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Doctoral Thesis DOCTORAL THESIS CHARACTERIZATION OF THE KIIRUNAVAARA IRON ORE DEPOSIT FOR MINERAL PROCESSING WITH A FOCUS ON THE HIGH SILICA ORE TYPE B2 Kari Niiranen, M.Sc. Chair of Mineral Processing Department Mineral Resources and Petroleum Engineering Montanuniversitaet Leoben, Austria Affidavit: I declare in lieu of oath, that I wrote this thesis and performed the associated research myself, using only literature cited in this volume. Leoben, 20 October 2015 Kari Niiranen, M.Sc. ACKNOWLEDGEMENT This thesis would not have been possible without support, supervision and encouragement from many friends and colleagues at LKAB in Sweden and at the Institute of Mineral Processing, Montanuniversitaet Leoben in Austria throughout the years. A huge amount work has been done during this study and many people have performed their best at LKAB to get new information about the Kiirunavaara iron ore deposit. First of all, my sincerest thanks go to Dr. Andreas Böhm at the Institute of Mineral Processing, Montanuniversitaet Leoben, for your support. I’m deeply grateful for your time and interest in this study. Your excellence in mineral processing and guidance, your encouragement and immense knowledge during the research work made it possible for me to reach the target. Working with you was a true pleasure and I hope for a good cooperation also in the future. Furthermore, I would like to thank Professor Dr. Helmut Flachberger and the staff, my colleagues, and friends at the Institute of Mineral Processing, Montanuniversitaet Leoben, for encouragement and for a nice time working together. During this study many international contacts, especially in Austria, could be established and they provided valuable input to various aspects of this work. I have encountered a very open mind which is much appreciated. I especially acknowledge Dr. Andreas Fredriksson for you encouragement and support during this work and for reading and valuable comments on this thesis. I also want to thank Susanne Rostmark for interest and for allowing me the time to write this thesis. I would like to thank my colleagues Therése Lindberg, Charlotte Mattsby, David Alldén, and Dr. Henrikki Rutanen for your interest and the staff at LKAB’s mineral processing laboratory in Malmberget to name but a few. Thanks also to all my colleagues at LKAB R&D who have always encouraged me during this work. Furthermore, I acknowledge Christopher Gordon for language checking and comments. Last but not least I would like to thank Dr. Heinrich Mali at the Institute of Geology and Economic Geology, Montanuniversitaet Leoben, for interesting discussions, Sandra Haslinger for your help at the laboratory work in summer of 2010, and all my dear friends in Finland, Sweden, Austria and Germany for encouragement during these years. KURZFASSUNG Die Eisenerzlagerstätte am Kiirunavaara zeigt derzeit einen eher niedrigen SiO2-Gehalt (ca. 2,3 bis 3,3% SiO2), aber es wird erwartet, dass er in den tieferen Teilen der Lagerstätte ansteigen wird. Im Jahr 2007 wurde ein Projekt „Silica in the Mine“ mit dem Ziel gestartet, ein vereinfachtes Verfahren im Labormaßstab in Bezug auf Aufbereitungseigenschaften zu entwickeln, um den Energieverbrauch und den SiO2 Gehalt der Magnetit-Konzentrate und weitere aufbereitungstechnische Eigenschaften des Roherzes vorherzusagen. Das erste Ziel dieser Studie war es, die Zerkleinerungs- und Aufbereitungstests, die im Ramen des Projekts „Silica in the Mine“ im Aufbereitungslabor von LKAB durchgeführt wurden, mit den Zerkleinerungs- und Aufbereitungstests im Labor des Lehrstuhls für Aufbereitung und Veredlung, Montanuniversität Leoben, zu vergleichen und zu ergänzen. Für diesen Zweck wurden drei ausgewählte Proben, die die Haupterztypen (B1, B2 und D) der Lagerstätte repräsentieren, nach der Methode der „Optimierten Zerkleinerungskette“ (OZK) zerkleinert. Daraus kann geschlossen werden, dass diese drei Erztypen einen Unterschied in ihrer Bruchcharakteristik aufweisen, was durch die Unterschiede in der Korngrößenverteilung der Zerkleinerungsprodukte sowie unterschiedlichen in dem maßspezifischen Energieverbrauch angezeigt wird. Eine wichtige Erkenntnis aus der Zerkleinerungstests im Labor des Lehrstuhls für Aufbereitung und Veredlung ist das untypische, korngrößenabhängige Zerkleinerungsverhalten. Dieses könnte mit der Textur des Magnetiterzes erklärt werden. Da offensichtlich der Anteil des SiO2-reichen Erztyps B2 in Zukunft zunehmen wird, wurden detaillierte Aufbereitungstests wurden für die prozessmineralogische Charakterisierung dieses Erztyps im Labor des Lehrstuhls für Aufbereitung und Veredlung im Sommer 2010 durchgeführt. Diese Tests kombinierten geologische, mineralogische und geochemische Daten mit aufbereitungstechnischen Eigenschaften wie