Kolodezhnaya E.V., Gorlova O.E., Shadrunova I.V., Garkavi M.S., Khardin I.S., Shavakuleva O.P. Prospects for Processing the Low-Grade Brown Iron Ores of the Southern Urals

DOI: 10.18503/1995-2732-2025-23-3-5-16

Abstract

Problem Statement (Relevance). As the traditional raw material base of magnetite ores is depleted, it is necessary to carry out a set of measures aimed at assessing the prospects and developing technologies for processing low-grade brown iron ores, of which there are over 20 known deposits in the Southern Urals. The article considers new technological approaches to the processing of oxidized difficult-to-dress iron ore raw materials using one of the brown iron ore deposits of the Zigazino-Komarovo Formation as an example. Objectives are evaluation of the possibility of enriching brown iron ore using the simplest and least expensive dry enrichment processes and development of a process flow diagram for obtaining iron concentrate suitable for metallurgical processing. Methods Applied. The material composition of the ore sample was studied using X-ray fluorescence and optical-mineralogical methods, and the mag-netic properties were studied using the oscillographic method. Differential thermal analysis was performed on the STA 499 F3 Jupiter device. Grinding and classification of ore were carried out in the CG-0,36 grinding complex, working with the CC-0,3 centrifugal classifier. Dry magnetic separation was carried out on the EVS-28/9 roller separator with a magnetic induction of 1,7 T; wet magnetic separation was carried out on a polygradient wet magnetic separator with a cassette with ferromagnetic bodies. Originality. A technological scheme for dry enrichment of brown iron ore (without magnetizing roasting) has been developed, making it possible to obtain concentrate for sintering and blast-furnace pro-duction with an iron mass fraction of 47,5–49,1% (52,9–54,7% on a calcined substance basis) at a sufficiently high extraction of 55,5–72,3% for this type of ore. Result. This process flow chart can be considered as an alternative to gravity enrichment and wet magnetic separation in a strong magnetic field, roasting-magnetic enrichment of brown iron ores in the feasibility study of developing some small deposits. The optimal ore grinding size during dry enrichment was established (0,315 mm), and the feasibility of ore desliming before dry magnetic separation was shown. Practical Rele-vance. The technology can be implemented as a mobile crushing and enrichment unit for dry preliminary enrichment of brown iron ore directly at the deposits, which does not require water supply and drainage. This will increase the com-mercial attractiveness and potential for using small brown iron ore deposits for the metallurgical industry of the South-ern Urals.

Keywords

brown iron ore, specific magnetic susceptibility, enrichment tests, magnetizing roasting, dry enrichment, magnetic separation, desliming, grinding and classifying unit.

For citation

Kolodezhnaya E.V., Gorlova O.E., Shadrunova I.V., Garkavi M.S., Khardin I.S., Shavakuleva O.P. Prospects for Processing the Low-Grade Brown Iron Ores of the Southern Urals. Vestnik Magnitogorskogo Gosudarstvennogo Tekhnicheskogo Universiteta im. G.I. Nosova [Vestnik of Nosov Magnitogorsk State Technical University]. 2025, vol. 23, no. 3, pp. 5-16. https://doi.org/10.18503/1995-2732-2025-23-3-5-16

Ekaterina V. Kolodezhnaya – PhD (Eng.), Lead Researcher, Research Institute of Comprehensive Exploitation of Mineral Resources of Russian Academy of Sciences, Moscow, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.. ORCID 0000 0002 0252 4479.

Olga E. Gorlova – DrSc (Eng.), Professor, Nosov Magnitogorsk State Technical University, Magnitogorsk, Russia; Lead Researcher, Research Institute of Comprehensive Exploitation of Mineral Resources of Russian Academy of Sciences, Moscow, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.. ORCID 0000-0003-1142-0652.

Irina V. Shadrunova – DrSc (Eng.), Professor, Head of the Department of the Mining Ecology, Research Institute of Comprehensive Exploitation of Mineral Resources of Russian Academy of Sciences, Moscow, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.. ORCID 0000-0002-4410-8182.

Mikhail S. Garkavi – DrSc (Eng.), Deputy Chief Engineer, Ural-Omega CJSC, Magnitogorsk, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.. ORCID 0000-0002-1912-5415.

Igor S. Khardin – Laboratory Assistant, Ural-Omega CJSC, Magnitogorsk, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it..

Olga P. Shavakyleva – PhD (Eng.), Associate Professor, Nosov Magnitogorsk State Technical University, Magnitogorsk, Russia. E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.. ORCID 0000-0001-6291-2687.

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