Conceptual Processing Strategy for Utilizing Banded Magnetite Quartzite

From Haraginadoni Area, Belagal Range Sandur Schist Belt, Karnataka, India
A Kumara Swamy1, N Suresh1, P Sharath Kumar2 and B P Ravi2
1
Department of Fuel, Minerals and Metallurgical Engineering, IIT, Dhanbad 836206
2
Department of Mineral Processing, VSKUPG Centre Nandihalli– Sandur, 583119
Email; ravibelavadi @gmail.com

ABSTRACT
A composite mixed banded magnetite quartzite[BMQ] from Haraginadoni area, Belagal ranges of Sandur
schist belt, Ballari district, Karnataka, India was subjected to characterization, mineral processing, amenability to
pelletization and direct iron production studies The BMQ sample analyzed 36.00% Fe[t] 28.5% Fe[Mag], 47.44%,
SiO2, 1.00 % Al2O3, 0.14% Mn,0.05% TiO2, 0.06% CaO, 0.06% MgO,0.06% Na2O, 0.05 K2O, 0.01% P, 0.01%
S and 1.00% LOI It comprises, of fine grained (<70 µ) mainly magnetite [55-60%], very fine grained (<40 µ)
quartz [35- 40%] and fine grained (<70 µ) minor amounts of mica, hornblende and pyroxene [1-5%], which are
mutually intimately intermixed and inter grown. A fair degree of liberation of hematite is observed at- 74 µ. The
BMQ is amenable to gravity concentration by tabling, reverse flotation and WLIMS at MOG minus 74µ D80 50 µ,
The final conventional process comprising of pre concentration by dry medium intensity drum magnetic
separation at minus3mm, Grinding of pre concentrate at minus 74 µ, D80 45 µ, followed by gravity concentration
and WLIMS of table rejects (slimes, tails and middling‟s) at 0.1 Tesla intensity, produced a composite
concentrate [gravity and magnetic] assaying 64.5% Fe, 6.002% SiO2, 0.29% Al2O3 and 0.63% LOI, -74 µ, D80 50
µ, 1750 cm2/gm specific surface [Blaine No.] with 71.5% Fe distribution at 39.3 wt. %, meeting the pellet grade
specification. The dry bulk concentrate thus produced was subjected to optimum balling conditions of 45o angle
of inclination, 22.5 rpm, 9.4% moisture, 0.9% binder Bentonite and 1.25%, magnesite flux. The -25+8mm green
pellets were dried for 1 hour at 150oC and subsequently for 3 hours at 300o C in trays of drying oven, followed by
preheating[300-700oC(6‟)], indurating [1000-1350o C (12‟)] and cooling [350oC(15‟)] in the pot grate furnace to
produce fired pellets analyzing 64.10 %Fe, 6.85%SiO2 0.42 Al2O3%,0.10% CaO, 0.63% MgO, 0.18%
Na2O,0.05% K2O,0.01% P,0.01% S,0.06Al2O3/SiO2,7.27% (SiO2+Al2O3) and traces LOI.-20+6.25 mm, 2.1 t/m3
bulk density, 94% Tumbler index, 5% Abrasion index, 260 kg cold crushing strength, 25% apparent porosity, 7%
Reduction degradation index, 2.5% Thermal degradation index, 65% Relative Reducibility and 16% swelling
index, meeting the specifications of the iron and steel industry. Thus produced pellets produced sponge iron
assaying 91%Fe[T] 82% Fe[M], <5% gangue [SiO2+Al2O3+ CaO+MgO], 0.2%C, 0.05%S and P and 2.2 t/m3 bulk
density. An order of magnitude viability for 0.5 MTPY steel production indicated that the project needs 100
million USD as capita which is paid back in 2 years and the internal rate of return of the conceptual project is
15% and seems attractive. The concept of beneficiation, pelletizaton, DRI and steel production for 10 years life of
BMQ resource paves the way for conservation, sustenance and sustainable development of the local steel hub.
Keywords; BMQ, WLIMS, gravity concentration, pelletization of concentrate and DRI from pellets
INTRODUCTION
