QUALITY ASPECTS OF

BENEFICIATION & PELLETIZATION

• The average feed ore composition may change for different sources depending upon its availability of respective plants. Adapting the changes to maintain the quality is a challenge for Beneficiation.

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• Optimal liberation of the ore matrix is very much required task for the up gradation. Incomplete liberation can impact poor efficiency of the beneficiation process and the overall quality and yield of the final product achieved.

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• Managing this variability is challenging but essential for maintaining consistent quality.

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Beneficiation Hurdles/Target

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The feed ore should be mostly constant even though different sources of material availability with various grades.

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GPIL operates magnetic beneficiation circuit through a MIMS/LIMS/HGMS bank for achieving desired concentrate suitable for pellet plant requirement.

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Maintaining proper feed ratio, feed rate, mill discharge pulp densities, and specific grinding size of the iron ore is the prime requirement for attaining the beneficiated product with a consistent Blaine for achieving proper filtration moisture, meeting pellet plant requirements.

Magnetic Ore

Concentrate Filter Cake

Green Pellets

Indurated Pellets

GPIL Feed, Concentrate & Product Scenario

Pellet Plant Hurdles/Target

• Pellet induration is the final task in the Pellet production but

many vital parameters play an important role in achieving the said requirement. Pellet porosity is such key parameter in Pellet production.

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• Porosity is defined as a measure of voids

volume with respect to the total volume

of the pellet which is represented in

percentage.

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Porous Pellet

Porosity Apparatus

• Many pellet plants are facing the porosity problems,

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• This is due to the excessive grinding resulting more fineness in the iron ore filter cake with high grind and Blaine. Lack of the porosity may end up with induration problems such as improper firing, over firing in the pellet product . This will create negative results in the post firing characteristics namely low reducibility, high swelling index and high RDI (Reduction Degradation Index).

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• In pellet plant the agglomeration of the green ball depends on the ore grinding nature of the material with suitable grind size and Blaine.

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• In Beneficiation process, need to remove as much fines as possible to avoid regrinding for maintaining a suitable grind size. This will further provide a required porosity in the final pellet induration.

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• The sub microns particle in the final filter cake of d10µ should be 15 to 25% for ideal balling & good porosity.

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• This could be achieved through continuous study of the material by conducting the R&D studies in laboratory on ore grinding, filtration and balling test for attaining optimum results.

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Typical Parameters of GPIL Iron Ore Feed, Concentrate & Product

Quality Control Hurdles/Target

• Quality Control Plays a vital role in the Beneficiation & Pelletization process.

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• To know the characteristics of the material, conduct various tests like the particle size distribution, size analysis & fractional chemical analysis for assessing the ore behaviour.

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• Continuous monitoring of in process Quality Control parameters like, the pulp density, physical analysis and chemical analysis as per the sampling plan and schedule.

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• Proper collection of samples as per standard norms is

very crucial for the quality control to operate the Plant

effectively. The representative sample collection and accurate testing ensures effective process operation.

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• Adhering to the QAP (Quality assurance plan) of the sampling plan/schedule will determine accuracy of the analysis results.

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• Special samples as and when required for the process improvement should be collected by the quality control such as, complete beneficiation circuit analysis, individual equipment feed and product analysis. This will give a clear picture to take a forward step in the process with any correction if required.

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• Skilled personnel are required for sample collection,

analysis and process monitoring.

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• Accuracy of the weight has the direct impact on the accuracy of the

results obtained. Hence a proper digital calibrated balance is required.

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• Use always AR (Analytical Reagent) grade chemicals for the testing and calibrated glassware for measuring the analysis.

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• Standardization of the solutions and cross checking with the CRM (Certified Reference Material) samples is essential for achieving accurate results.

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• Cross functional analysis checking between persons to be done from time to time for precision analysis evaluation.

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• Timely calibration of the measuring and monitoring devices is a must for the quality control with proper validation.

Conclusion:

• GPIL Quality control maintains all the required standards for meeting the process requirements and achieving the targeted production with quality and quantity meeting customer demands.

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