Recovery of Iron Values with the Advanced Characterization and the Reduction Kinetics of Banded Hematite With Coal

Table of Contents

• Chapter 1: Introduction
  • 1.1 Objective of the Present Research
  • 1.2 Scope of the Present Investigation
• Chapter 2: Geological Configuration
  • 2.1 General Concept on Evolutionary Trend of Archean Basement
  • 2.2 Chronostratigraphic arrangement of the Singhbhum-Orissa Craton
  • 2.3 Generalised chronostratigraphic succession of the Singhbhum-North Orissa Craton
  • 2.4 Metallogenic development during the Crustal Evolution of Archean
  • 2.5 Geology of the Research Area
  • 2.6 Local Geology of the Ghatkuri Iron Ore Deposits
• Chapter 3: Characterisation of ore
  • 3.1 Introduction
  • 3.2 Literature study
  • 3.3 Materials and Method
  • 3.4 Results and Discussion
  • 3.5 Conclusions
• Chapter 4: Kinetics Of Reduction Of Banded Haematite Jasper Ore With Coal
  • 4.1 Introduction
  • 4.2 Literature Study
  • 4.3 Materials and Methods
  • 4.4 Results and Discussion
  • 4.5 Conclusion
• Chapter 5: Reduction roasting of Banded Hematite Jasper with Coke Oven Gas
  • 5.1 Introduction
  • 5.2 Literature study
  • 5.3 Materials and Methods
  • 5.4 Results and Discussion
  • 5.5 Conclusion

Objectives and Key Themes

This research investigates the recovery of iron values from Banded Hematite Jasper (BHJ) ore found in Ghatkuri, Jharkhand, India. The study aims to characterize the ore's physical, mechanical, and metallurgical properties, develop cost-effective upgrading methods, and understand the reduction kinetics of BHJ with coal. The ultimate goal is to lay the groundwork for the economical exploitation of this low-grade ore for the steel industry.

• Characterisation of Banded Hematite Jasper (BHJ) ore.
• Development of cost-effective beneficiation processes for BHJ.
• Kinetics of BHJ reduction using coal as a reductant.
• Investigation into low-temperature reduction roasting of BHJ with coke oven gas.
• Correlation between ore characteristics and reduction behavior.

Chapter Summaries

Chapter 1: Introduction: This chapter introduces the context of the research, highlighting the increasing demand for iron ore and the depletion of high-grade reserves in India. It emphasizes the need to utilize low-grade ores like BHJ, stating the limited research on its processing. The chapter outlines the research objectives, focusing on characterizing BHJ, developing cost-effective upgrading techniques, studying reduction kinetics with coal, and exploring low-temperature reduction roasting with coke oven gas. The study aims to contribute to the development of processes for the economical exploitation of BHJ.

Chapter 2: Geological Configuration: This chapter provides a detailed geological background of the study area. It discusses the evolutionary trends of the Archean basement, the chronostratigraphic arrangement of the Singhbhum-Orissa craton, and the metallogenic development during Archean crustal evolution. The chapter then focuses on the regional and local geology of the Ghatkuri iron ore deposit, describing the topographical features, rock formations, and the specific characteristics of the BHJ ore body within the Iron Ore Group. It includes data on annual production from the Ghatkuri mines.

Chapter 3: Characterisation of ore: This chapter presents a comprehensive characterization of the BHJ ore using various techniques. It includes a literature review of existing characterization studies on similar ores. The experimental methodology details physical, mechanical, and metallurgical characterization methods, encompassing ore microscopy, petrography, Bond Work Index analysis, Vickers Hardness tests, grain size analysis, liberation studies, chemical analysis, SEM-EDX, and XRD. The results reveal the intricate interlocking of iron-rich and gangue minerals, high Bond Work Index suggesting that traditional beneficiation routes might be uneconomical, and a predominantly hematitic composition with significant silica content. The chapter concludes by summarizing the physical, mechanical, and metallurgical characteristics observed.

