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By Franklin G. Pardee

WARTIME depletion of the reserves of iron ore in the Lake Superior region of the grade and character now being shipped down the Lakes was serious. The time has come to take stock of the resources that remain in order to plan our future program of supply for our blast furnaces and protect, as far as possible. the tremendous investment made in the Lake Superior iron mining industry. Hugh M. Roberts and William H. Crago have estimated the reserves of the Lake Superior region in the United States at two billion long tons. These reserve figures are of direct-shipping ore and those concentrates produced by methods now in commercial use or those methods that may be expected in the near future. In their estimate they have assigned 392 million long tons to the Michigan ranges (all reserves in long tons) : 112 million tons for the Gogebic. 140 million tons for the Menominee, and 140 million tons for the Marquette.

Jan 1, 1948

By Magnus Ericsson

The unexpectedly quick recovery in world crude steel production in the second half of 2009 was due almost entirely to increased production in China that began in late 2008. Previous peaks in monthly production in China were matched by April 2009. The rest of the world had still not reached pre-crisis production rates by May 2010. Chinese production drives growth, but there has been some growth in most other larger crude steel producing countries as well, compared to production in 2009. If the production rate of the first four months of 2010 continues, the total output of crude steel in 2010 will be somewhere around 1,410 Mt (1.5 billion st), the same as in the record year of 2007.

Jan 1, 2010

By S. A. Mahon

AN interesting feature among the mining structures, on the Mesabi. iron range is the iron ore stacker erected in 1934 at the Mesabi Chief washing plant at Keewatin, Minn. It is built of structural steel, and carries a system of belt conveyors which collects the washed product of the plant and places it on a stockpile for subsequent shipment. Although the only one of its kind in the Lake Superior iron district, installations of similar nature have been used elsewhere in the handling of coal and gravel and in earthwork construction. The reasons for stocking Lake Superior iron ores may be as various and diversified as the methods used in building the piles. At the under¬ground mines the existence of the huge piles in evidence at each active shaft is due, principally, to climatic conditions in this north country where the shipping period is much shorter than the operating season. Conversely, at the washing. plants it may be desirable to stockpile washed ores because the shipping season is commonly of longer duration than the period during which the plants may be operated. Washed ores, and mixtures of which washed ores are a component part, have found high favor with the oper

Jan 1, 1935

By J. S. Hall

The productivity and fuel efficiency of iron-ore blast furnace operations has greatly increased in recent times. These improvements, particularly to the Japanese steel industry, have primarily arisen from process engineering studies of the blast furnace and associated operations such as sintering. The development of fluxed sinter based on iron-ore fines reacted to produce highly reducible, low slag sinters has contributed further to a reduction in fuel requirements. The Pilbara province of Western Australia is a significant source of these iron-ore fines supplied to the international market. Increasingly, this market is being offered high quality ores from other foreign sources. To technically assist companies in improving the processing efficiency of ores, and to improve the technical marketing of ores by modelling the processing characteristics of Australian/international ore blends, the Commonwealth Scientific and Industrial Research Organization (CSIRO) is actively assisting the industry by researching the general theme of 'iron ore from mine to metal in this paper we outline progress towards a numerical description of: a. ore deposit classification. b. Degradation during transport. c. Direct reduction of iron ore. d. Liquid bath ore reduction/smelting. e. Industrial sintering.

Jan 1, 1986

By W. M. Goodwin

"IntroductionIN THE preceding paper we have learned about Canada's resources of metallurgical coal. There is an adequate amount in Nova Scotia, a very large reserve on the eastern flank of the Rocky mountains, and a strictly limited supply on the Pacific coast. Added to these is an unknown quantity of coking coal in the Peace River district, at present rather isolated but possibly capable of industrial development in the future.The chief use of metallurgical coal is to make iron and steel. For this, an adequate supply of iron ore is required. So we should now scan the Canadian supply of iron ore, the possibility of its increasing use at home, and the probable markets abroad.Trade in iron ore tends to be international, as is the case with many other raw materials. The present tendency with iron and steel, in contrast, is to keep its manufacture within national boundaries, and there is no evidence that this will change much in the years to come. We should keep these two points clearly in mind when considering the disposal of iron ore from Canadian mines. We should remember, also, that the modern blast furnace and steel plant has such a large output that a correspondingly large population, reasonably compact, is needed to consume its products.Large Ore Supply in East, Small in WestCanada has now four major iron ore fields, well situated to serve adequately the eastern half of the country. Wabana .and Labrador are well placed to serve overseas markets and plants on the eastern seaboard and eastern interior of the United States and Canada."

