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Process route for low grade itabirites

concentration: Magnetic separation preceding
flotation

João Paulo Melo Silva, Antônio Eduardo Clark Peres & Augusta Cerceau Isaac

To cite this article: João Paulo Melo Silva, Antônio Eduardo Clark Peres & Augusta
Cerceau Isaac (2017): Process route for low grade itabirites concentration: Magnetic
separation preceding flotation, Mineral Processing and Extractive Metallurgy Review, DOI:
10.1080/08827508.2017.1399888

To link to this article: http://dx.doi.org/10.1080/08827508.2017.1399888

Published online: 09 Nov 2017.

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 MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW
https://doi.org/10.1080/08827508.2017.1399888

Process route for low grade itabirites concentration: Magnetic separation preceding
flotation
João Paulo Melo Silva, Antônio Eduardo Clark Peres, and Augusta Cerceau Isaac
UFMG, Belo Horizonte, Brazil

ABSTRACT KEYWORDS
Cationic reverse flotation of quartz is the standard or reference concentration route for itabirites Iron ore concentration; iron
containing at least 45% iron. Preceding the flotation stage, desliming in hydrocyclones must be ore flotation; iron ore
conducted to remove ultrafine and colloidal particles from the flotation feed. The flotation performance magnetic separation; iron
assessed by weight and metallurgical recoveries and silica contamination in the concentrate is impaired ore desliming
by lower iron feed grades. Exploratory experiments of magnetic separation indicated that iron oxide
particles in the size range <37 µm are entrained toward the non-magnetic product. This finding
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suggested a campaign of testing an alternative circuit consisting of magnetic separation preceding

reverse flotation. Magnetic separation plays the roles of desliming and pre-concentration. The achieved
content of silica in the alternative route concentrate was 1.46%, meeting the market specification for
blast furnace pellet of 2%. The alternative route yielded significant gains in weight and metallurgical
recoveries, reaching values 3.3% and 4.4% higher, respectively.

1. Introduction the development of permanently magnetic materials rendered

possible the use of magnetic separation applied to a wide range
The experience of almost 40 years of cationic reverse flotation
of materials with respect to particle size range and magnetic
of itabirite iron ores plant practice allows to conclude that the
susceptibility (Svoboda and Fujita, 2003).
rougher stage must be preceded by desliming and should be
Nesset and Finch (1980) stated that the determination of
conducted in mechanical machines, either conventional or
the minerals magnetic susceptibility is essential for the defini-
tank cells. Nevertheless, the optimum iron feed grade should
tion of the potential for application of magnetic separation,
be at least 43% to 45% in order that the required silica content
due to the fact that a significant difference in the magnetic
in the concentrate (~2%) is achieved at high metallurgical
susceptibility is required for a successful separation.
recovery levels. The trend for the “future” ROM of most
The magnetic properties of the minerals result from atomic
operations in the Iron Quadrangle points toward iron con-
properties that are specific for a group of elements. The minerals
tents of 35% or even lower.
classified as diamagnetic are formed by atoms with electron
Traditional flotation machines were upgraded and pneu-
configuration similar to that of noble gas, with electrons paired
matic cells received special attention. Splitting the flotation
at the d orbital. The minerals classified as paramagnetic present
feed in two ranges of particles size enhances the flotation
the electron configuration characteristic of the transition ele-
performance (Lima et al., 2013; Reis 2015). Changes in circuit
ments such as Fe, Mn, Ti, and Cr, which present unpaired
configuration also contribute to the rational use of each bench
electrons at the d orbital (Klein and Dutrow, 2007).
in mechanical flotation (Silva 2015). All these advances are
The physical property magnetic susceptibility is the exter-
not enough to yield concentrates meeting the market specifi-
nal expression of the internal characteristics of the atoms that
cations at high metallurgical recovery levels from low grade
constitute the minerals and explain the behavior of minerals
ROMs.
under the action of an external magnetic field. According to
The introduction of a pre-concentration stage would add
Blum (1997), the magnetic susceptibility is the level or degree
to the costs and render the operation more complex (three
to which a certain material or mineral may be magnetized
stages: pre-concentration, desliming, and concentration). A
when submitted to an external magnetic field. The specific or
pre-concentration stage capable of eliminating desliming
mass susceptibility is expressed according to equation 1.
would solve the abovementioned problems. Magnetic separa-
tion was the pre-concentration option selected for testing in k
X¼ (1)
the present investigation. ρ
The practical relevance of magnetic separation was recognized
where k is the volume magnetic susceptibility, a dimensionless
late in the 19th century. The feasibility of separating strongly
number that indicates the degree of magnetization of a mate-
magnetic particles from non-magnetic gangue was demonstrated.
rial in response to an applied magnetic field, ρ is the material
The increasing knowledge of the fundamentals of magnetism and

