting for beneficiation of refractory a beneficial way to reduce carbon emissions, which can be
iron ores needs to be solved. called clean and green magnetization roasting technology. In
the future, technical research on clean and green magnetiza-
tion roasting should be strengthened. Maybe microwave mag-
Table 3. Merits and demerits of different magnetic reduction roasting furnaces. netization roasting using biomass/H2/siderite as reductant can
Furnaces Merits Demerits be further studied for a more effective and greener magneti-
Shaft furnace Handle massive ore with Low processing capacity zation of iron ores.
a granularity of (25t/h); Long roasting time
15 mm ~ 75 mm (6 ~ 10 h); Chemically
heterogeneous roasted ore
Rotary kiln Roasting and separation Low processing capacity
performance of iron ores in (45t/h); High roasting
Disclosure statement
rotary kiln are better than shaft energy consumption; The authors report no conflicts of interest. The authors alone are
furnace Clinker ring forming responsible for the content and writing of the article.
Flash High reduction temperature Low processing capacity
roasting (750 ~ 950°C); Low CO (70t/h); Reductive
furnace concentration (0 ~ 5 vol.%); atmosphere in the reactor is
Short roasting time (0 ~ 60 s) hard to be controlled
Multi-stage Low reduction temperature Low processing capacity
Funding
circulating (450°C); Low roasting energy (12t/h); Multi-level fluidized
fluidized consumption (about 36 kgce/t) reduction roasting
This work was supported by the National Natural Science Foundation of
bed China [Grant No. 51734005, and 51674064], China Postdoctoral Science
Suspension Low reduction temperature High CO or H2 concentration Foundation [Grant No. 2018M631812] and Open Foundation of State
roasting (450 ~ 600°C); Large processing (>60 vol.%) Key Laboratory of Mineral Processing [Grant No. BGRIMM-KJSKL
furnace capacity (200 t/h); Low roasting -2019-09].
energy consumption (<42 kgce/
t); Efficient recycling of energy
Microwave Rapid heating; Non-contact Currently, it is limited to
oven heating; Material-selective laboratory research without
heating; Volumetric heating semi-industrial or industrial ORCID
and non-pollution applications Jianwen Yu http://orcid.org/0000-0002-6050-0192
10 J. YU ET AL.
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