Jan 1, 1952

By E A. Agorhom, P N. Aabulleh

The bulk of the worldÆs production of iron ore is processed into steel. The needs of the steel industry therefore demand a high exploration and exploitation of iron ore. One trend within the industry has been a great increase in the demand of iron ore and this is reflected in an increase in world steel production from 1955 to date. In addition to the high demand for steel, is ChinaÆs high appetite to feed its steel industry. It is therefore important that the iron ore potential of Ghana is showcased for eventual exploitation by potential investors to meet this enormous demand for the commodity in the industry globally. Ghana has three main iron deposits of potential industrial and commercial importance. They are: Shieni sedimentary iron ore (reserves: 1.270 X 106 metric tonnes), Pudo titaniferous-magnetiferous iron ore and the Opon-Mansi lateritic iron ore deposits. The Opon-Mansi iron ore deposit occurs in the Western region of Ghana. The ore deposits are located on top of the range of 15 hills, which extend over a distance of 24 km from Opon-valley, south of the Western region to Dunkwa. The area has an estimated 147 Mt of iron deposit, with Fe content of 52.5 per cent. This paper looks at the iron ore potential of Ghana and how it is capable of attracting potential investors to exploit this valuable mineral for global consumption.

Jan 1, 2007

By Jean G. Fortin

The manufacturers' proposed technology has been a key factor in selecting production, mobile and fixed equipment in order to achieve the targets set in our 2026 mining plan. This paper will present an overview of the most recent technologies adopted by Québec Cartier Mining Company for communications, power supply, dewatering, drilling, loading, hauling and processing. All these new technologies contribute to the improvement of our day to day operations while operating with a state of the art asset reliability program.

May 1, 2007

By J. Du, V. Shukla, C. R. Kumar, U. Shivangi, D. P. Chakraborty

During the processing of iron ores, a large quantity of low-grade tailings containing abundant iron values in fine particle size range is produced. Due to the increasing demand in the high-grade ores for metallurgical operations and the stringent environmental conditions imposed on mining activity, it is essential to utilise the waste tailing pond slimes. Recovery of iron values from these tailing ponds not only enhances the life of the existing operating mines, but also enables achievement of a sustainable process. Iron ore tailing/slime (-150 μm) is produced after scrubbing and wet screening of a low-grade iron ore. Tailing beneficiation of iron ore has been addressed either by flotation or wet high intensity high gradient separation. The present paper aims to recover iron values from discarded slime containing assay ~56% Fe, ~6.5% SiO2, and ~7.0% Al2O3 from the Noamundi processing plant by using a high gradient magnetic separator (HGMS). In this process, tailings are effectively processed with a vertical pulsating high gradient magnetic separator to produce a relatively high-grade iron concentrate. The results of investigation indicate that this novel process is capable of producing an iron concentrate assaying ~ 60% Fe and ~3.25% alumina with a yield of ~55 % on weight basis and recover > 65 % iron bearing particles from the tailings. More importantly, the corresponding tailing contained ~45% Fe. It was concluded that this novel process may be effectively used to recover iron values from low-grade hematite tailings. Keywords: Iron ore slime, Fe recovery, HGMS, yield, Noamundi

