The thesis has been divided into several chapters dealing with extensive literature and experimental studies. It focuses on the geological aspects (i.e. correlation with other mineral/ rock in the type area, lithological alignment, availability of different types of fauna and flora and the geomorphological attributes.
Second part of the thesis is based on the experimental aspects of Banded Hematite Jasper. It includes different methods of characterisation and its implications on the development of new processes for beneficiation. These experimental techniques also help in understanding the interlocking pattern, % of ore & gangue, extent of liberation and magnetic behaviour of the ore. The experimental section also describes the mechanical and metallurgical behaviour of the ore (Bond Work Index, Vickers Hardness Test).
Those parameters help in knowing inter-molecular structure, presence of hydroxyl ion and up to some extent it reveals the quantitative nature of the ore. The experimental part also describes the kinetic behaviour of the ore with coal (i.e. extent of metallisation, factors responsible for reducibility and the activation energy) required for the ore. The experimental section describes the temperature of reduction of the ore with coke oven gas. In this section focus has been given to evolve a correlation between the grain size and the residence time with varying temperature.
Table of Contents
Chapter -1. Introduction
1.1. Objective of the Present Research
1.2. Scope of the Present Investigation
Chapter – 2. Geological Configuration
2.1. General Concept on Evolutionary Trend of Archean Basement
2.2. Chronostratigraphic arrangement of the Singhbhum-Orissa Craton
2.3. Generalised chronostratigraphic succession of the Singhbhum- North Orissa Craton
2.4. Metallogenic development during the Crustal Evolution of Archean
2.5. Geology of the Research Area
2.6. Local Geology of the Ghatkuri Iron Ore Deposits
Chapter – 3. Characterisation of ore
3.1 Introduction
3.2 Literature study
3.3 Materials and Method
3.3.1 Materials
3.3.2 Methods
3.3.2.1 Physical Characterisation
3.3.2.1a Ore Microscopy (Reflected light microscopy)
3.3.2.1b Petrography (transmitted light microscopy)
3.3.2.2. Mechanical Characterisation
3.3.2.2a. Bond Work Index analysis (BWIA)
3.3.2.2b. Vickers Hardness Number (VHN)
3.3.2.2c. Grain Size analysis
3.3.2.2d. Liberation Study
3.3.2.2e. Davis tube test
3.3.2.2f. Chemical analysis
3.3.2.2g. Size-Wise chemical analysis
3.3.2.2h. Sink and Float analysis
3.3.2.3. Metallurgical Characterisation
3.3.2.3a. XRD, SEM-EDS
3.4. Results and Discussion
3.4.1. Physical attributes
3.4.2. Microscopic observation
3.4.3. Power input estimation through Bond Work Index
3.4.4. Mechanical nature of grains through Vickers Hardness Number
3.4.5. Results of Grain Size Analysis
3.4.6. Nature of grain alignment through liberation characteristics
3.4.7. Davis Tube Test for the untreated BHJ
3.4.8. Chemical and Material Characterisation
3.4.9. Result of the size wise chemical assay
3.4.10. Result of sink and float analysis of BHJ
3.5. Conclusions
Chapter – 4. Kinetics Of Reduction Of Banded Haematite Jasper Ore With Coal
4.1. Introduction
4.2. Literature Study
4.3. Materials and Methods
4.3.1. Materials
4.3.1a. Raw Materials
4.3.1b. Apparatus
(i) Empty Quartz Capsule
(ii) Horizontal Tabular Furnace
4.3.2 Methods
4.3.2.1. Chemical Analysis
4.3.2.2. Characterisation Studies
4.3.2.2a. X-Ray Diffraction Analysis
4.3.2.2b. Scanning Electron Microscopy
4.3.2.3. Experimental Procedure
4.3.2.4. Rate laws in reduction
4.3.2.5. Factors controlling the rate of reduction
4.3.2.6. Various Kinetic Models used in present work
4.3.2.7. Determination of Activation Energy
4.3.2.8. Metallurgical System and Approaches in Kinetic Analysis
4.3.2.8a. Factors Determining Rate
4.4. Results and Discussion
4.4.1. Reduction of BHJ with Coal
4.4.2. Degree of reduction
4.4.3. Reduction of BHJ sample of Ghatkuri (Gua); West Singhbhum, Jharkhand at 1000 °C at constant time with varying temperature
4.4.4. Kinetics of Reduction of BHJ with Coal
4.4.5. Calculation of Activation Energy
4.4.6. Characterisation Studies
4.4.6a. X-ray Diffraction
4.4.6b. Scanning Electron Microscopy
4.5. Conclusion
Chapter –5. Reduction roasting of Banded Hematite Jasper with Coke Oven Gas
5.1. Introduction
5.1.1. Reduction roasting
5.1.2. Magnetic behaviour of the elements
5.2. Literature study
5.3. Materials and Methods
5.3.1. Materials
5.3.2. Methods
5.3.2a. Reactions involved in the Iron Ore Reduction
5.4. Results and Discussion
5.4.1. Effect of Particle size
5.4.2. Effect of Roasting Temperature
5.4.3. Effect of varying Roasting time
5.5. Conclusion
Research Objective and Scope
The research focuses on the recovery of iron values from low-grade Banded Hematite Jasper (BHJ) found in the Ghatkuri region of Jharkhand, India, addressing the depletion of high-grade iron reserves by evaluating its geological characteristics and developing viable processing methods for its industrial utilization.
