International Journal of Mineral Processing 122 (2013) 47–53

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International Journal of Mineral Processing

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Characterisation and separation studies of Indian chromite beneficiation plant tailing

Sunil Kumar Tripathy ⁎, Y. Rama Murthy, Veerendra Singh
Research and Development Division, Tata Steel Ltd., Jamshedpur, India

a r t i c l e i n f o a b s t r a c t

Article history: Detailed characterisation and recovery of chromite from the beneficiation plant tailing of Sukinda, India, was
Received 19 October 2012 investigated. Different characterisation techniques viz. size analysis, size-wise chemical analysis, size-wise
Received in revised form 15 April 2013 density measurement, X-ray diffraction analysis, heavy liquid separation, scanning electron microscopy,
Accepted 20 April 2013
mineral analysis by QEMSCAN and thermo gravimetric analysis were carried out. Based on the results, two
Available online 2 May 2013
flow sheets comprising gravity, magnetic separation and flotation, were used to recover chromite values. A
Keywords:
chromite concentrate of 45.0% Cr2O3 with a Cr:Fe ratio of 2.3 can be produced from the tailing analyzing
Chromite Beneficiation 17.0% Cr2O3 and Cr:Fe ratio of 0.49.
Plant Tailings © 2013 Elsevier B.V. All rights reserved.
Characterisation
Beneficiation
Flow Sheet Development

1. Introduction 2. Materials and methods

Chromite is the main source for chromium metal and chemicals
and for use in refractories. Based on certain physical and chemical
properties, the ore is classified for different users. The total chromite
deposits of the world and beneficiation prospects have been
described by various authors (Atalay and Ozbayolu, 1992; Guney et al.,
2001; Murthy et al., 2011). India is the world's third largest producer
of chromite ore and produces about 3.5–4 MTPA. The estimated reserve
of chromite deposit in India is about 187 MT. About 98% of the reserves
are from the Sukinda valley of Odisha, which is noted for its complex
mineralogy (Murthy et al., 2011). During the beneficiation of chromite
ore of Sukinda region, approximately 50% (by weight) of the total feed
is discarded as tailing which contains a significant amount of chromite.
Several studies have focused on reduction of chromite losses in the
beneficiation plant tailing (Rao et al., 1987; Raghukumar et al., 2009;
Tripathy et al., 2011). However, there is no specific study on the benefi-
ciation of Indian chromite plant tailing along with detailed characterisa-
tion. In the present investigation, two process flow schemes were
studied for the recovery of chromite values from the beneficiation
plant tailing of Sukinda along with detailed characterisation.
2.1. Characterisation studies
The tailing sample collected from a typical beneficiation plant of
Sukinda region of India had the following assay values: 17.0% Cr2O3,
23.9% Fe(T), 24.4% Al2O3, 11.3% SiO2, 3.6% MgO and 8.7% loss on igni-
tion (LOI). The Cr-to-Fe ratio of the tailing sample is 0.49. Further,
the tailing sample was subjected to particle size analysis, size-wise
chemical analysis and size-wise density analysis. The results are
given in Table 1. XRD study of the tailing sample is shown in Fig. 1.
Thermo-gravimetric analysis (TGA) was carried out to confirm the
presence of different oxide/hydroxide minerals, and the results are
shown in Fig. 2. Sink-float analysis was carried out for each size frac-
tion with a heavy liquid of density 2810 kg/m 3 (Bromoform), and the
results are given in Table 2. Prior to the mineral analysis, elemental
analysis was carried out for different minerals by using SEM-EDX
and images along with micro-analysis are shown in Fig. 3. Mineral
analysis was carried out by using QEMSCAN to quantify different min-
eral phases in the tailing and the results are tabulated in Table 3. Fur-
ther, liberation analysis for the chromite and gangue minerals in the
tailing are also analysed in Fig. 4.

