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

3.3.1 Materials

3.3.2 Methods

3.3.2.1 Physical Characterisation

3.3.2.1a Ore Microscopy (Reflected light microscopy)

3.3.2.1b Petrography (transmitted light microscopy)

3.3.2.2. Mechanical Characterisation

3.3.2.2a. Bond Work Index analysis (BWIA)

3.3.2.2b. Vickers Hardness Number (VHN)

3.3.2.2c. Grain Size analysis

3.3.2.2d. Liberation Study

3.3.2.2e. Davis tube test

3.3.2.2f. Chemical analysis

3.3.2.2g. Size-Wise chemical analysis

3.3.2.2h. Sink and Float analysis

3.3.2.3. Metallurgical Characterisation

3.3.2.3a. XRD, SEM-EDS

3.4. Results and Discussion

3.4.1. Physical attributes

3.4.2. Microscopic observation

3.4.3. Power input estimation through Bond Work Index

3.4.4. Mechanical nature of grains through Vickers Hardness Number

3.4.5. Results of Grain Size Analysis

3.4.6. Nature of grain alignment through liberation characteristics

3.4.7. Davis Tube Test for the untreated BHJ

3.4.8. Chemical and Material Characterisation

3.4.9. Result of the size wise chemical assay

3.4.10. Result of sink and float analysis of BHJ

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

4.3.1. Materials

4.3.1a. Raw Materials

4.3.1b. Apparatus

(i) Empty Quartz Capsule

(ii) Horizontal Tabular Furnace

4.3.2 Methods

4.3.2.1. Chemical Analysis

4.3.2.2. Characterisation Studies

4.3.2.2a. X-Ray Diffraction Analysis

4.3.2.2b. Scanning Electron Microscopy

4.3.2.3. Experimental Procedure

4.3.2.4. Rate laws in reduction

4.3.2.5. Factors controlling the rate of reduction

4.3.2.6. Various Kinetic Models used in present work

4.3.2.7. Determination of Activation Energy

4.3.2.8. Metallurgical System and Approaches in Kinetic Analysis

4.3.2.8a. Factors Determining Rate

4.4. Results and Discussion

4.4.1. Reduction of BHJ with Coal

4.4.2. Degree of reduction

4.4.3. Reduction of BHJ sample of Ghatkuri (Gua); West Singhbhum, Jharkhand at 1000 °C at constant time with varying temperature

4.4.4. Kinetics of Reduction of BHJ with Coal

4.4.5. Calculation of Activation Energy

4.4.6. Characterisation Studies

4.4.6a. X-ray Diffraction

4.4.6b. Scanning Electron Microscopy

4.5. Conclusion

Chapter –5. Reduction roasting of Banded Hematite Jasper with Coke Oven Gas

5.1. Introduction

5.1.1. Reduction roasting

5.1.2. Magnetic behaviour of the elements

5.2. Literature study

5.3. Materials and Methods

5.3.1. Materials

5.3.2. Methods

5.3.2a. Reactions involved in the Iron Ore Reduction

5.4. Results and Discussion

5.4.1. Effect of Particle size

5.4.2. Effect of Roasting Temperature

5.4.3. Effect of varying Roasting time

5.5. Conclusion

Research Objective and Scope

The research focuses on the recovery of iron values from low-grade Banded Hematite Jasper (BHJ) found in the Ghatkuri region of Jharkhand, India, addressing the depletion of high-grade iron reserves by evaluating its geological characteristics and developing viable processing methods for its industrial utilization.

• Characterization of the physical, optical, and mechanical properties of BHJ ore.
• Development of low-cost, energy-efficient beneficiation processes.
• Investigation of reduction kinetics using coal and coke oven gas.
• Analysis of temperature and particle size effects on the degree of reduction.

Excerpt from the Book

Summary of Chapters

Chapter -1. Introduction: Discusses the surging demand for iron ore, the depletion of high-grade reserves in India, and the necessity of utilizing low-grade ores like Banded Hematite Jasper.

Chapter – 2. Geological Configuration: Details the evolutionary trends of the Archean basement in the Singhbhum region and provides the geological context for the research area.

Chapter – 3. Characterisation of ore: Presents a comprehensive scientific analysis of the physical, mechanical, and mineralogical properties of the BHJ ore samples.

Chapter – 4. Kinetics Of Reduction Of Banded Haematite Jasper Ore With Coal: Explores the reaction kinetics and the reduction behavior of BHJ ore using coal at varying temperatures.

Chapter – 5. Reduction roasting of Banded Hematite Jasper with Coke Oven Gas: Examines the efficacy of reduction roasting using coke oven gas as an energy-efficient beneficiation technique.

Keywords

Banded Hematite Jasper, Iron Ore, Beneficiation, Reduction Kinetics, Singhbhum, Ghatkuri, Geochemistry, Carbothermic Reduction, Coke Oven Gas, Mineral Characterization, Bond Work Index, Vickers Hardness, Metallurgy, Ore Processing, Sustainable Development

Frequently Asked Questions

What is the core subject of this research work?

The research focuses on the potential for utilizing low-grade Banded Hematite Jasper (BHJ) as a sustainable source of iron to address the rapid depletion of high-grade hematite ore reserves in India.

Which regional deposits are analyzed?

The study specifically analyzes BHJ ore samples collected from the Ghatkuri Iron Ore Mines, located in the Gua area, West Singhbhum, Jharkhand.

What is the primary objective of this study?

The primary aim is to recover iron values from BHJ through advanced characterization and a thorough investigation of its reduction kinetics and roasting parameters to establish a commercially viable industrial process.

Which scientific methods are employed for material testing?

The research uses a variety of methods including ore microscopy (reflected/transmitted), SEM-EDX, XRD, Bond Work Index analysis, Vickers Hardness testing, and sink-and-float analysis.

What are the main thematic areas covered in the chapters?

The work covers geological settings, material characterization, reduction kinetics with coal, and the evaluation of reduction roasting techniques using coke oven gas.

What key keywords characterize this research?

Key terms include Banded Hematite Jasper, iron ore beneficiation, reduction kinetics, mineral characterization, Singhbhum region, and sustainable mining.

How does the presence of SiC affect the reduction process at lower temperatures?

At temperatures between 1000-1100 °C, the formation of silicon carbide (SiC) as a predominant phase acts as a barrier, hindering the reduction of iron oxide in the ore.

What are the optimized parameters for reduction roasting discovered by the author?

The study concluded that the optimized parameters for reduction roasting include a temperature of 600 °C and a residence time of 60 minutes, using a particle size of 13 mm.