- Characterization of the physical, optical, and mechanical properties of BHJ ore.
- Development of low-cost, energy-efficient beneficiation processes.
- Investigation of reduction kinetics using coal and coke oven gas.
- Analysis of temperature and particle size effects on the degree of reduction.
Excerpt from the Book
3.4.1. Physical attributes
The Banded Hematite Jasper under investigation depicted banded massive form arranged in a rhythmic pattern (Fig.3.6). It was reddish brown in colour, cherry red streak and thickness varying from few mm to as long as a certain meter. Iron bands were metallic whereas cherry red bands exhibit vitreous lustre. Hardness varied from 5(Iron Oxide) to 8 (Jasper) (according to Mo ‟s r n ss s l or Number). At places, Jasper bands showed a braided structure with variable thickness.
Summary of Chapters
Chapter -1. Introduction: Discusses the surging demand for iron ore, the depletion of high-grade reserves in India, and the necessity of utilizing low-grade ores like Banded Hematite Jasper.
Chapter – 2. Geological Configuration: Details the evolutionary trends of the Archean basement in the Singhbhum region and provides the geological context for the research area.
Chapter – 3. Characterisation of ore: Presents a comprehensive scientific analysis of the physical, mechanical, and mineralogical properties of the BHJ ore samples.
Chapter – 4. Kinetics Of Reduction Of Banded Haematite Jasper Ore With Coal: Explores the reaction kinetics and the reduction behavior of BHJ ore using coal at varying temperatures.
Chapter – 5. Reduction roasting of Banded Hematite Jasper with Coke Oven Gas: Examines the efficacy of reduction roasting using coke oven gas as an energy-efficient beneficiation technique.
Keywords
Banded Hematite Jasper, Iron Ore, Beneficiation, Reduction Kinetics, Singhbhum, Ghatkuri, Geochemistry, Carbothermic Reduction, Coke Oven Gas, Mineral Characterization, Bond Work Index, Vickers Hardness, Metallurgy, Ore Processing, Sustainable Development
Frequently Asked Questions
What is the core subject of this research work?
The research focuses on the potential for utilizing low-grade Banded Hematite Jasper (BHJ) as a sustainable source of iron to address the rapid depletion of high-grade hematite ore reserves in India.
Which regional deposits are analyzed?
The study specifically analyzes BHJ ore samples collected from the Ghatkuri Iron Ore Mines, located in the Gua area, West Singhbhum, Jharkhand.
What is the primary objective of this study?
The primary aim is to recover iron values from BHJ through advanced characterization and a thorough investigation of its reduction kinetics and roasting parameters to establish a commercially viable industrial process.
Which scientific methods are employed for material testing?
The research uses a variety of methods including ore microscopy (reflected/transmitted), SEM-EDX, XRD, Bond Work Index analysis, Vickers Hardness testing, and sink-and-float analysis.
What are the main thematic areas covered in the chapters?
The work covers geological settings, material characterization, reduction kinetics with coal, and the evaluation of reduction roasting techniques using coke oven gas.
What key keywords characterize this research?
Key terms include Banded Hematite Jasper, iron ore beneficiation, reduction kinetics, mineral characterization, Singhbhum region, and sustainable mining.
How does the presence of SiC affect the reduction process at lower temperatures?
At temperatures between 1000-1100 °C, the formation of silicon carbide (SiC) as a predominant phase acts as a barrier, hindering the reduction of iron oxide in the ore.
What are the optimized parameters for reduction roasting discovered by the author?
The study concluded that the optimized parameters for reduction roasting include a temperature of 600 °C and a residence time of 60 minutes, using a particle size of 13 mm.
- Quote paper
- Sanjeev Kumar Das (Author), 2018, Recovery of Iron Values with the Advanced Characterization and the Reduction Kinetics of Banded Hematite With Coal, Munich, GRIN Verlag, https://www.grin.com/document/489479