CONTACT Antônio Eduardo Clark Peres aecperes@demet.ufmg.br UFMG, Av. Antonio Carlos 6627 Belo Horizonte 31270-901, Brazil.
© 2017 Taylor & Francis Group, LLC
 2 J. P. MELO SILVA ET AL.

density and X is the specific or mass magnetic susceptibility of
the material or mineral (m3/kg).
Nesset and Finch (1980) utilized the Frantz Isodynamic
Separator to determine the specific magnetic susceptibility of
iron minerals. The separation occurs in a tray positioned
between two magnetic poles that keep constant the magnetic
field intensity along the full tray length.
Based on laboratory scale flotation experiments and pilot
scale wet high intensity magnetic separation, a comparison is
presented between two concentration routes: (i) traditional
(desliming followed by flotation) and (ii) alternative (mag-
netic separation preceding flotation). In the alternative route
magnetic separation plays the dual role of desliming and pre-
concentration.
2. Material and method
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The WEMCO flotation machine (2,400 mL cell) was oper-
ated at 1,300 rpm. The iron oxides depressant was corn meal
(locally known as “fubá”) gelatinized with sodium hydroxide
at weight ratio 5 (starch):1 (NaOH). The collector was ether
amine partially neutralized with acetic acid. The solids con-
tent in the pulp was 42% (w/w) and the pulp density was
3.847 (reference route) and 4.847 (alternative route). Rotor
speed was 1,300 rpm. Conditioning time was 5 min and
flotation time was 3 min.
Pilot scale magnetic separation tests were conducted in a
Minimag G3600 carrousel type WHIMS equipment, manu-
factured by Gaustec, operating at a dry basis feed rate of
288 kg/h. In the rougher stage the operation conditions
were: grooved plate matrix spacing 5.0 mm, magnetic field
intensity 1.2T, carrousel speed 5.0 rpm, wash water pressure
3.5 kgf/cm2 for the concentrate and 2.5 kgf/cm2 for the
medium fraction. In the scavenger stage, the operation con-
ditions were: grooved plate matrix spacing 1.5 mm, magnetic