2.2. Beneficiation studies

Based on the findings of the characterisation studies, two different

⁎ Corresponding author at: Iron and Ferro Alloys Research Group, Research and
Development Department, TATA STEEL, Burma Mines, Jamshedpur, JH 831 007, India.
Tel.: +91 657 214 8960, +91 92040 58167 (mobile); fax: +91 657 227 1510.
E-mail address: sunilk.tripathy@tatasteel.com (S.K. Tripathy).
process flow sheets were conceptualized. The first flow sheet was
designed with a combination of gravity concentration and magnetic
separation. The second flow sheet included gravity separation, mag-
netic separation and flotation. Classification and gravity separation
were carried out using a hydrocyclone (diameter of 25, 50 mm) and

0301-7516/$ – see front matter © 2013 Elsevier B.V. All rights reserved.
http://dx.doi.org/10.1016/j.minpro.2013.04.008
48 S.K. Tripathy et al. / International Journal of Mineral Processing 122 (2013) 47–53

Table 1 particles with size b 355 μm have a higher density. It is also observed
Particle size, chemical and density analyses of chromite beneficiation plant tailing. that higher density particles segregated at intermediate size fractions,
Size (μm) Wt. (%) Density Assay value (%) and the same was also replicated from size-wise chemical analysis.
retained (g/cc) The diffractogram of the XRD analysis of the tailing sample is
Cr2O3 Fe(T) Al2O3 SiO2
depicted in Fig. 1, which revealed that chromite, goethite, hematite,
+500 10.1 2.88 10.6 26.7 27.8 14.4
gibbsite, quartz and kaolinite are the mineral phases present in the
−500 + 355 5.6 2.95 10.9 25.1 28.2 12.6
−355 + 250 17.7 3.41 11.8 25.5 27.6 12.3 tailing. The weight loss graph with respect to temperature was
−250 + 150 27.5 3.40 17.1 21.8 23.6 12.8 measured in Thermo Gravimetric Analyser and depicted in Fig. 2. It
−150 + 105 16.4 3.51 23.2 21.5 23.2 10.7 is evident from Fig. 2 that there is a weight loss of about 2% due to
−105 + 75 5.8 3.64 24.8 26.5 22.0 8.8 the moisture content, which is shown as region ‘a.’ Above 200 °C, a
−75 + 53 2.5 3.61 23.2 22.1 24.0 7.4
−53 + 37 4.6 3.70 23.9 22.1 23.2 7.7
weight loss of about 6% may have been due to the presence of
−37 + 25 1.8 3.45 16.1 38.3 14.4 8.6 goethite and gibbsite. These two minerals reduce to hematite
−25 7.9 3.23 16.7 25.4 20.6 6.9 and boehmite, respectively, at this temperature zone (regions ‘b’
and ‘c’). At this temperature, kaolinite also decomposes to meta-
kaolinite. It is also seen that at > 700 °C, the weight loss is marginal.
a multi-gravity separator (MGS) of C900 model, respectively. Both cy- So the total weight loss is about 8%, which is resembled with the
clone and MGS were supplied by Richard Mozley Ltd (Redruth, UK). LOI value. Size-wise sink-float studies were carried out by using
Floatex density separator (FDS) was the LPF-0230 model and sup- bromoform (density of 2.88 g/cc) to quantify the heavy (>2.88) and
plied by Outokumpu Technology Inc.(Jacksonville, USA), whereas light (b 2.88) mineral content in the tailing sample. This heavy liquid
the Wilfley table was (model no. 15S) was supplied by the Deister separation study indicates that the quantity of lighter minerals is
Concentrator Company Inc., USA. Magnetic separation studies were 28.17% in the tailing (Table 2). It is also reported that the content of