In India, domestic steel production, is expected to rise annually by ~10 %, thereby increasing the steel
production to 300 MTPA and iron ore requirement to 500 million tons by 2030. India has a sizable amount of iron
ore resources located in well-defined belts in Odissa, Jharkhand, Chhattisgarh, Maharashtra, Goa and Karnataka
amounting 31,213 million tons, of which about 10,747 million tons (34%) is of magnetite and the rest belongs to
hematite type, which is the primary source of supply of iron(IBM (2011)) The fast depletion of high-grade iron
ore deposits, closure of some of the high-grade iron ore mines due to environmental regulations, increased
demand for quality iron ores –agglomerates, have forced the mineral engineers to look into the processing of iron
ore wash-plant tails and the banded magnetite quartzite/jasper (BMQ/J) to produce quality grade agglomerates as
input to the existing steel making technologies like blast furnace [BF] and direct reduction of iron [DRI].
Unfortunately, most BMQ/J mines are locked in eco-sensitive forest areas where any infrastructure activity is
banned. The problem of Indian hematite iron ores is their high Al 2O3 content and Al2O3/SiO2 >1, which needs to
be addressed also. It is known that1% decrease in alumina content of iron ore leads to a 2.5% decrease in coke
rate with an increase of 4% in blast furnace productivity and a reduction in flux consumption of 30 kg per ton of
hot metal. An increase in 2% Fe increases productivity by 2%. An increase in the BF productivity by 40% is
reported when charged fully with pellets (IBM 2005).
 The Sandur Schist belt is a lens of about 60 Km in length, with a maximum width of 28 Km in the
central part. (Refer Fig.1) has a vital iron ore reserve of 811 million tons in 8 ranges, producing 50 million tons of
iron ore per year, consisting of Ramgad range (213 Million tons), Kumarswamy range (253 million tons),
Donimalai range (156 million tons), Thimmppanagudi range (27 million tons), NEB range (82 million tons),
Devadari range (26 million tons) Ettinahati range (37 million tons) and Belagal range (30 million tons). Mostly
mineralization occurs as banded hematite quartzite [BHQ]/ banded hematite jasper [BHJ], intercalation of
ferruginous shale, long, narrow and scattered patches of hematite with intervening shale bands with an estimated
reserve of 160 million tons of which of which 30 million tons of BMQ Type is reported from Belagal range. A
good number of researchers since 1838 have worked on various lithological units of Ballari district with special
reference to the Sandur greenstone belt, but very few have done studies on the Haraginadoni area. Captain
Newbold (1838-1842) was the first to traverse various parts of the Ballari district to study the rock formations. He
has reported copper mineralization at the Sugalammadevi Konda area of Copper Mountain Bruce Foote (1884-
1895) identified granites, gneisses and schistose formations of the Sandur greenstone belt and he found traces of
copper mineralization in old workings in the shallow caves of the Copper Mountain Range Sadasivaiah et.al. have
concluded that thin ferruginous layers of Haraginadoni area containing aegirine and riebeckite are metasomatic in
origin. Roy and Biswas have studied structures of the Sandur greenstone belt. According to them, Copper
Mountain Range is a syncline plunging towards the north-west at a moderate angle of 35° The geological map of
the Haraginadoni area is shown in Figure3.

