Removing Impurities from Iron Ores: Methods and Industrial Cases

"The inclusion of small amounts of silicon, phosphorus and sulphur in iron ores or concentrates can have a profound effect on the steel making process and thus on the final iron and steel products. In nature however, it is inevitable that iron deposits contain unwanted elements. Each element has its own distinct effect on the final steel product. The effect of high silicon is the formation of gray iron. Phosphorus mainly increases hardness and strength, lowers solidus temperature and increases fluidity and cold shortness. Finally sulphur contamination causes cracks in the iron texture when smelting and forms white iron when casting. Overall, the acceptable level of phosphorus, sulphur and silica in the iron concentrate should be less than 0.04%, 0.15 % and 1.5 % respectively.Scarcity of high grade iron ores necessitates using lower grade ores with higher amounts of impurities. The purpose of iron concentrators is to increase iron grades to an appropriate level suitable for steel making as well as removing impurities. Although many impurities can be traced in the ore, the most predominant impurities are limited to one or two elements. In this paper the beneficiation methods for removing SiO2, P and S are presented, including flotation, and the parameters that need to be considered in the design of beneficiation plants are discussed. Finally industrial cases are discussed along with their metallurgical performance.INTRODUCTIONIn metal sector, value of iron ores and concentrates is determined by iron percentage as well ascontent of:• Useful elements (Mn, Ni, Cr, V, Ti): natural alloying elements in steel• Deleterious impurities (S, P, As, Zn, Pb, K, Na): impair metal properties or complicate operational process in blast furnace• Fluxing components (Si, Ca, Mg,, Al)Sulphur and copper result in red-short, phosphorus is the cause of cold brittleness and arsenic and copper decrease welding characteristics. Sulphur should not exceed 0.15 in commercial ore. Acceptable sulphur content in ores and concentrates for producing sinter and pellets is 0.6%max, as sintering and heat hardening of pellets remove sulphur 60-90%. Phosphorous content in ores, sinter and pellets is limited to 0.07%-0.15%. 0.00.1% As max, 0.1-0.2% Zn max and up to 0.2% Cu are allowed in iron-ore part of the blast furnace burden for the production of standard conversion pig iron. Slag-forming components are divided into basic oxides (Ca, Mg) and acidic (Si, Al). Higher ratios of basic to acidic oxides are preferred since this reduces raw fluxing material."