Up-grading of agbado-okudu iron ore using magnetic separation and shaking table techniques
Table Of Contents
- PAGE
DECLARATION- – – – – – – – – – – – iii
CERTIFICATION- – – – – – – – – – – – iv
DEDICATION- – – – – – – – – – – – v
ACKNOWLEDGEMENT- – – – – – – – – – vi
ABSTRACT- – – – – – – – – – – – – vii
TABLE OF CONTENTS – – – – – – – – – viii
LIST OF TABLES- – – – – – – – – – – – xi
LIST OF FIGURES– – – – – – – – – – – xiii
Chapter ONE
INTRODUCTION
- – – – – – – – – – – – – 1
Chapter TWO
LITERATURE REVIEW
- 2.0Literature Review- – – – – – – – – – – 4
- 2.1Nigeria Iron Ore Deposits- – – – – – – – – 4
2.
- 1.1Agbado-Okudu Iron Ore- – – – – – – – – 5
2.
- 1.2Mineralogy of Agbado-okudu Iron Ore- – – – – 6
- 2.2Study of some Nigerian Iron Ores Characteristics- – – – 7
2.
- 2.1Iron Ore Beneficiation Process- – – – – – – – 9
2.
- 2.2Gravity concentration process- – – – – – – 9
2.
- 2.3Magnetic separation- – – – – – – – – – 11
ix
2.
- 2.4Froth flotation- – – – – – – – – – – 13
- 2.3Methods for the Beneficiation of Iron Ore- – – – – 13
2.
- 3.1Beneficiation route for the Itakpe Iron Ores- – – – 14
- 2.4Procedures for development of conceptual flow sheet
for a newly discovered ore- – – – – – – – – 17
- 2.5Particles Size Analysis – – – – – – – – 19
- 2.6Size/Assay Analysis – – – – – – – – – – 20
- 2.7Determination of liberation size of the valuable Minerals
in the Ore – – – – – – – – 20
- 2.8Work index Determination – – – – – – – – 23
2.
- 8.1Standard bond method- – – – – – – – – 23
Chapter THREE
SYSTEM DESIGN AND IMPLEMENTATION
- 3.0Materials and methods- – – – – – – – – – 26
- 3.1Samples collection and equipment used- – – – – – 26
- 3.2Methods- – – – – – – – – – – – 26
3.
- 2.1Preparation of the bulk sample for chemical analysis- – -26
3.
- 2.2Chemical analysis- – – – – – – – – – – 26
3.
- 2.3Microscopy- – – – – – – – – – – – 27
3.
- 2.4Size/Assay analysis- – – – – – – – – – 28
3.
- 2.5Work index Determination- – – – – – – – – 29
3.
- 2.6Separation test using shaking table technique- – – – 29
3.
- 2.7Separation test using Magnetic Separator- – – – – 30
x
3.
- 2.8Shaking table separation followed by Magnetic
Separation techniques – – – – – – – 31
Chapter FOUR
SYSTEM TESTING AND EVALUATION
- 4.0Results and Discussions- – – – – – – – 32
- 4.1Results – – – – – – – – 32
- 4.2Discussions – – – – – – – – 32
4.
- 2.1Chemical analysis- – – – – – – – – – – 32
4.
- 2.2Mineralogical analysis- – – – – – – – 33
4.
- 2.3Size/Assay Analysis of the Head Sample – – – 34
4.
- 2.4Work index Determination- – – – – – – – 35
4.
- 2.5Concentration test using Shaking Table – – – – – 36
4.
- 2.6Magnetic separation technique- – – – – – – 40
4.
- 2.7Results of concentration test using shaking table
followed by magnetic Separation Techniques – – – – 43
Chapter FIVE
SUMMARY, CONCLUSION AND RECOMMENDATIONS
- 5.0Conclusions and Recommendations – – – – 46
- 5.1Conclusions- – – – – – – – – – – – 46
- 5.2Recommendations- – – – – – – – – – – 46
References- – – – – – – – – – – – – 58
Thesis Abstract
The beneficiation of the Agbado Okudu iron ore deposit located in
Kogi State, Nigeria was investigated. The investigation involved
determining the chemical composition and mineralogical characteristics of
the run-of-mine. Followed by determination of the work index of the ore
and then separation tests using shaking table, magnetic technique and a
combination of the two techniques. The results of the tests carried out
revealed that the Agbadu okudu iron ore contained on the average a total
iron content (38.82% FeT), 49.10% (Si02) and other element. Thin sections
of the ore sample examined under polarized light revealed that the iron
bearing minerals are predominantly magnetite and hematite with a
combined average percentage distribution of 69% and the mineral in
abundant after the iron bearing minerals is quartz. The grindability test
reveals that the Agbado Okudu iron ore has and average work index of
about 4.32 kwh/tonne. The results of gravity separation shows that a
concentrate with a maximum grade of 55.81% (FeT), and a recovery of
66.40% at particle size fraction -56 + 45ïm could be produced. While
magnetic separation alone produced a concentrate with an optimum grade of
57.43% (FeT), and a recovery of 82.12% at particle size fraction of –
80+63ïm. However, combination of gravity separation technique (shaking
table) followed by magnetic separation technique could only produce a
concentrate with an optimum grade of 57.17% (FeT), and a recovery of
80.85% at a particle size fraction of –63+53ïm. Hence, based on the results
obtained from the concentration tests, the Agbado Okudu iron ore deposit
can be best beneficiated using magnetic technique to produce a concentrate
that can serve as feed for pig iron production by conventional blast furnace
route.
