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<p>Steel industries are looking for beneficiation technologies for producing steel from low-grade ores, driven by the rapid depletion of high-grade ores and environmental sustainability. The current study aims to evaluate the performance of froth flotation and magnetic separation processes for the beneficiation of iron ore slimes. Experiments were conducted by varying the three major process parameters (Froth flotation: impeller speed, collector dosage, and frother dosage; Magnetic separation: feed rate, magnetic intensity, and matrix size) to measure the outputs in terms of concentrate grade, yield, and separation efficiency. For froth flotation, the maximum separation efficiency of 29.9% in the experimental range was achieved at an impeller speed of 800 RPM, collector dosage of 50&#xa0;ml/kg, and frother dosage of 80&#xa0;ml/kg. Similarly, the maximum separation efficiency of 28% in the experimental range was achieved at a feed rate of 10 L/min, magnetic intensity of 1.5&#xa0;T, and matrix size of 1&#xa0;mm. Based on the experimental data, the process parameters were optimized using the response surface method (RSM) approach. In the experimental range, the optimum process parameters for froth flotation were determined as 540 RPM impeller speed, 80&#xa0;ml/kg collector dosage, and 50&#xa0;ml/kg frother dosage to obtain a concentrate grade of 62.0% (predicted)/61.7% (observed) with yield value of 46.5% (predicted)/49.6% (observed) and separation efficiency 29.7% (predicted)/27.7% (observed). Similarly, the optimum process parameters for magnetic separation were determined as 10 L/min feed rate, 1.6&#xa0;T magnetic intensity, and 1&#xa0;mm matrix size to obtain a concentrate grade of 61.7% (predicted)/61.4% (observed) with a yield value of 51.4% (predicted)/47.4% (observed) and separation efficiency of 28.7% (predicted)/25.5% (observed) in the experimental range.</p>

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Analyzing the Efficiency of Iron Ore Slime Beneficiations (Froth Flotation and Magnetic Separation) Processes and their Optimizations using Response Surface Method

  • 期刊论文

  • 发表日期：

    2025年9月27日

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  • S. K. Pradhan,
  • A. K. Gorai,
  • B. K. Pal

摘要

Steel industries are looking for beneficiation technologies for producing steel from low-grade ores, driven by the rapid depletion of high-grade ores and environmental sustainability. The current study aims to evaluate the performance of froth flotation and magnetic separation processes for the beneficiation of iron ore slimes. Experiments were conducted by varying the three major process parameters (Froth flotation: impeller speed, collector dosage, and frother dosage; Magnetic separation: feed rate, magnetic intensity, and matrix size) to measure the outputs in terms of concentrate grade, yield, and separation efficiency. For froth flotation, the maximum separation efficiency of 29.9% in the experimental range was achieved at an impeller speed of 800 RPM, collector dosage of 50 ml/kg, and frother dosage of 80 ml/kg. Similarly, the maximum separation efficiency of 28% in the experimental range was achieved at a feed rate of 10 L/min, magnetic intensity of 1.5 T, and matrix size of 1 mm. Based on the experimental data, the process parameters were optimized using the response surface method (RSM) approach. In the experimental range, the optimum process parameters for froth flotation were determined as 540 RPM impeller speed, 80 ml/kg collector dosage, and 50 ml/kg frother dosage to obtain a concentrate grade of 62.0% (predicted)/61.7% (observed) with yield value of 46.5% (predicted)/49.6% (observed) and separation efficiency 29.7% (predicted)/27.7% (observed). Similarly, the optimum process parameters for magnetic separation were determined as 10 L/min feed rate, 1.6 T magnetic intensity, and 1 mm matrix size to obtain a concentrate grade of 61.7% (predicted)/61.4% (observed) with a yield value of 51.4% (predicted)/47.4% (observed) and separation efficiency of 28.7% (predicted)/25.5% (observed) in the experimental range.