Up-grading of agbado-okudu iron ore using magnetic separation and shaking table techniques

Table Of Contents

PAGE DECLARATION- – – – – – – – – – – – iii CERTIFICATION- – – – – – – – – – – – iv DEDICATION- – – – – – – – – – – – v ACKNOWLEDGEMENT- – – – – – – – – – vi ABSTRACT- – – – – – – – – – – – – vii TABLE OF CONTENTS – – – – – – – – – viii LIST OF TABLES- – – – – – – – – – – – xi LIST OF FIGURES– – – – – – – – – – – xiii

Chapter ONE

Introduction- – – – – – – – – – – – – 1

Chapter TWO

2.0 Literature Review- – – – – – – – – – – 4 2.1 Nigeria Iron Ore Deposits- – – – – – – – – 4 2.1.1 Agbado-Okudu Iron Ore- – – – – – – – – 5 2.1.2 Mineralogy of Agbado-okudu Iron Ore- – – – – 6 2.2 Study of some Nigerian Iron Ores Characteristics- – – – 7 2.2.1 Iron Ore Beneficiation Process- – – – – – – – 9 2.2.2 Gravity concentration process- – – – – – – 9 2.2.3 Magnetic separation- – – – – – – – – – 11 ix 2.2.4 Froth flotation- – – – – – – – – – – 13 2.3 Methods for the Beneficiation of Iron Ore- – – – – 13 2.3.1 Beneficiation route for the Itakpe Iron Ores- – – – 14 2.4 Procedures for development of conceptual flow sheet for a newly discovered ore- – – – – – – – – 17 2.5 Particles Size Analysis – – – – – – – – 19 2.6 Size/Assay Analysis – – – – – – – – – – 20 2.7 Determination of liberation size of the valuable Minerals in the Ore – – – – – – – – 20 2.8 Work index Determination – – – – – – – – 23 2.8.1 Standard bond method- – – – – – – – – 23

Chapter THREE

3.0 Materials and methods- – – – – – – – – – 26 3.1 Samples collection and equipment used- – – – – – 26 3.2 Methods- – – – – – – – – – – – 26 3.2.1 Preparation of the bulk sample for chemical analysis- – -26 3.2.2 Chemical analysis- – – – – – – – – – – 26 3.2.3 Microscopy- – – – – – – – – – – – 27 3.2.4 Size/Assay analysis- – – – – – – – – – 28 3.2.5 Work index Determination- – – – – – – – – 29 3.2.6 Separation test using shaking table technique- – – – 29 3.2.7 Separation test using Magnetic Separator- – – – – 30 x 3.2.8 Shaking table separation followed by Magnetic Separation techniques – – – – – – – 31

Chapter FOUR

4.0 Results and Discussions- – – – – – – – 32 4.1 Results – – – – – – – – 32 4.2 Discussions – – – – – – – – 32 4.2.1 Chemical analysis- – – – – – – – – – – 32 4.2.2 Mineralogical analysis- – – – – – – – 33 4.2.3 Size/Assay Analysis of the Head Sample – – – 34 4.2.4 Work index Determination- – – – – – – – 35 4.2.5 Concentration test using Shaking Table – – – – – 36 4.2.6 Magnetic separation technique- – – – – – – 40 4.2.7 Results of concentration test using shaking table followed by magnetic Separation Techniques – – – – 43

Chapter FIVE

5.0 Conclusions and Recommendations – – – – 46 5.1 Conclusions- – – – – – – – – – – – 46 5.2 Recommendations- – – – – – – – – – – 46 References- – – – – – – – – – – – – 58

Project Abstract

The beneficiation of the Agbado Okudu iron ore deposit located in Kogi State, Nigeria was investigated. The investigation involved determining the chemical composition and mineralogical characteristics of the run-of-mine. Followed by determination of the work index of the ore and then separation tests using shaking table, magnetic technique and a combination of the two techniques. The results of the tests carried out revealed that the Agbadu okudu iron ore contained on the average a total iron content (38.82% FeT), 49.10% (Si02) and other element. Thin sections of the ore sample examined under polarized light revealed that the iron bearing minerals are predominantly magnetite and hematite with a combined average percentage distribution of 69% and the mineral in abundant after the iron bearing minerals is quartz. The grindability test reveals that the Agbado Okudu iron ore has and average work index of about 4.32 kwh/tonne. The results of gravity separation shows that a concentrate with a maximum grade of 55.81% (FeT), and a recovery of 66.40% at particle size fraction -56 + 45ïm could be produced. While magnetic separation alone produced a concentrate with an optimum grade of 57.43% (FeT), and a recovery of 82.12% at particle size fraction of – 80+63ïm. However, combination of gravity separation technique (shaking table) followed by magnetic separation technique could only produce a concentrate with an optimum grade of 57.17% (FeT), and a recovery of 80.85% at a particle size fraction of –63+53ïm. Hence, based on the results obtained from the concentration tests, the Agbado Okudu iron ore deposit can be best beneficiated using magnetic technique to produce a concentrate that can serve as feed for pig iron production by conventional blast furnace route.