carried out using both laboratory dry induced roll magnetic separator low-density minerals decreases with particle size. The maximum
(IRMS) supplied by the Readings of Lismore, Australia, and laboratory quantity (51.76%) of float is reported at >500 μm, indicating the
wet high intensity magnetic separator (WHIMS) supplied by the presence of a higher quantity of low-density gangue, whereas mini-
Rapid Box Mag separator, UK. Flotation was carried out using a mum content (0.35%) reported at b25 μm size fraction. It is believed
Denver D-12 sub-aeration flotation cell supplied by Denver Equip- that the floated material mainly consists of free quartz, gibbsite, kao-
ment Company, Colorado. Optimised test results were considered linite, iron silicate minerals (olivine group minerals) and serpentine
for the flow sheets, and these flow sheets along with mass balance as well as these minerals in their locked forms with other minerals
data are given in Figs. 5 and 6, respectively. including chromite, hematite and goethite in different proportions.
Several tailing sample moulds were prepared and processed in the
3. Results and discussion SEM-EDX, and a few salient micro-graphs along with the elemental
analysis are narrated in Fig. 3. It can be seen from Fig. 3a that the
3.1. Characterisation studies chromite minerals are euhedral in shape and have interstitial/micro
cracks in some grains (points 2, 5 and 6 of Fig. 3a). There are two dif-
Particle size distribution of the chromite tailing sample is given in ferent types of chromite grains which are present in the tailing. One
Table 1. The results show that the sizes of about 80% (by weight) of type of grain is rich in Cr values with minimum amounts of Fe, Al
the particles are b260 μm and 50% b190 μm. Chemical analysis given and Mg (point 1 of 3a), whereas the other one is rich in Fe, Al and
in Table 1 indicate that as the particle size decreased, Cr2O3 content Mg along with Cr (point 6 of 3b). Some of the gangue minerals are
increased up to 37 μm, and below that, it decreased. Further, the rich in Al along with Si (point 3 of Fig. 3a and point 2 of 3b), and
size-wise distribution of different radicals revealed that all the constit- these grains are believed to be kaolinite. In addition to this, there
uent were evenly distributed at all size fractions and the maximum are free iron-rich gangue minerals in the sample (point 1 of Fig. 3b).
quantity (70.76%) of the Cr2O3 was distributed in −355 + 75 μm Further, the micro cracks inside the chromite grains are observed in
size fraction. Size-wise density was measured by using 50 ml. The SEM-EDX and found that the cracks are filled majorly with Fe (point
standard density bottle and the values are also shown in Table 1. 2 of Fig. 3c). This impurity may be attributed to the weathering of
It can be observed that the coarser size fractions have a density chromite in the ultramafic belt. Further, QEMSCAN was used to ascer-
b3.0 g/cc, which indicates the abundance of gangue minerals whereas tain the mineral contents, the mineral inter-locking characteristics of
the chromite. The mineral composition of the tailing is tabulated in
Table 3 and found that goethite and Fe silicate–bearing minerals
10000 COB Plant Taily (Head)_R
are predominant in the tailing along with chromite. Elemental

