The upgrading of low-grade iron ore: optimization of recovery and reduction of feed volume

Document Type : Research Paper

Authors

Mining Engineering Department, Tabriz University of Technology, Tabriz, Iran.

10.22059/ijmge.2025.395655.595259

Abstract

The present study investigated the potential for iron recovery from magnetite-bearing iron ore tailings at the Sangan Company’s old dumps, aiming to reduce environmental challenges through wet magnetic separation as a pre-beneficiation stage. This method selectively removed coarse gangue while maximizing magnetite recovery. A full factorial experimental design evaluated the effects of magnetic field intensity (1200, 2700, 3400 gauss), drum speed (1, 1.4 m/s), and pulp solids content (25%, 35%). Concentrate analysis was performed using titration and Satmagan methods. Partial Least Squares (PLS) modeling revealed that higher magnetic field intensities significantly improved magnetite recovery, enabling a feed mass reduction of 18–22% with negligible magnetite loss (~2–3%). Magnetite recovery from tailings represents a novel approach, achieving up to 97.21% recovery under optimal conditions. Davis Tube tests confirmed that lost magnetite, with iron grades below 13.63%, is unsuitable for the final concentrate, enhancing overall concentrate quality by its removal. This pre-upgrading process improves concentrate quality, reduces operating costs, and supports sustainable tailings management.

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References

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International Journal of Mining and Geo-Engineering
Volume 59, Issue 2
June 2025
Pages 165-170

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