Project Overview

NTRODUCTION Iron is one of the most common elements on earth. Nearly every structure put on by man contains at least a little iron. It is also one of the oldest metals and was first fashioned into useful and ornamental objects about 3,500 years ago (Lambert and Mark, 1988). One of the most important determining factors for establishing Iron and steel plants is the availability of iron ore deposit with good geological, mineralogical and metallurgical properties. There is an estimated 2,707 million tonnes of iron ore deposit in the country out of which 200 million tones are in the proven reserve (Umunnakwe, 1988). Iron ore is simply the largest single raw material input in iron and steel making process and the country is endowed with abundant reserves of it but with varying characteristics. The deposits abound in different parts of the country as shown in Table 2.1. Most of the iron ores discovered in the country are however, low grade (their iron content in the crude ranges between 28-45% FeT). This meant that for them to be used in iron and steel production they have to undergo substantial beneficiation and upgrading. (Also and Yakubu, 1995). The Itakpe iron ore had been the most intensively studied and exploited deposit with a proven reserve of 200million tones with an average iron content of 36% FeT. This is presently being up-graded to obtain a 2 concentrate of 64% FeT for use at Ajaokuta and Aladja steel plants. Apart from the Itakpe iron ore deposit there are other deposit which reserves are estimated at over 2.3 billon tonnes as shown in (Table 2.1) within 150km radius of the Ajaokuta steel plant. To ensure security of supply of the iron ore for the nation Steel industries, further research and development need to be carried out on these new founded deposits to enable their full exploitation. With these reserves, conservative estimates indicate that the nation could be self-sufficient in iron ore for a period ranging between 100- 150 years (Umunnakwe1988). The role of iron and steel in the national economy is enormous. One cannot name an economic branch where iron and steel find no application and to some extend the economic power of a country is determined by its consumption and output of steel products. It is on this basis, that the Federal Government of Nigeria in 1971 launched the country into a new era of iron and steel technology by the establishment of the Delta and Ajaokuta steel projects. Though, the establishment of these projects was laudable inadequate attention was given to the development of local raw materials to feed the plants thus, making the plants on commissioning to import iron ore concentrate form countries like Brazil, Liberia and Guinea. Recently there has been renewed interests on the souring of locally available raw materials to feed these plants because the Itakpe iron ore project and the total iron ore requirement of Ajaokuta at 1.3 million tonnes of steel per 3 annum is about 2.135 million tones of iron concentrate and at this rate the Itakpe iron ore project is conservatively estimated to last for about 25 years, (Also and Yakubu, 1995). Also, the Itakpe iron ore plant commissioned on the 80s to deliver iron concentrate to Ajaokuta and later closed and now concessioned to Indians. Would not be able to meet the demand of Ajaokuta Steel plant when it finally takes off fully. It is therefore, important that these types of studies be conducted so as to increase the source of Iron Ore for Ajaokuta plant. And through such studies the technology for the beneficiation of various Nigerian iron ore deposits for onward supply to Ajaokuta and Delta steel plants will be developed. Since the goal of every beneficiation process, mineral-processing operation in particular, is to effectively separate the valuable material from the gangue with minimum loss to the tailings; the need to develop and employ a sustainable, effective and relatively economical method of separation is imperative. The concentration of the valuable minerals from the gangue involves exploitation of the differences in physical, chemical and electrical properties of the ore after effective comminution Akande et al (2000). This work, therefore, is aimed at developing a process route for the beneficiation of the Agbado- Okudu iron ore deposit located close to Jakura village in Kabba, Kogi State for its possible utilization in Ajaokuta and Delta Steel Plants.

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