Thesis Overview
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NTRODUCTION<br>Iron is one of the most common elements on earth. Nearly every<br>structure put on by man contains at least a little iron. It is also one of the<br>oldest metals and was first fashioned into useful and ornamental objects<br>about 3,500 years ago (Lambert and Mark, 1988).<br>One of the most important determining factors for establishing Iron<br>and steel plants is the availability of iron ore deposit with good geological,<br>mineralogical and metallurgical properties. There is an estimated 2,707<br>million tonnes of iron ore deposit in the country out of which 200 million<br>tones are in the proven reserve (Umunnakwe, 1988). Iron ore is simply the<br>largest single raw material input in iron and steel making process and the<br>country is endowed with abundant reserves of it but with varying<br>characteristics. The deposits abound in different parts of the country as<br>shown in Table 2.1. Most of the iron ores discovered in the country are<br>however, low grade (their iron content in the crude ranges between 28-45%<br>FeT). This meant that for them to be used in iron and steel production they<br>have to undergo substantial beneficiation and upgrading. (Also and Yakubu,<br>1995). The Itakpe iron ore had been the most intensively studied and<br>exploited deposit with a proven reserve of 200million tones with an average<br>iron content of 36% FeT. This is presently being up-graded to obtain a<br>2<br>concentrate of 64% FeT for use at Ajaokuta and Aladja steel plants. Apart<br>from the Itakpe iron ore deposit there are other deposit which reserves are<br>estimated at over 2.3 billon tonnes as shown in (Table 2.1) within 150km<br>radius of the Ajaokuta steel plant. To ensure security of supply of the iron<br>ore for the nation Steel industries, further research and development need to<br>be carried out on these new founded deposits to enable their full<br>exploitation. With these reserves, conservative estimates indicate that the<br>nation could be self-sufficient in iron ore for a period ranging between 100-<br>150 years (Umunnakwe1988).<br>The role of iron and steel in the national economy is enormous.<br>One cannot name an economic branch where iron and steel find no<br>application and to some extend the economic power of a country is<br>determined by its consumption and output of steel products. It is on this<br>basis, that the Federal Government of Nigeria in 1971 launched the country<br>into a new era of iron and steel technology by the establishment of the Delta<br>and Ajaokuta steel projects. Though, the establishment of these projects was<br>laudable inadequate attention was given to the development of local raw<br>materials to feed the plants thus, making the plants on commissioning to<br>import iron ore concentrate form countries like Brazil, Liberia and Guinea.<br>Recently there has been renewed interests on the souring of locally available<br>raw materials to feed these plants because the Itakpe iron ore project and the<br>total iron ore requirement of Ajaokuta at 1.3 million tonnes of steel per<br>3<br>annum is about 2.135 million tones of iron concentrate and at this rate the<br>Itakpe iron ore project is conservatively estimated to last for about 25 years,<br>(Also and Yakubu, 1995).<br>Also, the Itakpe iron ore plant commissioned on the 80s to deliver<br>iron concentrate to Ajaokuta and later closed and now concessioned to<br>Indians. Would not be able to meet the demand of Ajaokuta Steel plant<br>when it finally takes off fully. It is therefore, important that these types of<br>studies be conducted so as to increase the source of Iron Ore for Ajaokuta<br>plant. And through such studies the technology for the beneficiation of<br>various Nigerian iron ore deposits for onward supply to Ajaokuta and Delta<br>steel plants will be developed.<br>Since the goal of every beneficiation process, mineral-processing<br>operation in particular, is to effectively separate the valuable material from<br>the gangue with minimum loss to the tailings; the need to develop and<br>employ a sustainable, effective and relatively economical method of<br>separation is imperative. The concentration of the valuable minerals from<br>the gangue involves exploitation of the differences in physical, chemical and<br>electrical properties of the ore after effective comminution Akande et al<br>(2000). This work, therefore, is aimed at developing a process route for the<br>beneficiation of the Agbado- Okudu iron ore deposit located close to Jakura<br>village in Kabba, Kogi State for its possible utilization in Ajaokuta and<br>Delta Steel Plants.
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