The methodology employed consisted of sample characteriza- field intensity 0.8T, carrousel speed 4.5 rpm, wash water
tion and technological experiments comprising simulation of pressure 4.0 kgf/cm2 for both concentrate and medium
the reference process route consisting of desliming and flota- fractions.
tion and of the alternative route in which magnetic separation
preceded flotation. The sample was collected at the Iron
Quadrangle, Minas Gerais state, Brazil.
The sample characterization consisted of chemical and
3. Results and discussion
mineralogical analyses, size distribution determinations, and 3.1 Sample characterization
measurement of magnetic susceptibility by size ranges.
The results of the chemical analysis are presented in Table 1.
The size analysis (Tyler series) was carried out with the use
Results of iron grade in each particles size range and
of: (i) square vibrating screens (50 cm × 50 cm) for the size
cumulative iron content are illustrated in Figure 1. The iron
range from 9.525 mm to 1.0 mm, and (ii) 20 cm diameter
grade is lower in the size range between 210 µm and 53 µm.
sieves in a RO TAP test shaker for the size range from 840 µm
The iron content is higher than 42.27% for particles larger
to 37 µm.
than 210 µm and smaller than 53 µm. The lowest iron grade,
The mineralogical analyses were conducted in a Leica
21.21%, was achieved for particles smaller than 149 µm and
optical microscope, model DMLP, magnification up to 500
larger than 105 µm. This distribution pattern is characteristic
times. Polished mineral sections were embedded with cold
for ores from the Alegria mine and other mines in the Iron
cure resins. Alumina paste was used for final polishing. At
Quadrangle.
least 500 particles were used in grains counting for determi-
Results of the mineralogical analysis are presented in
nation of weights of mineralogical phases.
Table 2. The values are indicated in weight percent.
A Frantz Isodynamic Magnetic Separator was utilized for
Significant amounts of goethite and porous hematite were
the determination of the magnetic susceptibility according to
detected, 22.82% and 17.44%, respectively, and the magnetite
the method proposed by Nesset and Finch (1980). The
content is low, 2.25%.
method consists of determinations at different tray slope
The magnetic susceptibility in each size range was calcu-
angles. For each angle, different values of current were
lated from weight recoveries considering three angles of the
applied. The selected angles were 5°, 10°, 15°, 20°, 25°, 30°,
Frantz Isodynamic Magnetic Separator tray slope. For the
and 35°. The applied current varied from 0.05A to 0.80A.
fractions −37 µm and +37–44 µm the selected angles were
The laboratory test sequence included grinding, flotation,
10°, 20°, and 30° while for the fractions +44–53 µm, +53–
desliming, and regrinding. The magnetic separation stage was
74 µm, +74 µm105 µm, +105 µm149 µm, and +149–210 µm
conducted at pilot scale. The dimensions of the mills
with angles of 5°, 15°, and 25° were chosen. The selected
employed in grinding were 0.2032m (diameter) by 0.3048m
angles are different for finer and coarser fractions aiming at
(length), the rotation speed was 71% of the critical velocity
equalizing the flow rate of material in the separator tray. For
and the charge occupied 25% of the mill. The regrinding tests
each tray slope angle, the recoveries were determined for
were performed in mills with dimensions 0.2540m by
currents applied to the equipment coils in the range from
0.2540 m, operated at 65% of the critical velocity, the charge
0.05 A to 0.80 A with constant increments of 0.10A.
occupying 30% of the mill.
Desliming was conducted in a 4,000 mL vessel. The weight
of solids was 1,700 g. Sodium hydroxide (3%w/v) was used as
dispersant, the dispersion pH being 10.5. The pulp was agi- Table 1. Results of the chemical analysis of the itabirite sample.
tated by hand for five minutes and then water and solids in %Fe %SiO2 %Al2O3 %P %PPC %MnO2
suspension were collected by siphoning. 44.72 32.56 0.55 0.034 2.53 0.05
 MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW 3

Figure 1. Iron content by size range and calculated cumulative iron grade.

Table 2. Results of the mineralogical analysis. Values of current (I50) and tray slope angle (θ) are also
presented. Lower values of magnetic susceptibility were
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Specular Porous Free Mixed

hematite hematite Goethite Magnetite quartz quartz Other achieved for the coarser fractions. The magnetic susceptibility
26.27 17.44 22.82 2.25 24.82 4.61 1.79 was calculated according to equation 3 (Hess 1966).

20  sin θ
I50 is the current applied to the poles of the isodynamic X¼  106 (2)
separator corresponding to 50% mass split to magnetic and I50 2
non-magnetic flows. The values of I50 calculated for the three
The high value of the specific magnetic susceptibility determined
slope angles for the size ranges −37 µm, +37–44 µm, +44–53 µm,
for the fines (fraction −37µm) might suggest that fine iron oxide
+53–74 µm, +74–105 µm, +105–149 µm, and +149–210 µm are
particles should report preferentially to the magnetic fraction.
presented in Figure 2. The values of I50 are plotted as a function
Nevertheless, the iron content (41.2%) in the non-magnetic
of the sin of the tray slope angle. The calculated values of I50 are
product of the alternative is slightly lower than that in the slimes
lower for the finer fractions. For the angle 15°, the calculated
of the reference route (43.9%) route. Water entrainment of fines
value of I50 for the fraction +44–53 µm was 0.316 A, while for the
prevails over magnetic attraction resulting in the desirable
fraction +149–210 µm, the value achieved was 0.769 A. The
desliming of the magnetic pre-concentrate.
coarser particles, besides being heavier, presented lower iron
content, thus they required stronger magnetic fields to be col-
lected in the magnetic fraction.
Table 3. Results of specific magnetic susceptibility achieved for the size ranges
for the size fractions  37 μm; þ37  44 μm; þ44 −37µm, +37–44µm, +44–53µm, +53–74µm, +74–105µm, +105–149µm, and
 53 μm; þ53  74 μm; þ74  105 μm; þ105 +149–210µm.
 149 μm; and þ 149  210 μm: Size range (µm) I50(A) θ (º) X(cm3/g)
−37 0.177 20 2.2E-05
+37-44 0.327 20 6.4E-06
Results of specific magnetic susceptibility achieved for the size +44-53 0.316 15 5.2E-06
fractions −37µm, +37-44µm, +44-53µm, +53-74µm, +74-105µm, +53-74 0.383 15 3.5E-06
+105-149µm, and +149-210µm are presented in Table 3. Iron +74-105 0.538 15 1.8E-06
+105-149 0.693 15 1.1E-06
contents in the selected size ranges are presented in Figure 1. +149-210 0.769 15 8.7E-07

Figure 2. Values of I50 calculated for the three angles.

