Geometallurgy of iron ores

Geometallurgy is an emerging field of research that has the aim to quantify compositional variability of ores contained in a deposit. Relevant parameter spaces to be considered include geochemistry, mineralogy, metal deportment and microfabric. These quantitative parameters need to be integrated with macroscopic geological and technical characteristics to define so-called geometallurgical domains, i.e., portions of an ore body that will exhibit similar beneficiation characteristics. This knowledge may then be used to optimize mining schedules and beneficiation routes, to optimize resource and energy efficiency, to maximize product quality and to minimize environmental impact. The value of developing a geometallurgical model is obvious for ore bodies that are either complex and/or of low grade. Important examples include PGE and Au deposits as well polymetallic base metal deposits. In accordance there are a number of case studies for such ore deposit types readily available in literature.

Iron ore deposits are, at least at first sight, not at all complex. In the last four decades very few deposit types have dominated the global supply of iron ore. High-grade iron ore deposits hosted by Precambrian iron formations clearly dominate, as these are often able to produce a direct shipping lump ore (DSO with > 60 wt%) Fe by simple crushing, screening and desliming. In fact, these deposits form the world’s largest virtually monomineralic ore bodies, not uncommonly reaching billions of tons of ore in size. Other deposit types that contribute significantly to the worlds iron ore supply are metamorphosed iron formation deposits (often referred to as taconites), Kiruna-type magnetite-apatite deposits and Robe River-type deposits. Magnetite deposits hosted by mafic/ultramafic intrusive complexes are increasingly gaining economic significance. Common to these deposit types are high concentrations of iron (≥ 50 wt.% Fe, but note that taconite only contains about 35 wt. % Fe) and uniform ore mineralogy, with only hematite, magnetite, and goethite of any significance.

The question thus arises what value geometallurgy may add to the utilization of iron ore deposits. In fact, a number of tangible benefits are being realized by taking this approach. Ore bodies that do not produce DSO require grinding followed by magnetic separation and/or flotation. Pellets need to be produced from the concentrate in order to have a saleable product. To assure that stringent quality requirements by the customer steel mills are being met consistently requires detailed knowledge of ore and gangue mineralogy – and its spatial variability across the ore body. Variations in gangue mineralogy, in particular, will determine concentrations of deleterious elements (Si, Ti, Al, P, S and alkali elments), whereas ore mineralogy will determine the suitability of beneficiation unit operations. Even if mineral assemblages remain uniform, relative proportions and microfabric relations (e.g., mineral grain sizes, intergrowth) will determine comminution and liberation characteristics, thus determining comminution energy requirements.