JMMCE  Vol.8 No.5 , May 2009
Pilot Scale Froth Flotation Studies To Upgrade Nigerian Itakpe Sinter Grade Iron Ore To A Midrex-Grade Super-Concentrate
The sinter grade concentrate of Itakpe iron ore found in the North Central Kogi state of Nigeria with cumulative undersize of 6.34% and 2.12% passing 90μm and 63μmsieves, respectively, and that assayed 63.63% Fe, 5.90% silica and 0.72% alumina was ground in ball mill to produce a pilot plant froth flotation feed with cumulative undersize of 74.37% and 42.94% for 90μm and 63μm sieves, respectively. The ball mill discharge was then treated in three stages of roughing, cleaning and re-cleaning in a pilot plant froth flotation process line and the products obtained gave 66.66%, 66.51%, 65.44% (Fe) and total acid (silica and alumina) contents of 4.22%, 4.39%, 5.15%, respectively, for the three stages. The super-concentrate obtained also gave 81.13%, 55.19% and 30.57% cumulative undersize for 90μm, 63μm and 45μm sieves, respectively. The results obtained showed that the roughing stage of the flotation process produced a super-concentrate that fall in the range of 66% to 68% for use in midrex direct reduction plant at the Delta Steel Plant, Nigeria. The lowest total acid gangue content of 4.22% was also obtained for the roughing stage, indicating that the two subsequent processes of cleaning and re-cleaning were not needed. Although, the total acid content of 4.22% for the roughing stage product slightly exceeds the upper limit of 3.50% for the Midrex process, Itakpe sinter grade concentrates with up to 5% acid gangue has been successfully used at the Delta Steel Plant Midrex plant.

Cite this paper
S. Ola, G. Usman, A. Odunaike, S. Kollere, P. Ajiboye and A. Adeleke, "Pilot Scale Froth Flotation Studies To Upgrade Nigerian Itakpe Sinter Grade Iron Ore To A Midrex-Grade Super-Concentrate," Journal of Minerals and Materials Characterization and Engineering, Vol. 8 No. 5, 2009, pp. 405-416. doi: 10.4236/jmmce.2009.85036.

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