Enhanced Recovery
of Iron Values from Low-Grade Ores and Tailings through Reverse Cationic Flotation
Raju Mudhunuru Varma, Vardhan Harsha, Byra Reddy Raghunatha Reddy, Shanmugam Bharath
Kumar and Hanumanthappa Harish
Disaster Advances; Vol. 18(5); 170-176;
doi: https://doi.org/10.25303/185da1700176; (2025)
Abstract
India is well-known for its rich deposits of high-quality hematite ores, making
it a vital player in the global market. As the availability of high-grade iron ores
diminishes, the need to process low-grade ores, fines and slimes through beneficiation
is becoming increasingly important to meet market requirements. The creation of
fines and slimes leads to a mineral loss of about 20 to 25% of the overall mineral
value during processing. This research investigates the beneficiation of iron ore
tailings using reverse cationic flotation, with Sokem reagent acting as a collector
and starch serving as a depressant. A series of comparative assessments involving
magnetic separation and gravity separation were performed. An initial mineralogical
examination showed that hematite and goethite were the main iron-bearing minerals,
accompanied by quartz and kaolinite as significant gangue materials.
The selective flocculation technique proved effective, enhancing the iron grade
from 41.05% to 57.03% Fe, with a recovery rate of 47.35%. After desliming, the outcomes
improved further, yielding 58.25% Fe and a recovery of 29.00%. These results underline
the potential for successful beneficiation of iron ore tailings, offering valuable
insights for enhancing the recovery of high-grade iron from low-grade ores and reducing
mineral losses during processing.
