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Iron ore beneficiation, Summaries of Engineering

Iron ore processing od Ballari area Karnataka

Typology: Summaries

2023/2024

Uploaded on 03/07/2025

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Namaste sir,
Garudhadri Impex Pvt Ltd,
ML No 2583
Extent 20.64 Hectares
Lease alloted 2008
Valid upto. 2028
Deemed Extension upto 2058 (under process.)
Mineral: Iron ore & Manganese
Reserves:- With present Core drilling under process the approxmetely reserves expected is about 3.00 Million tons of
35+ Fe iron ore and 10 + Mn of Manganese ore.
We are planning for a small beneficiation plants of approx 0.30 MTPA outside the lease area, also planning for Brick
plant outside the lease area from the remains of OVER BURDEN (OB).
In this regard please guide us how to go about sir.
Thanks & Regards
Manoj Jain
Managing Director
Garudhadri Impex Pvt Ltd
OK. I think IOB may be possible. Regarding Mn it may be difficult as Mn ores from Sandur are ferruginous. Please
ask him to share the specs for iron ore concentrates. Also the Ore data of iron ore and approval of Environment dept..
The Capacity of IOB seems to have been decided based on Life of Mine and Reserve of 3 million tons for 10 years at
0.3MTPY Assuming 3shifts operation for 7200 hours, the minimum TPH of plant amounts to .50 tph and for one shift
operation amounts to 150 with 80% availability, safety and over design factor
The project normally is undertaken in the following stages;
1. Exploration stage where spilt [1/8] drill core samples are subjected to process diagnostic amenability tests for
characterizing ore type and to draw geo technical map of the resource The product specs may have to be
given by the client -2 months
2. Preparation of composite sample from [1/8] core sample for bench scale beneficiation study generating data
for conceptual plant Response of different ore type to the process. Preparation of metallurgical balance- 4-6
months
3. Site analysis, equipment sizing, choice and preliminary techno economic viability report-2 months
4. Project engineering for tender preparation, contractor identification, supervisor of project, erection,
commissioning and baseline data collection and auditing for optimisation 6 to 18 months with a minimum 12
months
A typical example of the plant with no grind process is given below;
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Namaste sir,

Garudhadri Impex Pvt Ltd,

ML No 2583

Extent 20.64 Hectares

Lease alloted 2008

Valid upto. 2028

Deemed Extension upto 2058 (under process.)

Mineral: Iron ore & Manganese

Reserves:- With present Core drilling under process the approxmetely reserves expected is about 3.00 Million tons of

35+ Fe iron ore and 10 + Mn of Manganese ore.

We are planning for a small beneficiation plants of approx 0.30 MTPA outside the lease area, also planning for Brick

plant outside the lease area from the remains of OVER BURDEN (OB).

In this regard please guide us how to go about sir.

Thanks & Regards

Manoj Jain

Managing Director

Garudhadri Impex Pvt Ltd

OK. I think IOB may be possible. Regarding Mn it may be difficult as Mn ores from Sandur are ferruginous. Please

ask him to share the specs for iron ore concentrates. Also the Ore data of iron ore and approval of Environment dept..

The Capacity of IOB seems to have been decided based on Life of Mine and Reserve of 3 million tons for 10 years at

0.3MTPY Assuming 3shifts operation for 7200 hours, the minimum TPH of plant amounts to .50 tph and for one shift

operation amounts to 150 with 8 0% availability, safety and over design factor

The project normally is undertaken in the following stages;

1. Exploration stage where spilt [1/ 8 ] drill core samples are subjected to process diagnostic amenability tests for

characterizing ore type and to draw geo technical map of the resource The product specs may have to be

given by the client - 2 months

2. Preparation of composite sample from [1/8] core sample for bench scale beneficiation study generating data

for conceptual plant Response of different ore type to the process. Preparation of metallurgical balance- 4 - 6

months

3. Site analysis, equipment sizing, choice and preliminary techno economic viability report-2 months

4. Project engineering – for tender preparation, contractor identification, supervisor of project, erection,

commissioning and baseline data collection and auditing for optimisation 6 to 18 months with a minimum 1 2

months

A typical example of the plant with no grind process is given below;

VIRTUAL MATERIAL BALANCE OF 0.3MYPY IRON ORE WASHING PLANT OF HSPL Ginegera Based on data of siliceous iron ore fines from BHS for Sub grade of 5 5 % Fe. For Producing Export Grade Concentrate~58% Stream data Wt% TPH SOLID

M^3 PH

Water

TPH

PULP

M^3 PH

Pulp PD % S %Fe Assay Distn Feed 100.0 50.0 50.0 12.5 4.0 100 54.75 100. 1 mm screen feed 1. 8 x 3m DD[10-1] 100.0 40.0 40.0 80.0 50.0 1.60 50.0 54.75 100.

- 10+1 mm sand Conc 1 40.0 20.0 2.0 22. 0 6.8 3.24 90.0 58.00 42. Wash water to screen 1 22.

  • 1 mm to stub cyclone 75 mm disc pump 60.0 30.0 60.0 90.0 63.2 1.42 33.3 52.56 57.
  • 1 +0.2 mm stub u/f 30.0 15.0 3.75 18.75 7.5 2.50 80.0 58.00 31.
  • 1+0.2 mm dewatered Conc 2 30.0 15.0 1. 5 16.5 5. 3 3.10 90.0 58.00 31.
  • 0.2 mm Stub over flow feed and DWS U/S to 5” cyclone 75 mm disc pump
  • 0.2+0.04 mm5” cyclone OF 10.0 5.0 53.5 58.5 50. 4 1.16 9.0 39.44 7.
  • 0.2+0.04 mm5” cyclone UF feed to spirals 20.0 10.0 5.0 15.0 7.5 2. 00 66.7 51.04 18. spiral water 15. HG10- 4 Triple feed Spiral feed 20.0 10.0 20 .0 30.0 22.5 1.33 33.3 51.04 18. spiral concentrate to CT 10.0 5.0 5.0 10.0 6.2 1.60 50.0 58.00 10. Spiral conc thickner u/f 10.0 5.0 2.5 7.5 3.7 2.05 66.7 58.00 10. Filtered spiral Conc 10 .0 5.0 0.5 5.5 1.7 3.3 90.0 58.00 10. spiral tails to tails thickener 10.0 5.0 15.0 20.0 15.7 1.27 25.0 43.62 8. VPHGMS 1.25 m dia1T feed 20.0 10.0 68. 5 78.5 66.1 1.19 12.7 41.57 15. VPHGMS Water 11. VPHGMS Conc 5.0 2.50 22.50 25.0 23.1 1.08 10.0 56.95 5. Conc thickener 6 m feed 15.0 7.50 23.50 30.5 24.8 1.23 24.50 57.67 15. Conc thickner UF/Filter feed 1.5 m PF 6 15.0 7.50 3.75 11 .25 5.05 2.23 66.7 57.67 15.
  • 1 mm concentrate cake 15.0 7.50 0.75 8.25 2. 15 3.84 90.9 57.67 15. VPHGMS NM Tails thickener 6 m feed 15.0 7.50 67.5 75.0 69.5 1.08 10.0 36.50 10. Tails thickener u/f1.5 m PF12 15.0 7.50 7.50 15.0 9.5 1.5 8 50.0 36.50 10. Tails filter cake 15.0 7.50 1.0 8.50 3.0 2.83 88.2 36.50 10. Comp Concentrate cake 85.0 42.5 0 4.25 46.75 12.3 3. 80 90.0 57.97 90. 50 tph sub – medium grade iron ore beneficiation plant HSL