Fig. 1; Iron ore resources in Sandur Schist belt (After Roy and Biswas (2008)

Fig. 2: Location of study area of Haraginadoni Fig. 3: Geological map of Haraginadoni area

Pelletization and utilization of BMQ from the Sandur schist belt are of paramount importance for the
sustenance of the local steel industry and little work except that of Sharthakumar (2018) has been conducted.
Work on beneficiation of BHQ from Sandur schist belt have been conducted by Raj et al., (2007) Anupam et al.,
(2010), Das et al., (2012), Mohan Rao et al., (2012), Gurulakshmi et al. (2010 and 2012), Nanda and Gopalkrisha,
(2014). But the work pelletization of concentrates from beneficiation of BM/HQ is limited except the works of
Sinha et.al. (1974), Nanda (2015) and Sharathkumar et.al. (2018) for the utilization Therefore, the present paper's
objective has been to carry out beneficiation studies on BMQ sample from Haraginadoni area to produce a pellet
grade concentrate ,amenability of concentrate to pelletization and evaluate the pellets for use in DR industry
followed by a preliminary economic evaluation Haraginadoni area reported about 18 million tons BMQ. The
specification of iron and steel industry for pellets is Fe >63 %, (SiO2+ Al2O3) <8%, P<0.05%, S<0.05%,
Al2O3/SiO2 < 1 Tumbler index >90%, Abrasion index <10%, Crushabiity >200kgs. Size -20+6.25mm, swelling
index <20% and 20-30% porosity

EXPERIMENTAL
The BMQ samples weighing about 5 tons from the AP Mines Haraginadoni area were collected for a
detailed investigation like characterization studies, beneficiation studies to produce pellet grade concentrates,
amenability to pelletisation and evaluation of pellets for DRI production followed by economic evaluation The
lumpy sample was stage crushed in a jaw crusher150mm wide X 250mm ( M/s Mineral Processing Equipment
(MPE), Mumbai) followed by a secondary closed circuit crushing in 200mm X 150mm laboratory rolls crusher
of (MPE-Mumbai, make) in a closed circuit with a 2 mm screen. The crushed product was thoroughly mixed
and riffled 256 Nos of ~16 kilos sacks of stock ore samples. 1kg stock sample was stage ground in laboratory rod
mill [175 X 350mm rod mill with 13kgs of rods with sizes ranging from 25 to 40mm, MPE Mumbai] at 67 %
solids pulp density to diverse MOG size maintaining 5 minutes stage grinding time The MOG size analysis is
shown in Fig.5. The experimental test procedures and analysis were conducted as recommended by the handbook
(SME (1980) and IBM (2012)). The composite dry black coloured powder concentrate produced was used for
pelletization. The binder bentonite was pale yellow coloured powder minus 53 µ assaying 9.2% Fe(T), 54.00%
SiO2, 13.07% Al2O3,6.56% Na2O, 0.95%, K2O, CaO 0.31%, MgO 0.03%. and 7.76% LOI. The flux magnesite
concentrate powder minus 53 µ assayed 43.31% MgO, 1.75% CaO,0.30% acid insolubles and 52% LOI Technical
grade 98%CaO -53µ powder was also used as a flux. The standard disc pelletizer of 1m dia x 0.2 m lip height.
The disc had a variable rpm of 20 to 30. The slope of the disc pelletizer can be varied from 35 to 55 degrees. The
