With the gradual depletion of the high-grade iron ore
reserves, it becomes obligatory on the part of the mining industry to consider
the exploitation and utilization of low/lean grade ores. In the present
investigation, the emphasis was on the development of a cost-effective process
flow sheet to benefit these ores to make them suitable for the user industry.
In this study, a three-level, three-factor Box- Behnken factorial design
combined with Response Surface Methodology (RSM) for modeling of process parameters
of Multi Gravity Separator (MGS) for recovery Iron values from sub-grade iron
ore, Deposit No. 5, Bailadila complex has been developed. The three significant
operational parameters of MGS, Drum rotational speed, Drum inclination and wash
water Flow rate were considered in the experimental work and all other
parameters like feed percent solids, shake frequency and shake amplitude were
maintained constant. The 'as received' sub-grade iron ore sample is an
admixture of lump and fines and chemically assayed and
Loss on Ignition (LOI). Experiments were conducted with representative
sample ground to -100 mesh as per the
design matrix. The obtained results were evaluated with the Box-Behnken
factorial design, RSM and also Quadratic programming (QP). Second-order
response functions were developed for a grade (
and recovery (% yield) of the concentrate fraction. Taking advantage of
quadratic programming (QP), it was observed that a maximum grade of achieved at a drum inclination of 3 degrees,
wash water flow rate of 6 Liters Per Minute (LPM) and a drum rotational speed
of 175 Revolutions Per Minute (RPM). Similarly, a maximum concentrate recovery
(Yield) of by weight could be achieved
at 5 degrees drum inclination, 2 LPM wash water flow rate and a drum rotational
speed of 225 RPM. Predicted values of responses obtained using model equations
were in good agreement with the experimental values. The influence of the
process variables of multi gravity separator on concentrate grade and recovery
was discussed. This finding proved that Box–Behnken design, response surface
methodology could efficiently be applied for modeling of some sub-grade iron
ore from Bailadila and that it is an economical way of obtaining the maximum
amount of information in a short period of time and with the fewest number of
experiments.
Author(s) Details
Gottumukkala
Venkateswara Rao
R&D Centre, NMDC Limited, Hyderabad, India.
Ravvala Markandeya
JNTUH College of Engineering, Manthani, India.
Rajan Kumar
JNTUH College of Engineering, Manthani, India.
Please see the book here:- https://doi.org/10.9734/bpi/caert/v5/8892A
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