Abstract
M.Sc.
An estimated 98% of the iron ore exploited in the world is used in the manufacture of pig iron and steel, which are non-substitutable backbones of modern society. The rapid increase of world steel production over the last few years, driven mainly by economic growth in China, have required an equal increase in iron ore production, from 876.8 Mt in 2006 to 948.1 Mt in 2007. The increased rate of exploitation of iron ores has resulted in a rapid depletion of known high-grade iron ore deposits. This, in turn, has led to a dramatic increase of prices, especially for highly thought-after high-grade lumpy iron ores from BIF-hosted deposits. In the absence of any major new discoveries of high-grade iron ore deposits, mining companies have turned to lower-grade materials to assess their beneficiation potential to expand their production base and beneficiation capacity, in order to satisfy future demand. Within this existing framework, this research project was initiated to assess the beneficiation potential of low-grade lumpy stockpiles and high-grade iron ore fines at Beeshoek Iron Ore Mine, owned by Assmang Ltd. The mine is located 7 km West of Postmasburg, in the Northern Cape Province of South-Africa, and processes currently 5.60 million tons of uncontaminated run-of-mine ore per annum. Crushing, washing, classification and jigging are used to produce 2.12 million tons of (37.8% of ROM) of lumpy iron ore product. The balance (3.48 million tons) is currently not used, but is stockpiled or discarded. This includes 0.90 million tons (16.2% of ROM) of ore-grade fines, 0.86 million tons (15% of ROM) of tailings sludge and 1.74 million tons (31% of ROM) of lumpy low grade material. Both ore-grade fines and low-grade lumpy material are discarded separately; they are currently considered as waste. The low-grade lumpy is stockpiled while the fines are used to fill-in mined-out open pits. The evaluation of the beneficiation potential of these two material streams is the main goal of this study.
Representative samples were collected from ore-grade fines and the current stockpile for low-grade lumpy material. Hand sorting and lithological categorization of the lumpy material facilitated petrographic and mineralogical studies using light and scanning electron microscopy, as well as X-ray powder diffraction studies. Major and trace element geochemistry were determined using X-ray fluorescence spectrometry and titrimetry (to accurately determine the concentration of iron). Whole rock densities were determined for all lithotypes recognized in the low-grade lumpy material. The grain size distribution was determined for the lumpy materials by actual measurement of the diameter of a representative number of particles, and for fines by sieve analysis. Fines beneficiation tests were conducted using spiral separation and simple classification tests. Washing was used as additional beneficiation method on the fines.