charge to pelletizer consisted of 20 kg of iron ore concentrate ground of D8045µ,180 gm bentonite,2 5 gms
MgCO3 flux,10 gms CaO flux were mixed in a Muller for 30‟. The material is slowly charged to a rotating
pelletizer and noted quantum of water of 1900 cc for 8.5% moisture. The formed pellets are rolled for 5‟. The
contents are discharged and screened over a 6.25 mm round holed screen. The % +6.25mm pellet formed are
noted. The mean drop number and compression strength of green pellets are recorded. The pellets are dried and
physical strengths are determined. A 300 mm die pot grate with turn table facility for down and up draft suction
of hot air, oil fired main burner, gas based pilot burner and thermo couples were used for pot grate tests [~15
mm depth for charged pellets]. The prescribed procedure as per the operating manuals was adopted for the
studies. The dried -20+6.25mm pellets are charged. The physical and metallurgical properties of fired pellets were
evaluated by Universal testing machine, Tumbler drum and Linde test (Kurt 1980).
RESULTS AND DISCUSSION
Feed material characterization;
The as received sample consisted of Steel greyish, Reddish brown, hard and compact lumps of 100
mm size, exhibiting banding32° angle of repose, 2.0 t/m3 bulk density, 3.3 specific gravity. The Bond‟s ball mill
work index of the ore was 10 Kwh/short ton and that of pre concentrate was found to be 15 Kw/short ton. The
mineralogical characteristics of the sample indicated that the BMQ is fine grained material. It comprises, of fine
grained(<70 µ) mainly magnetite[55-60%], very fine grained (<40 µ) quartz [35- 40%] and fine grained(<70 µ)
minor amounts of mica, pyroxene and hornblende [ 1-5%], which are mutually intimately intermixed and
intergrown,[ Refer Fig 4 and 6] A fair degree of liberation of magnetie is observed at minus 74 µ size [refer Fig
5]. Fig 7 confirms the mineralogy data by XRD. The sample assayed 36.00% Fe[t] 28.5% Fe[Mag], 47.44%, SiO2,
1.00 % Al2O3, 0.14% Mn,0.05% TiO2, 0.06% CaO, 0.06% MgO,0.06% Na2O, 0.05 K2O, 0.01% P, 0.01% S and
1.00% LOI The characterization data indicated that the main gangue quartz is very fine grained nature, is
associated with magnetite necessitating a fine size liberation of minus 74 µ. The %Fe is also lower than TLV of
45%Fe stipulated for iron ore beneficiation plant tails The results of liberation akin to the findings of previous
works of Anupamet al.,(2010), Das et al.(2012), Mohanrao et al.(2012) and Nanda et al.(2020) dealing with BHQ
and that of Krishna et. al. (2013) and Sharathkumar (2018) dealing with BMQ from Ballari area. Process
amenability tests at -.074 mm MOG heavy liquid separation using TBE 3SG followed by wet low intensity bar
magnetic separation at 0.1Tesla yielded a sink mag assaying 62.5%Fe with 58%Fe distribution at 33.4 wt.%
 Fig.4. Association of Amphibole(Amp) Quartz (Qz) and Fig.5 Majority of magnetite m a r t i t i z e d magnetite and quartz
Magnetite [X-200] grainsare free as shown in EPMA at -0.07mm