0
a
-2
Counts

Wt (%) Loss

2500 -4

b
-6

c
-8

0
20 30 40 50 60 70 80 -10
0 200 400 600 800
Position (Degree 2 )
Temperature (0Cent.)
Fig. 1. X-ray diffraction (XRD) pattern of tailing sample with identified mineral phases
(▲: chromite, ■:hematite, ◆: kaolinite, ●: gibbsite, ✚: quartz, α: goethite). Fig. 2. Weight loss graph for the tailing sample.
 S.K. Tripathy et al. / International Journal of Mineral Processing 122 (2013) 47–53 49

Table 2 followed by separation studies for each stream with the combination
Results of heavy liquid separation of the tailing sample with bromoform. of the gravity concentration and magnetic separation. The second
Size (μm) Weight (%) Float, wt.% Float, wt.% (w.r.t.feed) flow sheet utilized floatex density separator as a classifier and
hydrocyclone (25 mm) for the desliming purpose, whereas the sepa-
+500 10.1 51.8 5.2
−500 + 250 23.3 37.3 8.6 ration studies were carried out in an enhanced gravity concentrator
−250 + 150 27.5 26.8 7.4 (MGS) and froth flotation along with the conventional gravity and
−150 + 105 16.4 25.6 4.2 magnetic separators. The details of the result of the flow sheets are
−105 + 75 5.8 29.7 1.7
discussed in subsequent sections.
−75 + 53 2.5 20.2 0.5
−53 + 37 4.6 6.7 0.3
−37 + 25 1.8 6.4 0.2 3.3. Separation flow sheet 1
−25 7.9 0.4 0.1
Total 100.0 28.2 The detailed flow sheet along with the mass balance and process
conditions for the flow sheet 1 is depicted in Fig. 5, and the details
about the processes are explained. Classification studies of the tailing
deportments for different elements are analysed and found that ap- sample were carried out in a 50-mm-diameter hydrocyclone for clas-
proximately 20% Fe is reported from chromite mineral due to its com- sifying the feed into two streams. Several tests were carried out by
plex chemical formula. Among the gangue minerals, Fe silicates and varying the operating variables of the hydrocyclone, and the men-
goethite are the major sources for contributing Fe in the tailing. Simi- tioned optimised conditions were considered for this flow sheet. It
larly, the segregation of Al is majorly from the chromite and goethite can be observed that the underflow stream of the cyclone is enriched
and partly from the kaolinite and gibbsite. Deportment for Si is to 20.9% Cr2O3 with a distribution of 43.6%. It can also be noted that
reported majorly from silicate-bearing gangue minerals as well as there is not much change in silica and alumina contents in both the
from Fe silicates. The size-wise liberation of the chromite and other stream products. Further, these two stream products obtained from
gangue minerals was analyzed, and the results (given in Fig. 4) show the hydrocyclone were subjected for separation studies.
that the free chromite is predominant at finer sizes (b 300 μm). This
may be due to the liberation size of the chromite particle in the ore 3.3.1. Concentration studies of hydrocyclone underflow stream
fed to the beneficiation plant. The classified underflow stream was subjected to a Wilfley table
From the above-detailed characterisation, it is confirmed that for the separation of lighter gangue minerals. Several tests were
most of the chromite minerals are distributed at the intermediate carried out by varying the deck tilt angle and wash water flow rate
size fraction. So the feed material has to be classified in two/three with constant feed pulp density and feed rate. The optimum conditions
stages and beneficiated separately due to its wider particle size distri- mentioned in the flow sheet were selected and results are depicted in
bution. By keeping this as the objective, two conceptualized flow the flow sheet. It may be noted that about 34.5% of the material
sheets were studied. The details of the results are discussed in the reported to the concentrate stream, which was 12.3% w.r.t. the original
next section. feed. The concentrate stream product was enriched to 32.4% Cr2O3 but
could not be used by any user, so further improvement of the concen-
3.2. Beneficiation studies trate stream was carried out in a high-intensity magnetic separator
(IRMS). The concentrate stream produced from the Wilfley table was
The two conceptualized flow schemes with two-stage classifica- treated in IRMS by exploiting the difference between the iron-rich min-
tion followed by separation were formulated for producing the metal- erals (hematite, goethite, and Fe silicates) and chromite. The optimized
lurgical grade concentrate (b 40% Cr2O3). In the first flow sheet, test conditions, mentioned in the flow sheet, were chosen for the flow
classification and desliming were carried out by hydrocyclones sheet where the Cr2O3 content was enriched to 42.6% in the middling

Fig. 3. SEM photomicrograph with microanalysis of different mineral grains.