Jan 1, 2020

By G Senanayake, K Hazarika

The demand for iron-ore is ever increasing with the industry directly employing 60 500 people in a range of highly skilled roles in Australia. In the year 2019, the global iron-ore production was 2.85 billion tonnes. It is estimated that each tonne of beneficiated iron ore produces 400 kg of tailings. The IOTs are fine, dense and stable crystalline material mainly composed of iron oxides, alumina and silica. The current and most applied method of iron-ore tailings (IOTs) disposal is using subaqueous disposal of tailings in dams. The footprint generated by a tailings dam is massive and requires constant monitoring due to the possibility of a failure making the operation and maintenance of tailings dam extremely expensive. This review briefly discusses the known causes of tailings dam failures, their impact to the environment and day-to-day human life and potential applications of IOTs. The increase in water content enhances the pressure on dam walls. This in turn increases the liquefaction potential of the tailings and reduces the overall strength of the dam making it more vulnerable to failure. Potential applications of IOTs are in paints, aggregates in construction materials and bricks. The reuse of IOTs reduce waste and generates further revenue facilitating a path towards a sustainable future for the industry.

Nov 8, 2021

By I Sherrell, R Jain

Worldwide iron ore feed grades are trending downwards and will continue to do so with the increasing difficulties of upgrading ores. This has led to operations looking for ways to capture current tailings that still contain valuable material. In the past, these were acceptable to dispose of, but this practice is no longer economically feasible. With the increasing trend of re-mining previous tailings deposits that could be decades old, new equipment designs have been introduced to upgrade current or historic beneficiation plants. These designs can effectively upgrade these tailings to saleable products.Outotec conducted test programs for upgrading iron ore tailings from flotation rejects, thickener underflow or tailings dumps on samples provided by customers around the globe. The studies utilised Outotec’s SLon vertically pulsating high-gradient magnetic separator in combination with preprocessing equipment such as low-intensity magnetic separation, screen or scrubber and flotation for downstream processing of the magnetic concentrate. A review of the equipment required to economically process these tailings is provided, along with testing data and industrial implementation examples. The effect of different operational and design parameters on Fe grade and recovery from processing each tailings sample has been highlighted.CITATION:Jain, R and Sherrell, I, 2015. Iron ore tailings reprocessing to maximise ore production, in Proceedings Iron Ore 2015, pp 149–158 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By P Donecker

Like all chains, iron ore values chains are only as strong as their weakest link, which in ore processing is often the humble chute. While mechanically the simplest element in the iron ore flow sheet, chutes are often the most problematic and regularly the major cause of unscheduled downtime. Chute designs have remained static for decades, despite the extra demands being placed on them by grade reduction, which impacts chutes in three ways viz: 1. Higher volumetric rates as infeed increases to meet production targets. 2. Higher moisture content as mining goes below water table. 3. Stickier properties as the dilution phase is often clay based. While there is no shortage of ideas and the geometry options are infinite, the fact is that chute design has not kept pace with grade decline and has remained essentially unchanged. One reason cited for this lack of innovation is the difficulty evaluating and de-risking designs. While the power of computers running Discrete Element Method (DEM) models has advanced, the models themselves still need to be ‘calibrated’ with the dynamic properties of the ore. Flow properties commonly measured for bin design are useful for static situations only and were never intended to predict dynamic behaviour as in chutes, a critical qualification lost in the mists of time. So while they always produce a colourful and reassuring animation, DEM models informed by static ore properties often result in wildly inaccurate real world predictions. Responding to this low success rate, many operators are now utilising physical modelling to help reduce risk and avoid the consequences of having an underperforming chute in their value chain. Physical testing, in a dimensionless scale-down of the proposed system (bulk material and chute geometry), addresses the shortcoming of mathematical models designs and when used in combination with DEM is the best option. In the ideal world, the focus of chute modelling should be innovative design concepts aimed at addressing future needs, however in reality the focus is nearly always on modifications to installed chutes that are underperforming even today. This situation can be traced back to design procedures which if informed at all, are based static ore properties. As an industry, we need to break this cycle and become more proactive, which means addressing flaws in the current design process. In 30 years of providing modelling support to the industry, I have looking at hundreds of underperforming chutes in the iron ore industry. This practical experience has led to a unique and unbiased perspective on chute design and their performance in the real world. The knowledge presented in this paper can not only be used to help avoid baked-in problems now, but also help guide and evaluate designs so we can deal with the challenges of our low-grade future.