Fig. 6; Complex association of Amphibole (Amp), Quartz (Qz), Fig 7; XRD of BMQ sample
and irregular shaped Magnetite (Mag).[X- 100].,

Amenability to tabling, wet low intensity magnetic separation [WLIMS] and reverse flotation;
The characterization studies indicated that the iron minerals are liberated at -74 µ. Hence amenability of
BMQ at MOG of -74µ D80 50µ to gravity concentration by tabling, WLIMS 0.1Tesla intensity and reverse
flotation conditioning for 10‟ with 1.5kg/t caustic starch depressant for iron minerals and floating siliceous
gangue after conditioning for1‟ with 0.15 kg/t dodcyl amine cationic collector, were conducted. The results are
given in table 3. Tests at MOG coarser than 74 microns resulted in the production of inferior grades and loss in
tails due to interlocking. The recovery was low in gravity concentration due to the presence of very fine size
range/slimy liberated iron bearing minerals in the feed which were lost in reject fraction due to size limitations of
tabling. Nayak et.al. (2012) recommended MGS separation at fine MOG of minus 74 µ. The reverse flotation
produced concentrates with high % Fe recovery and concentration efficiency, as it is an effective slime particle
processing process. The slight fall in the tenor of concentrate in case of reverse flotation may be due to slime
interference at MOG of minus74 µ. Vijayakumar et.al. (2015) indicated that flotation by column cells would avert
the slime entrap problem and prevent the loss due to Fe slimes. WLIMS could produce pellet grade concentrate
but with maximum recovery Metchem (2006) recommended flotation of gravity concentrates to obtain pellet
grade. Raj et.al. (2007) indicated that WHIMS followed by flotation yielded better results. This indicates flotation
as a better refining concentration. A similar opininon was expressed by Sharathkumar (2018) for refining WLIMS
mag concentrate by flotation. Sharathkumar opined that pre concentration with dry medium intensity magnetic
separation followed by WLIMS and refining could produce high quality concentrates
Table 3; Amenability to tabling, WHIMS and reverse flotation at MOG-74µ, D80 50µ
Test % Fe
Product Wt.%
Grade Distn
Heavy Concentrate 27.9 64.52 50.0
Tabling
Rejects 72.1 24.96 50.0
-74µ D80 50µ 30%S
Feed Cal 100.0 36.00 100.0
WLIMS Mag Concentrate 41.2 62.90 72.0
-74µ D80 50µ 30%S 0.1Tesla, Rejects 58.8 17.14 28.0
Feed Cal 100.0 41.50 100.0
Reverse flotation Concentrate non float 31.7 62.50 55.0
-74µ,D8050µ,30%S 9pH,1.5kg/t Rejects 68.7 29.27 45.0
depressant,0.15kg/t collector Feed Cal 100.0 41.50 100.0
The final conventional process of DMIMS at -2mm, grinding precconcetrate tabling and, WLIMS of
table rejects obtained from pre concentrate;
The final conventional process consisted of crushing the sample to – 3000 microns, D80 1000 microns,
dry medium intensity drum magnetic pre concentration at 0.6 Tesla, Grinding the preconcentrate to – 74 microns
D80 45 microns Tabling followed by rougher, cleaner, scavenger wet low intensity magnetic separation at 0.12,
0.1 and 0.2 Tesla in the counter current configuration of table tails. The flowsheet is shown in figure 8. The
results are given in table 4. The process yielded a pellet grade concentrate assaying, 65.9% Fe, 6.00%
SiO2,0.29% Al2O3and 0.63% LOI, D80 45µ with 71.5%Fe recovery, at 39.3 wt.% The process eliminates the
energy intensive concentrate grinding stage. For bulk concentrate production, the -2mm stock sample was
subjected to 1.2 m wide 0.6 m dia 0.4Tesla WMIDMS drum separation. The magnetic concentrate was
pulverized in an IC pulverizer–air classifier to get dry powder of -74 µ, D80 45 µ. The dry ground product was
subjected in batches of 1 ton to continuous tabling at 0.25 tph and table rejects after thickening in an LGS 0.6 m
dia triple drum WLIMS. The table and WLIMS concentrate were thickened in 1.2m dia thickener and filtered in
1 m2 vacuum MPE pan filters. The air dried concentrate cake assaying ~65.0%Fe, D80 ~45 µ,~1750 cm2/g is used
for pelletization tests.
Table 4; Final conventional process flowsheet.
Dry Medium intensity magnetic separation at -3 mm, grinding of DMIMS preconcentrate to -0.074 mm, Tabling at -74 µ, D80 50 µ,
WLIMS of thickened table rejects with cleaner – scavenger counter current configuration at 0.1,0.11 and 0.2T intensity respectively

Product Wt% Fe % SiO2% %Fe

Assay Assay Dist
-200# Final Conc[ Mag+ gravity] 39.3 65.49 6.00 71.5
-200# Non mag tails 27.4 21.80 69.70 16.6
-3 mm DMIMS non mag tails 33.3 12.86 78.02 11.9
Head (Cal) 100.0 36.00 47.44 100.0
Pre cocenentrate 66.7 47.55 32.17 88.1
-200 #PC table conc 31.7 67.60 3.65 59.5
-200 #Mag feed [ PC table rejects] 35.0 29.40 58.00 28.6
-200# Cl Mag conc 7.6 56.84 15.81 12.0