50 S.K. Tripathy et al. / International Journal of Mineral Processing 122 (2013) 47–53
Table 3
Mineral analysis of the tailing sample.
Minerals
Chromite
Goethite
Hematite
Fe silicate
Kaolinite
Silicate
Gibbsite
Others
stream. Since the chromite mineral exhibits paramagnetic properties in
a magnetic field, hence the middling stream was enriched with chro-
mite mineral while iron-rich minerals (mass magnetic susceptibility
of hematite: 2025 m 3/kg × 10−9 and 315 m3/kg × 10−9 for goethite)
and silicate-bearing gangue minerals reported to the magnetic and
nonmagnetic streams, respectively. The iron and silica contents of the
middling stream were reduced to 19.5% and 3.4%, respectively.
3.3.2. Concentration studies of hydrocyclone overflow stream
The overflow stream of the classifying cyclone contains huge
quantity of the slime particle, which is abundant in iron-bearing
minerals, and so desliming of the material was carried out by
25-mm-diameter hydrocyclone by varying the main process vari-
ables such as spigot diameter, vortex finder diameter, feed pressure
and pulp density of the feed. The optimized conditions mentioned in
the flow sheet were chosen for the flow sheet. The overflow stream
which analysed 6.9% Cr2O3 was discarded as tailing and the
underflow stream enriched to 16.1% Cr2O3 with a yield of 86.7%.
The underflow of the deslimed cyclone was subjected to the Wilfley
table by varying the process variables, and the optimised results
along with the process conditions are depicted in the flow sheet. It
is observed that the concentrate stream was enriched to 26.4%
Cr2O3 with 14.5% yield (w.r.t. the original feed) at the mentioned
optimum conditions. The produced concentrate from the Wilfley
table was further subjected to WHIMS for further upgradation. Sev-
eral tests were conducted in WHIMS for the enrichment of the chro-
mite by discarding siliceous gangue minerals. Tests were conducted
by varying the applied current while the parameters, such as wash
water flow rate of 4 lpm, feed pulp density of 15% solids by weight,
were kept constant. It is observed that at optimum conditions, the
magnetic stream was enriched to 40.1% of Cr2O3 along with 22.5%
80
70
60
Mass Wt. (%)
50
40
30
20
10
0 free Silicate Minerals
+850
-850+500
-500+300
Size Fractions (Microns)
Fe. It can be observed that in magnetic separation both chromite
and iron-rich minerals reported to the magnetic stream, whereas
Wt.% diamagnetic particles of silicate-bearing minerals reported to the
nonmagnetic stream. So the target was made to discard siliceous/
36.9
26.2 iron-bearing silicates, and the details of the mass balance of the re-
1.4 sults are mentioned in the flow sheet. Further, reduction in the iron
24.1 content was found to be difficult in this process. This may be due to
2.7
the ultrafine particle size along with high near magnetic susceptibil-
4.6
1.5 ity of minerals.
2.6
3.4. Separation flow sheet 2
In the second flow sheet, the classification of the tailing was carried
out by using FDS whereas concentration was carried out by magnetic
separation for coarser fraction and a combination of enhanced gravity
separation and flotation for finer fraction. The classification of the tail-
ing was carried out in an FDS for classifying the feed into two streams.
Several tests were carried out by varying the key operating variables
such as teeter water flow rate and set point while keeping the others
constant (feed rate: 0.5 Tph of solids; and pulp density: 30% solids by
weight). The optimum condition (teeter water flow rate of 10 lpm
and set point of 42) was considered for the flow sheet, and the results
are mentioned the Fig. 6. The effect of different process variables and
their effect on particle classification were described in the previous
work (Raghukumar et al., 2009). It is observed that the underflow
stream was enriched to 22.6% Cr2O3 with a distribution of 52.83%. It is
also observed that at higher set point and intermediate teeter water
flow rate, the rejection of silica to overflow is maximum (78.7%). This
is due to the higher concentration criterion between chromite and
silicate-bearing minerals. It can also be noted that the alumina-bearing
minerals are also washed away to the overflow stream. But there is an
insignificant change in the iron content due to their equal settling
ratio under the same conditions.
3.4.1. Concentration of FDS underflow stream
The classified underflow stream of FDS was treated in the Wilfley
table for the separation of the light gangue minerals. Several tests
were carried out by varying the deck tilt angle and wash water flow
rate by keeping the other variables such as the feed pulp density
(15% solids by weight), feed rate (0.1tph) and shake amplitude
(15 mm) constant. The optimum conditions (6 lpm of wash water
flow rate and 3° of deck tilt angle) were chosen for the flow sheet,
and the results are depicted in it. The effects of different process
Locked chromite
Free Iron Minerals
Free Chtomite
-300+210
-210+150
-150+100 -100
Fig. 4. Liberation characterisation of the tailing.
 S.K. Tripathy et al. / International Journal of Mineral Processing 122 (2013) 47–53 51

Process TAILING SAMPLE 17.0 24.0

STREAM ID
Conditions VFD:35 mm
11.3 100
% Cr2O3 % Fe
SPD: 25 mm
FIP: 15 psi % SiO2 (%) Dist./Recovery
FPD: 10% sol.
HYDROCYCLONE(50 mm)

WWFR: 5 lpm
Underflow
20.9 20.7 14.9 25.8
DTA: 4 deg. Overflow
FPD: 10% sol 11.0 43.6 11.5 56.4 VFD:14mm
SA: 15 mm SPD: 6 mm
SFR: 0.1 tph FIP: 12 psi
FPD: 10% sol.
WILFLEY TABLE HYDROCYCLONE(25 mm)