Sep 18, 2023

By Carl Zapffe

JUST as 85 per cent of the total ore produced annually in the United States comes from the Lake Superior region, so does one of its six producing districts-the Mesabi --dominate that region both as to production and total reserves; also in ore Treatment, Mesabi practice is dominant. Therefore, in discussing future reserves or ore treatment one may visualize one big district with five smaller districts as so many satellites. In considering the future less thought need be given to processes than to, economic policies. For thirty years experimental work has now been in progress and every possible ore-treatment process now known has been given attention. This work was started when there was no recognizable danger of running short of ore because of rapid consumption. Thirty years ago the annual production had just progressed beyond the twenty-million bracket for the first time. Today fifty million tons is considered a small production, and last year the aim was for 65 million. At the recent rate of production the life of the estimated reserves of good ore is about 35 years. All who know the local terrain are convinced that, unlike thirty years ago, the chances for discoveries of new big deposits are nil; treatment of lean ores obviously is to become an all-important topic.

Jan 1, 1938

By D Tucker, K Harney

Hatch forecasts that an increasing share of seaborne traded iron ore will be ultrafine, being either concentrate or pellet feed. This provides several challenges for the iron and steel industries, but the principal concern is: how much ultrafine iron ore can be consumed on sinter strands and with a minimal effect on productivity?This paper will identify new supply by project through 2020. Demand will be estimated for sinter production and practical steps will be identified to increase ultrafine consumption in sinter strands. The long-term iron ore price will be forecast to balance supply and demand. The paper will conclude by assessing how the pricing of ultrafine ore will develop relative to the Chinese iron ore indices.CITATION:Tucker, D and Harney, K, 2015. Iron ore ultrafines challenges and opportunities, in Proceedings Iron Ore 2015, pp 501–504 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By M Zlatev, S Silge

Producers of primary resources such as iron ore face the challenge of processing crude materials with increasing levels of impurities, which may result in the requirement for wet processing. This results in a significant increase in water usage, power consumption and operating costs. Given the remote locations of most operations in Australia (Stewart et al, 2013; Prosser, Wolf and Littleboy, 2011), the required volumes of power and fresh water for wet processing can be very difficult to achieve.HAVER&TYLER is renowned across the world for their screening technology in wet and dry processes. Its innovative Hydro-Clean® system represents a cost-effective and eco-sensitive way to clean any crude materials and material blends with a grain size distribution of 0–150 mm that are contaminated with adhesive clay, slit and other impurities.CITATION:Silge, S and Zlatev, M, 2015. Iron ore washing – achieve more with fewer resources, in Proceedings Iron Ore 2015, pp 519–528 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 13, 2015

By Francois Clerf

IRON ORE fields are situated in both the East and West of France (see maps). The eastern deposit is by far the most important from a tonnage point of view, not only in France, but in all Europe. The ores of this region are known as minette, and are situated in the Lorraine ore fields and the Briey plateau. The iron ores of the West are those of Normandy, Anjou and Brittany. Before the war, a large number of important German companies had acquired considerable interests in these western fields and a heavy trade with Westphalia had begun. Recently, however, conditions have changed and some of the mines of Brittany and Anjou are now idle. From a geological point of view, in Anjou and Brittany, a series of synclines extends from the northwest to the southeast, containing a number of seams of varying thickness and generally intercalated in Silurian and sometimes in Devonian formations. The ore is generally a hematite or a magnetite. The composition varies from 48 to 52 per cent of iron and from 8 to 12 per cent of silica. Con¬servative estimates indicate a con¬siderable tonnage of workable ores (150,000,000 metric tons).