Amenability to pelletization;
The pelletisation test scheme and process flowsheet are given in figures5 and 6 respectively. Green pellets
were produced from ~20 kg concentrate of 65.50%Fe, D8045µ, 1800 cm2/gm Sp.SA, under optimum balling
conditions of 45o angle of inclination, 22.5 rpm, 9.4% moisture, 0.9% binder Bentonite and flux 1.25%. The
-25+6.25mm green pellets were dried for 1 hour at 150oC and subsequently for 3 hours at 300o C in trays of
drying oven, followed by preheating, indurating and cooling in the pot grate furnace. The temperature profile of
t h e pot grate furnace is given in Table 5. The fired cooled pellets are subjected to physical, chemical,
mechanical and metallurgical analysis. The results are given in Table 6. Figure 9 shows the flowsheet for the
pelletization of concentrates. The pellets obtained analyzed 64.10 %Fe, 6.85%SiO2 0.42 Al2O3%,0.10% CaO,
0.63% MgO, 0.18% Na2O,0.05% K2O,0.01% P,0.01% S,0.06Al2O3/SiO2,7.27% (SiO2+Al2O3) and traces LOI.-
20+6.25 mm, 2.1 t/m3 bulk density, 94% Tumbler index, 5% Abrasion index, 260 kg cold crushing strength, 25%
apparent porosity, 7% Reduction degradation index, 2.5% Thermal degradation index, 65% Relative Reducibility
and 16% swelling index, meeting the specifications of the iron and steel industry. The BMQ from Sandur schist
belt is amenable to beneficiation and pelletization as pellets meeting the specifications of the iron and steel
industry was produced paving way for conservation and sustenance fulfilling the aim.
Table 5; Temperature profile of pot grate furnace during induration
Sl. No. Ramp (Min) Temp. (oC) Hold (Min) Zone
1 5 350 2
Drying
2 4 500 2
3 4 700 2 Pre - heating
4 6 1000 2
5 4 1175 2 Firing
6 6 1310 6
7 20 350 15 Cooling
 Fig.8; Flowsheet of beneficiation process Fig.9; Flowsheet of pelletization plant

Dry Medium intensity drum mag separation of ROM Crushed To – 3mm

Pre conc mag ground to -0.07 mm Sandy Non mag tails

Slimy gravity concentration t Cl WLIMS of gravity tails

c c NM t
Dewatering of gravity and mag concentrate slimy tails thickener

Pellet grade concentrate cake Final tails to TSF

Table 6; Physcio chemical properties of pellets under optimum conditions

Particulars Properties
Properties of green pellets from concentrate 65.00%Fe, 6.00% SiO2, 0.29% Al2O3 & 0.63% LOI, D8045µ, 1750 cm2/g Sp.Sur, and 0.1basicity.
Recovery (-20+6.25 mm) (%) 72
Drop Number (1.5') 4
Green Crushing Strength (Grams) 1000
Dry Crushing Strength (Grams) 4000
Properties of fired pellets
Bulk Density [T/m3] 2.1
Tumbler Index [%+6.25mm] TI 94.0
Abrasion Index [%-0.5mm] AI 5.0
Crushing Strength (Kg) CCS 260
Apparent Porosity (%) AP 25
Reduction Degradation Index [%-2.8mm] RDI 7.0
Thermal Degradation Index [%-6.3mm]TDI 2.5
Relative Reducibility [%] RR 65.0
Swelling Index SI 16.0
Chemical analysis; 64.1%Fe, 6.85%SiO2, 0.42%Al2O3, 0.10% CaO, 0.63 %MgO, 0.18%Na2O, 0.05%K2O, 0.01%P, 0.01%S and traces LOI

Evaluation of pellets for DRI

It was reported that -12.5+6.25 size iron ore pellets thus produced was subjected to an open cycle sponge
iron production using a 0.76 m dia x 10.67 m long rotary kiln at the rate of 100 kg/h pellets, 100 kg/h non-coking
coal fines [ash<25%] produced sponge of 91%Fe[T] 82% Fe[M], <5% gangue [SiO2+Al2O3+ CaO+MgO], 0.2%C,
0.05%S and P and 2.2 t/m3 bulk density 90% metallization at 0.5t/m3/day(NML2016), which can be used make
steel by EAF (Refer Fig.10 to 12).
Fig 10 DRI from pellets Fig 11 SMS from DRI Fig 12 Process of steel rolling mill
ECONOMIC EVALUATION OF UTILIZTION CONCEPT
The proposed project comprises of ;
1 Open cast mining to 1.8 million tons per year of BMQ ore at the rate of 250 tpd of 24 hours operation
2 Fine crushing ROM to minus 3mm at 1.8 million tons per year, followed by dry medium intensity
drum magnetic separation at the rate of 250 tpd of 24 hours operation
3 Grinding to -.074 mm of pre concentrate and concentration by gravity and WLIMS and filtration to
produce pellet grade concentrates at the rate of 200 tph operation of 3 shifts 24 hours /day operation.
4 Grate kiln pelletization of concentrates to produce 0.6 Million tons per year pellets at 100 tph 3 shifts
34 hours/day operation.
5 Sponge iron production at 0.4 million tons per year from 0.6 million tons pellets
6 0.5 million tons per year SMS and steel mill shop using 0.4 million tons per year DRI and scrap
7 Co-generation of power and P sand from tails.