Concentrate Middling Tailing Underflow Overflow

32.4 18.2 20.4 14.6 7.8 31.3 16.1 23.8 6.9 38.8
4.9 23.4 9.0 15.5 20.9 4.8 11.3 52.9 12.9 3.4 WWFR: 3 lpm
DTA: 4 deg.
FPD: 10% sol.
AC: 1.5 Amp. WILFLEY TABLE SA: 10 mm
RS: 100 rpm INDUCED ROLL SFR: 0.05 tph
SFD: 0.1 tph MAGNETIC SEPARATOR
Concentrate Middling Tailing
26.4 16.4 18.6 23.8 8.3 28.1
Magnetic Middling Non Magnetic 7.8 22.6 7.3 18.1 16.1 12.1
34.5 22.3 42.6 19.5 16.4 9.3
AC:10 Amp.
4.4 11.2 3.4 9.2 7.7 3.0
WET HIGH INTENSITY WWFR: 4 lpm
MAGNETIC SEPARATOR FPD: 10% sol.

Concentrate Magnetic Non Magnetic

41.4 20.9 40.1 22.3 21.9 14.5
3.9 17.7 4.4 8.5 9.0 14.1

Fig. 5. Beneficiation flow sheet 1 (VFD: vortex finder diameter, SPD: spigot diameter, FIP: feed inlet pressure, FPD: feed pulp density, WWFR: wash water flow rate, DTA: deck tilt
angle, SA: shake amplitude, AC: applied current, SFD: solid feed rate, RS: rotor speed).

variables and on chromite recovery from the plant tailing were stud-
ied in the previous work (Tripathy et al., 2011). It may be noted that
about 22% of the feed reported to the concentrate stream, which is
8.76% of the original feed at the optimum condition. It is believed
that the free iron and alumina-bearing minerals in FDS underflow
were in finer fraction and washed away by the higher wash water
flow rate. It can also be noted that about 5.2% silica present in the con-
centrate stream may have been in interlock form. The concentrate
product was enriched to 37.6% Cr2O3, which could not be utilized,
and so further improvement of the concentrate stream was carried
out by IRMS. The concentrate stream produced from the Wilfley
table was subjected to IRMS, and the optimum results along with
the optimum conditions are depicted in the flow sheet. The splitter
positions were adjusted in such a manner that the middling stream
was enriched with chromite-bearing minerals, whereas the magnetic
and the nonmagnetic streams were enriched with iron and silicate-
bearing minerals respectively. The Cr2O3 content of the middling
stream was enriched to 48.2% with a yield of 3.9% (w.r.t. original
feed).
3.4.2. Concentration of FDS overflow stream
As the overflow of the classifying cyclone contained a huge quan-
tity of the slime material, which was abundant in iron and
silica-bearing minerals (29.8% Fe and 28.9% SiO2), desliming of this
was carried out in a 25-mm-diameter hydrocyclone by varying the
process variables. The mentioned optimized conditions were chosen
for the flow sheet. The overflow stream which analysed 5.7% Cr2O3
was discarded as tailing, while the underflow stream was enriched
to 16.3% Cr2O3 with 72% yield, which was 43.4% of the original feed.
The underflow stream of the desliming cyclone was subjected to
Wilfley table and the optimised results along with the optimum con-
ditions are depicted in the flow sheet. It is observed that the concen-
trate stream was enriched to 23.6% Cr2O3 with 23.8% yield with
respect to the original feed at these optimum conditions. It is also ob-
served that a major amount of silica and alumina-bearing minerals
are discarded. The concentrate stream of the Wilfley table was
subjected to MGS for further improvement in the quality. A number
of tests were carried out in an MGS for separating the near-gravity
minerals at ultrafine size from chromite. The process variables stud-
ied were drum tilt angle and wash water flow rate by keeping other
variables constant (shake amplitude: 20 mm, drum speed: 150 rpm,
feed pulp density: 15% solids by weight). The mentioned optimized
conditions in Fig. 6 were chosen for the flow sheet which analysed
33.7% of Cr2O3 in the concentrate stream with an overall yield of
13.1%. It can be also noted that the product contained a very low
amount of silica, i.e., 1.6%. Hence, it is found to be effective for the sep-
aration of ultrafine silica-bearing gangue minerals. The details on the
effect of process variables on chromite separation are described in the
previous literature (Tripathy et al., 2012). The produced concentrate
from the MGS still contained huge quantities of iron-bearing minerals
(Cr:Fe ratio of 1.3). So an alternative technique, i.e., floatation study,
was carried out for the concentrate product of MGS to separate the
chromite by utilizing the difference between the surface properties
of chromite and the other minerals. Several tests were conducted by
varying the depressing agent dosage, along with collector/frother
dosage by keeping the others constant. Sodium silicate was used as
dispersing agent (0.1 kg/ton), acacia starch was used as depressing
agent and oleic acid was used as collector as well as frother. The
results of the optimized condition (1 kg/ton of solid of oleic acid)
were incorporated in the flow sheet, which envisaged that the
52 S.K. Tripathy et al. / International Journal of Mineral Processing 122 (2013) 47–53