Jan 1, 1936

By Joseph Daniels

IN connection with a study of the feasibility of establishing a blast-furnace industry in the Puget Sound region of Washington, possible sources of ore supplies along the Pacific rim were investigated. Many of the South American countries are known to contain important resources of iron, particularly Brazil and Chile. This latter country, because of its position on the west coast and the easy accessibility of its de- posits, appeared to be a logical place to consider as a potential supply for the Pacific Northwest. Accordingly, a brief field study was made of the deposits in September, 1924. Attention was confined to a limited number of properties on the west coast in the provinces of Antofagasta, Atacama, and Coquimbo. Passing consideration was given to the question of coal resources, and a short visit was made to a blast-funace plant at Corral in southern Chile which had been operated for a limited period as a producer of pig iron. In the following paper, a brief outline is given of the general observations made and of the salient facts rioted in the time available for the general study.

Jan 1, 1926

By A. Kostin

GIS and multivariate geometric distribution have been used to predict the association of high-level intrusives with hydrothermal alteration related to iron oxide Cu-Au (IOCG) mineralizing systems. Several examples in the Russian northeast are presented in this paper. IOCG ore deposits can have enormous geological resources containing significant reserves of base, precious, and strategic metals, and hence are economically attractive targets for mineral exploration. To date, examples of this type of mineralization have not been reported from the northeastern area of Russia. The Tarinskiy ore cluster, located in Eastern Yakutia, shows brecciated altered rocks with sulphide and iron oxide cement, which is typical for IOCG mineralization of the iron oxide Cu-Au±U type. This cluster was formed near surface and is linked with the Rep- Yuruinskiy pluton. It has potential to host new world-class precious metal deposits in northeastern Russia

Jan 1, 2014

By Jiann-Yang Hwang

Microwave heating has been proved an effective method to rapidly heat iron oxide. This offers an opportunity to apply microwave heating in the steelmaking process. The reduction reaction of iron oxide is traditionally achieved at high temperature with reducing gases such as H2 and CO generated from various sources, including coke, coal, and natural gas. This study investigates the differences in iron oxide reduction using conventional and microwave heating under H2 and CO atmospheres. A special microwave thermal gravimetric device was designed and built to facilitate the investigation. With this device, iron oxides can be heated by electric resistance heating, microwave heating, or a combination of methods. The incoming CO and/or H2 also can be preheated to simulate a potential utilization of recovered heat. The iron oxide weight and temperature can be monitored during an entire reduction period. A series of reduction experiments have been conducted. The results are presented and discussed.

Jan 1, 2006

By H. R. Huffman

"This paper reviews the history of iron powder production, and outlines the varions production methods. The uses of iron powder and the reasons for its use are also covered. The paper concludes with a look at future trends in powder metallurgy.INTRODUCTION TO POWDERSTHE IRON POWDER INDUSTRY is enjoying a very rapid growth. The annual consumption of iron powder is now at the 100,000-ton level, twenty times higher than it was at the end of World War II, and the yearly in-crease bas been almost consistent at 20 per cent. This is expected to increase, bringing the tonnage to 200,-000, or even (according to some experts) to 270,000, in 1970. In any event, powder metallurgy is expanding at high speed and making an important impact on the production of iron and steel products. Some indication of the faith in the future market may be indicated by the commencement of three new powder production plants in Canada with a total capacity of 136,000 tons annually."

Jan 1, 1969

By C. R. Mambote

One of the processes developed for vanadium recovery from the fly ash of crude oil is through acid leaching. In the process, iron is one of the impurities that should be removed before vanadium precipitation, due to the fact that iron tends to co-precipitate with vanadium. The mechanism of iron precipitation is understood in terms of ferric hydrolysis, followed by the dimerization and subsequent polymerization of the crystalline iron compound. In order to develop a new approach for the fly ash processing, in the present paper the precipitation of iron from the liquor after the leaching process was studied with addition of NaOH or NH4OH in the presence of H2O2 or Na2C2O4 at 80°C. The objective was to investigate the feasibility of the selective precipitation which could be applied to vanadium and nickel recovery from the fly ash. The experimental results show the difficulties of removing iron by precipitation without co-precipitating nickel and vanadium.

Jan 1, 2014