The mining is open cast by engaging HEMMs using 4.5 m3 excavator[2], 3.5 m3 front end loader [3],150
mm dia wagon drill,[3], 15 nos 50t dumpers, 450m3 compressor[3]10 m3 dozer, with deep hole drilling and
blasting. Bench height & width are proposed to be 10 m and 15 m respectively. The average bench slope is
proposed to be 70 -80o. The drill hole diameter is proposed to be 115 to 150mm. Blasting is proposed to be carried
out with emulsion/slurry explosive
The ROM is crushed in mobile fine crushing and screening plant of 250 tph [2 each] to -3 mm using
primary jaw crushers, secondary cone crusher and tertiary gyradisc/ VSI Barmac crushers in a closed circuit with
a screen. The finely crushed material is passed over a 1.2 m dia x 3 m wide dry RE 0.6Tesla drum magnetic
separator each for each crushing circuit. The fine preconcentrate at 200 tph rate, is then ground to -0.074 mm in
closed circuit with 250 dia cyclone cluster – 0.075 mm parallel fed screen in 5 m diax10 m long Wet O/Fball
mills with 4500 kw drive. The deslimed ground -.074+0.025 mm fine sand is subjected to gravity concentration in
FM1 spirals [196] followed by thickening in 30 m dia middling thickener and subjected to Counter current
WLIMS[0.12Tesla] of 1.2 m diax 3 m wide with rougher- scavenger and cleaner counter current configuration to
obtain pellet grade concentrates. The concentrates are thickened in 30 m dia thickener and filtered in VPA80
filters of 2.5 m2 area to less than 10% moisture. The slimy tails are thickened in30 m dia thickener and pumped to
the tails dam. [ Refer fig 8]
The concentrate cake is balled with bentonite, flux and dried, preheatred and fired in grate - kiln of
0.6 MTPA Iron Ore Pelletisation Plant adopting dual firing system utilizing producer gas and heavy furnace
oil in the ratio of 70:30%[Refer fig 9]. DRI process based on coal which is a simple process with a single-step
furnace operation is being preferred. The kiln has a conical out let and the inlet holds the material in the kiln. The
kiln is placed in a slope from the feed end side at a slope of 2 ½%. The process flowsheet is shown in Figure 10.
The DRI unit consists of 3 Nos. Kilns with 500 TPD capacity each.. Iron ore is reduced in solid state at 800 to
1,050 °C (1,472 to 1,922 °F) either by reducing gas (H2+CO) or coal. The metallic scrap and the sponge iron
produced is being melted in an induction furnace in a steel melting shop. The liquid metal thus melted is treated
with alloys additions for required final product chemistry and cast in to the square shape called BILLET through
continues casting machine The billets are passed through the rolling mill 0.5MTPY making MS sheets, bars for
use.[Refer fig10 &11]
The capital cost of the proposed conceptual project is given under table 7 and order of magnitude
operating costs are given in table 8
Table 7; Order of magnitude of capital costs
No Particulars MUSD
1 Capital cost for Mining; involving exploration, MDO mobilization, licenses-approval costs, infrastructure and 12.5
mining equipment capital for 1.8MTPA @7200 Hours per year
2 Capital Cost for mineral processing; involving TSF, crushing, grinding, concentration and dewatering for 1.8 MTPY 20.0
at 7200 hours per year
3 Capital cost for pelletization involving storage yard, mixing, pre heating grate, firing rotary kiln, annular coolers, 15.0
including coal gasification for 0.6 MTPY at 7200 hours per year
4 Capital cost for 0.45 MTPY DRI plant of 500x3 kiln 20.0
5 Capital cost for 0.56 MTPY SMS and steel rolling mill 17.5
6 Waste hear recovery and power generation plant1 15.0
Gross capital 100.0
 Table 8; Order of magnitude of operating costs
No Particulars USD/t of ore
1 Mining costs 10.0
2 Processing cost 20.0
3 Pelletisation cost 30.0
4 DRI Manufacture for 0.45 MTPY DRI plant of 500x3 kiln 40.0
5 Operating cost for 0.5 MTPY SMS and steel rolling mill 10.0
6 Operating cost of Waste hear recovery and power generation plant1 15.0
Gross operating cost 125.0