TWFR: 10 lpm 17.0 24.0 STREAM ID

Process SP: 42 TAILING SAMPLE 11.3 100 % Cr2O3 % Fe
Conditions SFR: 0.5 tph % SiO2 (%) Dist./Recovery
FPD: 30% sol.
FLOATEX DENSITY SEPARATOR

WWFR: 6 lpm
DTA: 3 deg. 22.6 23.9 13.3 15.2 VFD:14mm
Underflow Overflow SPD: 6 mm
FPD: 15% sol. 6.1 52.8 14.8 47.2
SA: 15 mm FIP: 10 psi
SFR: 0.1 tph FPD: 10% sol.
HYDROCYCLONE(25 mm)
WILFLEY TABLE

Underflow Overflow
Concentrate Middling Tailing
16.3 21.7 5.6 29.8
37.6 15.2 23.6 19.9 13.8 31.9
9.4 41.6 28.9 5.6 WWFR: 3 lpm
5.2 19.3 11.0 20.0 2.2 13.5 DTA: 4 deg.
AC: 1.2Amp.
RS: 80 rpm FPD: 10% sol.
SFD: 0.1 tph SA: 10 mm
WILFLEY TABLE
INDUCED ROLL MAGNETIC SEPARATOR SFR: 0.05 tph

Concentrate Middling Tailing

SA: 20 mm
Magnetic Middling Non Magnetic 23.6 19.8 10.9 22.1 5.2 25.2 DS: 150 rpm
41.3 16.2 48.2 12.6 7.3 19.3 5.0 33.0 11.0 5.0 17.1 3.6 DTA: 4 deg.
3.4 7.4 WWFR: 6 lpm
7.7 11.2 2.7 0.7
SFR: 0.025 tph
FPD: 15% sol.
MULTI GRAVITY SEPARATOR

Concentrate Tailing
33.7 17.5 11.2 22.9
1.6 25.9 9.1 7.1
CD: 1 kg/ton
DAD: 0.8 kg/ton
FROTH FLOTATION FPD: 10% sol.
pH: 11

Concentrate Concentrate Tailing

45.0 13.4 42.5 14.1 28.3 19.6
4.1 24.7 1.3 12.4 1.9 13.5

Fig. 6. Beneficiation flow sheet 2 (VFD: vortex finder diameter, SPD: spigot diameter, FIP: feed inlet pressure, FPD: feed pulp density, WWFR: wash water flow rate, DTA: deck/drum
tilt angle, SA: shake amplitude, AC: applied current, SFD: solid feed rate, RS: rotor speed, pH: pH value, DAD: depressing agent dosage, CD: collector dosage).

product (froth) was enriched to 42.5% Cr2O3 with a yield of 37.9% and the recovery of the chrome vale can be increased further by grinding
Cr:Fe ratio of 2.07. and recycling of the middling fraction in each circuit. Further, mineral
analysis of both the products showed that the goethite content
3.5. Comparative analysis of flow sheets