 4 J. P. MELO SILVA ET AL.

3.2 Technological experiments There is no major difference between the energy consump-
tion in the regrinding stage of both routes.
The two process routes utilized in the technological experi-
Figure 4 illustrates the contents of iron in the tailings and
ments are summarized in Figure 3. Each route consists of
silica in the concentrate in the stages that constitute each
five stages. Grinding, rougher flotation, regrinding, and clea-
route. The dotted line represents the target for silica in the
ner flotation are common to both routes. The particles size
concentrate (SiO2 = 2.0%). The desliming underflow is coar-
distributions of the rougher flotation feed are similar for
ser (top size 420 µm; d80 105 µm) than the magnetic pre-
both routes. Desliming is present only in the reference
concentrate (top size 297 µm; d80 74 µm) resulting in higher
route and magnetic separation is present only in the alter-
contents of iron and SiO2 in the alternative route rougher
native route.
tailings. The differences in particles size in the rougher flota-
The reported figures are: iron content and weight recovery in
tion stage of each route does not affect the final SiO2 content
the desliming and magnetic separation feed, iron content in the
due to the fact that there is a regrinding stage prior to the
tailings and weight recovery in the rougher flotation stage,
cleaner flotation. The iron grade in the magnetic separation
regrinding stage energy consumption, and finally silica content
tailings is acceptable and the high contents of both, iron and
in the cleaner concentrate.
SiO2, in the slimes were as expected.
The results confirmed the potential of the alternative
A projection, considering the enrichment ratio of 1.24
route in which magnetic separation substitutes desliming.
achieved in the tests (55.42% Fe in the flotation feed/44% Fe
Comparison between the alternative route and the reference
in the plant feed), indicates the possibility of enriching ROM
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route indicated lower SiO2 content in the cleaner concentrate

of 35% iron to 43% in the pre-concentrate.
(1.46% versus 2.29%) and gains of 3.3% and 4.5% in absolute
values, respectively, in weight and metallurgical recoveries.
The global metallurgical recoveries were 75.7% (alternative
route) and 71.2% (reference route). The global weight recov- 4. Conclusions
eries were 53.6% (alternative route) and 50.3% (reference The specific magnetic susceptibility depends on particle size,
route). increasing toward finer size ranges.

Stage1 Stage 2 Stage 3 Stage 4 Stage 5

Rougher
Desliming Cleaner
Flotation Regrinding
%Feflot. feed: 43.78 Flotation
%Fetailing: 19.80 11.02kWh/t
WR: 89.64% %SiO2Conc..: 2.29
Grinding WR: 53.61%
Fe: 44.72%
9.65%>149µm
5.23kWh/t
Magnetic Rougher
Cleaner
Sep. Flotation Regrinding
Flotation
%Feflot. feed: 55.42 %Fetailing: 31.08 11.46kWh/t
%SiO2Conc..: 1.46
WR: 69.0% WR: 75.9%

Figure 3. Process routes utilized in the technological experiments consisting of five stages.

Figure 4. Results of SiO2 content in the concentrate and Fe content in the tailings in different stages that constitute the process routes.

Iron oxide particles in the finer size ranges report to the
non-magnetic fraction due to water entrainment.
Magnetic pre-concentration, besides increasing the iron con-
tent of the flotation feed, performs the desliming role.
The energy consumptions in the regrinding stages of both
routes are similar.
The performance of the alternative (magnetic separation +
flotation) was superior to that of the reference route (deslim-
ing + flotation). The SiO2 content in the concentrate was
lower (1.46% versus 2.29%), weight and metallurgical recov-
eries were 3.3% and 4.4% higher in absolute values.
Acknowledgments
The authors acknowledge Samarco and also PROEX CAPES, CNPq, and
FAPEMIG for the financial support to PPGEM.
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Disclosure statement
The authors report no conflicts of interest. The authors alone are
responsible for the content and writing of the article.
MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW 5
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