The viability of the project based on cash flow is given in table 9 with a 10year period for 18 Million
reserves. The revenue for 0.5MTPY steel at 175USD/ t of ore at the present rate of steel after deducting operating
expense of 125 USD/t of ore is 50 million USD/year and the capital of 100 million USD is paid back in 2 years
with an NPV of 246 MUSD at 5% inflation and 15%IRR. The conceptual project is attractive from an economic,
conservation point of view and is dependent on the price of steel and coal.

Table 9; Viability of the project

Years 0 1 2 3 4 5 6 7 8 9 10
Expense including capital and supplies MUSD 100 125 125 125 125 125 125 125 125 125 125
Revenues in MUSD - 175 175 175 175 175 175 175 175 175 175
Income inn MUSD - 50 50 50 50 50 50 50 50 50 50
Net revenue in MUSD -100 -50 0 50 100 150 200 250 300 350 400
NPV MUSD 246
%IRR 15%
Payback period 2 years

SUMMARY AND CONCLUSIONS

Utilization of Banded Magnetite Quartzite from Haraginadoni area, Belagal range, from Sandur schist
belt Karnataka through Beneficiation, Pelletization of concentrate and utilization of pellets is of paramount
importance for the sustenance of local steel industry to meet the increasing demand of steel and reduce the
problems posed by high Alumna ores. A composite mixed banded magnetite quartzite [BMQ] from Belagal
ranges of Sandur schist belt, Ballari district, Karnataka, India assaying 36.00% Fe[t] 28.5% Fe[Mag], 47.44%, SiO2,
1.00 % Al2O3, 0.14% Mn,0.05% TiO2, 0.06% CaO, 0.06% MgO,0.06% Na2O, 0.05 K2O, 0.01% P, 0.01% S and
1.00% LOI was subjected to characterization, mineral processing, amenability to pelletization and direct iron
production studies. The BMQ was a very grained ferromagnetic anhydrous iron oxide ore with -0.074 mm
liberation size. The process comprises of dry preconcentration at – 3mm finely crushed size with dry drum
medium intensity magnetic separator at 0.6Tesla intensity, grinding the preconcentrate to -0.074 mm, D80 45
microns and concentration by gravity and wet low intensity magnetic separation at 0.1Tesla, producing pellet
grade concentrate with 71.5%Fe recovery,39.7 wt.%. The concentrate upon pelletisation produced pellets
assaying,64.10 %Fe, 6.85%SiO2 0.42 Al2O3%,0.10% CaO, 0.63% MgO, 0.18% Na2O,0.05% K2O,0.01% P,0.01%
S, 0.06Al2O3/SiO2, 7.27% (SiO2+Al2O3) and traces LOI.-20+6.25 mm, 2.1 t/m3 bulk density, 94% Tumbler index,
5% Abrasion index, 260 kg cold crushing strength, 25% apparent porosity, 7% Reduction degradation index,
2.5% Thermal degradation index, 65% Relative Reducibility and 16% swelling index. The DRI test on pellets
produced sponge iron assaying 91%Fe[T] 82% Fe[M], <5% gangue [SiO2+Al2O3+ CaO+MgO], 0.2%C, 0.05%S and
P and 2.2 t/m3 bulk density which can be used to manufacture steel. An order of magnitude viability for 0.5
MTPY steel production indicated that the project needs 100 million USD as capita which is paid back in 2 years
and the internal rate of return of the conceptual project is 15% and seems attractive. Hence the concept of using
BMQ through beneficiation, pelletizaton, DRI and steel production for 10 years life of BMQ resource paves the
way for conservation, sustenance and sustainable development of the local steel hub.
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