Ilmenite Ore Processing Plant

quarry machinery May 4, 2012 Comments Off
Ilmenite Ore Processing Plant

Zenith plans to supply a complete set of ilmenite ore processing equipment for a Greenfield ilmenite ore beneficiation plant to be built in Saraikela district of Jharkhand in Eastern India. The value of the complete plant on delivered basis is some 15 million Euros.

Ilmenite Ore Fluidised bed processing

Fluidised bed processing presents a range of opportunities for the effective treatment of ilmenites. Our team has made significant advances in the use of this versatile technology which has applications ranging from pre-oxidation of primary ilmenites (to increase reduction rates) to improving impurity removal by enhancing the magnetic properties of ilmenites.

Key achievements include:

  • assisted in the development of new ilmenite processing technology known as NewGenSR
  • designed and purpose-built a circulating fluid bed reactor to test new ilmenite processing technologies
  • simulated roasting and magnetic separation conditions for Murray Basin deposits (in Victoria) to remove chrome spinels
  • developed the Murso process to treat ilmenite concentrates containing high levels of impurities that are not effectively removed in the Becher process.

Ilmenite ore beneficiation process

Generally, ilmenite ore beneficiation process often use “gravity separation- strong magnetic separation- flotation”. According to different particle size level, adopt different process. First, the raw material should be crushed by jaw crusher, then ball mill will milled it. The next procedure is gravity separation, then these ore mixture will be into magnetic separator to separate iron from it. Then will take next step: flotation. Through dryer, we will get dried ilmenite concentrate powder.

Ilmenite Ore Processing Methods:

We feed ore into a series of crushers and grinding mills to reduce the size of the ore particles and expose the mineral. Water is also added which turns the ore into a slurry.

We send this slurry to leaching tanks, where we add a weak cyanide solution to the slurry, which leaches gold and silver into the solution. This process removes up to 93 percent of the gold and 70 percent of the silver from the ore. Carbon granules are then added to the solution. The gold is pulled from the solution and attaches to the carbon.

We then “strip” the gold from the carbon by washing it with a caustic cyanide solution. The carbon is later recycled.
Next, we pump the gold-bearing solution through electro-winning cells, which extract metals from the solution using an electrical current.

After gold has been processed, the leftover waste material is called tailings. Tailings contain small amounts of cyanide and other hazardous chemicals, so they must be disposed of in an environmentally safe way. The tailings are stored in tailings dams, which are lined with impermeable layers. While the cyanide levels in the dam are safe, steps are taken to keep wildlife away from the dams. Over time, the chemicals break down and the solids settle to the bottom so that the water can be returned to the plant to be used in processing.

We then smelt the gold, which melts it in a furnace at about 2,100°F.

From there, the liquid gold is poured into molds, creating doré bars. Doré bars are unrefined gold bullion bars containing anywhere from 60 to 95 percent gold.

We finally send the bars to a refinery for further processing into pure gold.

Ilmenite Ore in Australia

Australia was the world’s largest producer and exporter of ilmenite ore in 2005–2006, with 1.1 million tonnes, followed by South Africa (952Kt), Canada (809Kt), China (~400Kt) and Norway (380Kt).

Development of large mineral sands operations in Sénégal, Côte d’Ivoire, Madagascar[6] and Mozambique will see extensive supplies of ilmenite, rutile, zircon and leucoxene reach world markets in coming years. This is reflected in the table at right in parentheses. This additional supply of ilmenite and titanium feedstock, approximating 1.5 million tonnes per annum, is in excess to world demand growth of 350Kt per annum.

Although most ilmenite is recovered from heavy mineral sands ore deposits, ilmenite can also be recovered from layered intrusive sources colloquially known as “hard rock titanium” ore sources.

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