A review on the enrichment of iron values of low-grade Iron ore resources using reduction roasting-magnetic separation

In 2021, global alumina production reached over 135 million tons and discharged approximately 200 million tons of red mud, leading to severe environmental safety hazards. More than 70% of raw materials originated from gibbsitic bauxite. This work reviews existing and potential process from open literature to treat gibbsitic bauxite and reduce red mud discharge from the alumina production process, which are divided into two categories. The first strategy involves non-Bayer methods such as smelting reduction, reduction roasting, sub-molten salt, ammonium sulfate roasting, acid leaching, and calcification–carbonation. The current obstacle to implementing these methods is the lack of economics, making industrial application challenging. The second potential industrial application strategy is to modify the current Bayer process, with critical measures involving the enhancement digestion of inert aluminum-bearing minerals, dissociation and recovery of iron minerals, and separation of desilication products. Analyzing the reaction mechanism and process flow clarify that the modified Bayer method is more favorable to the cost-effectively and synergistic extraction of aluminum, iron, and other elements. The red mud obtained by the modified Bayer process can be efficiently utilized. Therefore, a mini-summary of the areas where red mud is expected to be substantially dissipated (e.g., the steel industry, cement building materials, and ecological restoration of red mud stockpiles) is provided. The review can advance the current technology on the comprehensive utilization of gibbsitic bauxite, especially process discharge reduction approaches and large-scale abatement ways for red mud. Our results can contribute to the future development of sustainable green alumina production. 

Toward sustainable green alumina production: a critical review on process discharge reduction from gibbsitic bauxite and large-scale applications of red mud

Hematite-containing material is accumulated during exploitation and beneficiation of magnetite ore, thus forming tailings and other industrial wastes. Hence, processing the low-grade hematite ore becomes extremely important for the metallurgical industry. The transformation of weakly magnetic hematite into magnetite can enhance the efficiency of magnetic separation. In this work, chemical reduction of hematite to magnetite in an atmosphere with different gas composition was investigated. Gasification of charcoal in the flow of both air and carbon dioxide led to the formation of carbon monoxide. The output gas containing carbon monoxide was found to be an effective reductant for the transformation of hematite into magnetite. Even 5% of CO was sufficient to convert hematite into magnetite, which resulted in an increase in magnetization up to 85 Am2/kg. The kinetic analysis indicated that the reduction of hematite to magnetite is a single-step process, which can be described using the first-order reaction model.

Kinetics of hematite to magnetite transformation by gaseous reduction at low concentration of carbon monoxide

Beneficiation Strategies for Removal of Silica and Alumina from Low-Grade Hematite-Goethite Iron Ores

Techniques for dry processing low-grade iron ores and tailings are being investigated. Dry desliming tests using a rotating wheel air classifier and factorial design were performed on a dif...

Experimental study of dry desliming iron ore tailings by air classification

In this study, reductive roasting followed by low-intensity magnetic separation were used to upgrade iron ore from Gua mines in Jharkhand. The work aimed to maximise the recovery of iron values by ...

Investigation on beneficiation of goethite-rich iron ores using reduction roasting followed by magnetic separation

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Investigation on beneficiation of goethite-rich iron ores using reduction roasting followed by magnetic separation