Beneficiation of Low-Grade Hematite Iron Ore Fines by Magnetizing Roasting and Magnetic Separation

Present investigation includes the magnetizing roasting of low-grade iron ore fines followed by grinding and beneficiation using magnetic separation. The hematite iron ore used in the investigation contains 53.17% T Fe, 10.7% SiO₂, and 4.5% Al₂O₃. Powdered bituminous coal of 210 μm size with an ash content of 12.5% and fixed carbon of 54.25% was used as reductant during magnetizing roasting. Optical microstructures have shown where iron and silicate minerals are found and how they are interconnected. Hematite is the most abundant material in the specimen and is found in fine- and medium-sized grains. Hematite emerged as the predominant iron-bearing mineral, accompanied by magnetite and goethite phases in smaller proportions according to XRD analyses. The primary gangue mineral identified by scanning electron microscopy is quartz, with gibbsite, feldspar, and pyrolusite present in lesser levels. The effects of iron/coal ratio, roasting time, and roasting temperature were considered as variable parameters. Hematite ore's magnetic characteristics were significantly impacted by magnetizing roasting. By selectively magnetizing roasting, hematite is transformed into magnetite. With an Fe grade of 65.25% at a recovery value of 72.5% in the concentrate, magnetic separation produced the greatest result for Fe. The performance of magnetization and therefore the magnetic separation process were shown to be significantly impacted by temperature, reductant %, and roasting duration in this investigation.