Chapter 4: Kinetics Of Reduction Of Banded Haematite Jasper Ore With Coal: This chapter delves into the reduction kinetics of BHJ with coal. It begins with an introduction to reaction kinetics and a literature review of previous studies on iron ore reduction. The experimental methodology details the setup used for carbothermic reduction experiments at various temperatures and times. Different kinetic models (Ginstling-Brounshtein, Ash diffusion control, chemical contracting spherical reaction, gas film diffusion control, and nucleation controlled first order reaction) are applied to the data to identify the rate-controlling mechanism. The results show a low degree of reduction at lower temperatures, significantly improving at 1200°C, and the formation of SiC hindering the reduction at lower temperatures. X-ray diffraction (XRD) and Scanning Electron Microscopy (SEM) analyses of the reduced samples are presented and discussed. The chapter concludes with the calculated activation energy, suggesting that the Boudouard reaction plays a significant role.

Keywords

Banded Hematite Jasper (BHJ), iron ore, reduction kinetics, coal, coke oven gas, reduction roasting, magnetic separation, characterization, mineralogy, petrography, Bond Work Index, Vickers Hardness Number, XRD, SEM-EDX, beneficiation, steel industry, low-grade ore, geological configuration, Singhbhum craton, activation energy, Boudouard reaction.

Frequently Asked Questions: A Comprehensive Language Preview

What is the main topic of this research?

This research focuses on the recovery of iron values from Banded Hematite Jasper (BHJ) ore found in Ghatkuri, Jharkhand, India. The study aims to characterize the ore, develop cost-effective upgrading methods, and understand the reduction kinetics of BHJ with coal and coke oven gas to enable economical exploitation for the steel industry.

What are the key objectives of this research?

The main objectives include: characterizing BHJ ore; developing cost-effective beneficiation processes for BHJ; determining the kinetics of BHJ reduction using coal; investigating low-temperature reduction roasting of BHJ with coke oven gas; and correlating ore characteristics and reduction behavior.

What are the key themes explored in this research?

Key themes include the geological context of the BHJ ore deposit, detailed ore characterization using various techniques (microscopy, petrography, chemical analysis, SEM-EDX, XRD), kinetic analysis of the reduction process with coal and coke oven gas, and the evaluation of the suitability of different reduction methods for this low-grade ore.

What chapters are included in this research?

The research is structured into five chapters. Chapter 1 provides an introduction and outlines the research objectives. Chapter 2 details the geological configuration of the study area. Chapter 3 focuses on the characterization of the BHJ ore. Chapter 4 investigates the reduction kinetics using coal, and Chapter 5 explores reduction roasting with coke oven gas.

What methods were used to characterize the BHJ ore?

The characterization of the BHJ ore involved a range of techniques including ore microscopy, petrography, Bond Work Index analysis, Vickers Hardness tests, grain size analysis, liberation studies, chemical analysis, SEM-EDX, and XRD.

What reduction methods were investigated?

The study investigated two main reduction methods: carbothermic reduction using coal and reduction roasting using coke oven gas. Kinetic models were applied to the experimental data to understand the rate-controlling mechanisms.

What are the key findings regarding the reduction kinetics?

The reduction kinetics studies showed a low degree of reduction at lower temperatures, significantly improving at 1200°C. The formation of SiC hindered reduction at lower temperatures. The Boudouard reaction was found to play a significant role. Different kinetic models (Ginstling-Brounshtein, Ash diffusion control, chemical contracting spherical reaction, gas film diffusion control, and nucleation controlled first order reaction) were used to analyze the data.

What is the significance of this research?

This research contributes to the development of cost-effective processes for utilizing low-grade iron ores like BHJ, addressing the increasing demand for iron ore and the depletion of high-grade reserves. The findings can inform the economical exploitation of this resource for the steel industry.

What are the key geological aspects discussed?

The geological aspects covered include the evolutionary trends of the Archean basement, the chronostratigraphic arrangement of the Singhbhum-Orissa craton, metallogenic development during Archean crustal evolution, regional and local geology of the Ghatkuri iron ore deposit, and the characteristics of the BHJ ore body within the Iron Ore Group.

What are the key words associated with this research?

Key words include: Banded Hematite Jasper (BHJ), iron ore, reduction kinetics, coal, coke oven gas, reduction roasting, magnetic separation, characterization, mineralogy, petrography, Bond Work Index, Vickers Hardness Number, XRD, SEM-EDX, beneficiation, steel industry, low-grade ore, geological configuration, Singhbhum craton, activation energy, Boudouard reaction.