The summary of the results for the flow sheet is tabulated in

Table 4
Table 4. In flow sheet 1, with the two-stage classification by
Summary of the results in both flow sheets.
hydrocyclone followed by conventional gravity concentration process
such as Wilfley tabling and magnetic separation by IRMS and WHIMS, Product Yield (%) Assay value Cr:Fe ratio
the product quality is enriched to higher than 40% Cr2O3, but the (%)
Cr2O3 SiO2 Al2O3
Cr:Fe ratio is b 1.8, which cannot be used in the metallurgical
Flow sheet 1
industry. In addition to this, the Cr2O3 recovery in this flow sheet is Hydrocyclone U/F 35.6 20.9 11.0 24.1 0.7
very less, which may not be economical in real time operations. In Wilfley table Con. 12.3 32.4 4.9 16.9 1.2
the case of the second flow sheet, the tailing was classified in an IRMS Mid. 3.7 42.6 3.4 15.2 1.5
Hydrocyclone O/F 64.4 14.9 11.5 24.6 0.4
FDS, which is an advanced hydraulic classifier and deslimed in a
Hydrocyclone U/F(finer stream) 55.9 16.1 11.3 25.7 0.5
hydrocyclone. As in the first flow sheet, the coarse stream (FDS U/F) Wilfley table Con.(finer stream) 14.5 26.4 7.8 22.6 1.1
was treated in the same circuit as in the flow sheet 1, but for the WHIMS Mag. 3.6 40.1 4.4 13.0 1.2
finer stream, enhanced gravity separator (MGS) and froth flotation Flow sheet 2
was incorporated for the selective separation of the chromite Floatex Density Separator U/F 39.8 22.6 6.1 22.9 0.6
Wilfley table Con. 8.8 37.6 5.2 12.0 1.7
particles. The concentrate stream was upgraded to 45.02% Cr2O3,
IRMS Mid. 3.9 48.2 7.7 10.3 2.6
having Cr:Fe ratio of 2.3 with 23.6% recovery. It is seen that with the Floatex density separator O/F 60.2 13.3 14.8 25.4 0.4
incorporation of MGS and froth flotation, the rejection of iron-bearing Hydrocyclone U/F 43.3 16.3 9.4 24.7 0.5
minerals increased which resulted in higher Cr:Fe ratio. In a real-time Wilfley table Con.(finer stream) 23.8 23.6 5.0 17.6 0.8
MGS Con. 13.1 33.7 1.6 14.8 1.3
operation, the Wilfley table results can be simulated in a multi-start
Flotation Con. 5 42.5 1.3 12.5 2.1
spiral concentrate to achieve the same quality. At the same time,
 S.K. Tripathy et al. / International Journal of Mineral Processing 122 (2013) 47–53
influenced the Cr:Fe ratio, whereas Fe silicate accounted for the silica
content.
4. Summary and conclusion
The generation of tailing in the Indian chromite beneficiation
plant is about 50% of the total feed. The tailing from chromite benefi-
ciation plant, Sukinda, India, was analysed 17.02% of Cr2O3, with Cr:Fe
ratio of 0.49. Particle size of the tailing is finer in distribution with 50%
(by weight) of the tailing is b190 μm. Liberated chromite particles are
at finer particle size (b300 μm), and the associated minerals are goe-
thite and Fe silicates such as olivine, pyroxene, etc. It was concluded
that silica content in the sample contributed majorly from Fe silicate
minerals, whereas Cr:Fe ratio was from the goethite.
Two different flow sheets comprised of two stages of classification
followed by separation was studied to recover the chromite. The first
flow sheet comprised of two-stage classifications, gravity concentra-
tion and magnetic separation, which produced the concentrate
assaying of 41.37% Cr2O3 and Cr:Fe ratio of 1.35. Moreover, the
second flow sheet comprised of two-stage classification and enhanced
gravity concentration along with the conventional gravity concentra-
tion, magnetic separation and froth flotation, which produced a concen-
trate, assaying 45.02% Cr2O3, with Cr:Fe ratio of 2.3. Hence, for the
53
improvement of the Cr:Fe ratio of the fine material, the incorporation
of enhanced gravity separator and froth floatation in the flow sheet is
essential. Recoveries (%Cr2O3) of the concentrate stream in both flow
sheets were 17.1% and 23.6%, respectively. However, further improve-
ment in the recovery can be achievable by recycling the middling
stream of each circuit to the respective feed stream. In addition to
this, recovery can further enhanced by regrinding the middling streams
in the flow sheet.
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