Energieverbrauch, Korngrößenverteilung, Aufschlussgrad und Verwachsungen. Ein wesentlicher Teil dieser Studie waren die mineralogischen Untersuchungen mittels automatisierter Mineralogie (QEMSCAN®), um die modale Mineralogie, die Verteilung der Silikaten in den verschiedenen Korngrößenklassen nach der Zerkleinerung, die Verteilung von Silizium (Si) zwischen verschiedenen Silikaten sowie Aufschlussgrad und Verwachsungen von Magnetit und Silikaten zu untersuchen. Ein wichtiges Ergebnis dieser Studie war die Entdeckung von zwei Subtypen im Erztyp B2, die sich durch das Auftreten von Aktinolith im Subtyp B2-a unterscheiden. Das wird als Ursache für die unterschiedliche Mahlbarkeit (d.h. Bruchcharakteristik) dieser beiden Subtypen angesehen. SCLAGWORTE: Aufbereitung, Aufschlussgrad, Davis Rohrscheider, QEMSCAN, automatisierte Mineralogie, Magnetit, Aktinolith, LKAB, Kiirunavaara ABSTRACT The Kiirunavaara iron ore deposit shows a rather low content of silica (ca. 2.3 to 3.3% SiO2) but the silica grade is expected to increase in the deeper parts of the deposit. A project called “Silica in the Mine” was started in 2007 with the target to develop a simplified method in laboratory scale to predict the energy consumption and SiO2 grade in the magnetite concentrate at the industrial scale and further predict the physical properties of the crude ore with respect to mineral processing characteristics. The first target of this study was to control and compare the comminution and mineral processing tests in relation to the “Silica in the Mine” project carried out at LKAB’s mineral processing laboratory to the comminution and mineral processing tests at the laboratory of the Institute of Mineral Processing, Montanuniversitatet Leoben. For the purpose of this study, three samples were selected representing three main ore types (B1, B2, D) of the Kiirunavaara iron ore deposit. They were first were first ground according to the “Optimized Comminution Sequence” (OCS) method. It can be concluded that these three samples, representing different ore types, show a difference in their breakage behavior based on the ore characterization data defined by the differences in the particle size distribution within comminution products, as well as in differences in the mass-specific energy consumption. It is significant to note based on the information from the comminution test that there might be a deviant breakage characteristic in relation to the iron ore from the Kiirunavaara deposit, which can be explained can be explained with the crystal structure of magnetite. Furthermore, a separation with Davis magnetic tube was a crucial part of the mineral processing test to study the liberation of magnetite and silicates. As it was evident that the amount of the high-SiO2 ore type B2 increases, detailed mineral processing tests were carried out for process mineralogical characterization of this ore type at the laboratory of the Institute of Mineral Processing in summer of 2010. These tests combined geological, mineralogical, and geochemical information with mineralogical processing characteristics such as energy consumption, particle size distribution, and liberation and intergrowths. The essential part of this study was the mineralogical investigations using automated mineralogy (QEMSCAN®) to study the modal mineralogy, the distribution of silicates in the different particle size classes after comminution, the deportment of silicon (Si) between various silicates and degree of liberation and intergrowth of magnetite and silicates. An important result of this study was the discovery of two separate subtypes within ore type B2 based on the occur of actinolite in the subtype B2-a. This can be considered as the cause of the difference in grindability (i.e., characteristic) of these two subtypes. KEYWORDS: mineral processing, liberation analysis, Davis magnetic tube, QEMSCAN, automated mineralogy, magnetite, actinolite, LKAB, Kiirunavaara. ACKNOWLEDGEMENT KURZFASSUNG ABSTRACT 1. INTRODUCTION ............................................................................................................................. 1 1.1 Background ................................................................................................................................... 1 1.2 Previous studies ............................................................................................................................. 2 1.2.1 Mineral processing model for the Leveäniemi open pit ......................................................... 2 1.2.2 Comparing the comminution at laboratory scale to pilot and large scale ............................. 4 2. OBJECTIVES .................................................................................................................................... 4
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