Process Mineralogy of Low Grade Chrome Ore Beneficiation Plant Tailings

S.K. Das, Ms. R. Mohapatra and R.B. Rao

Institute of Minerals and Materials Technology, Bhubaneswar- 751013
Email: subir@immt.rers.in

Abstract: Mineralogical characterisation and liberation of valuable minerals are primary

concerns in mineral processing industries. A low grade chrome ore beneficiation plant
tailing was characterized by optical microscope and chemical analysis to ascertain the
mineral contents, mineral locking characteristics and grade. The sample was beneficiated
by a combination of routes comprising of hydrocylones to remove slimes, followed by
two stage tabling experiments to obtain marketable grade chromite ore concentrates
(Cr2O3 > 45%). The bulk sample is fine grained ranging from 1.0 mm to less than 0.038
mm size. The sample contains 21.16% Cr2O3, and is constituted of chromite, goethite
(mostly ochreous/limonite), gibbsite, hematite and minor amounts of quartz. The
chromite grains are euhedral to anhedral and the fractures and cavities in the chromite
grains are filled up by goethite and hematite. Quantitative mineralogical studies indicated
that bulk sample contained 29.86% free chromite grains with total chromite values being
37.34%. The degree of chromite liberation is estimated as 89% at less than 0.125 mm
size. The studies suggested recovery of chrome ore particles by concentration processes.
The tabling experiment of hydrocyclone underflow yielded a concentrate with 50.97%
Cr2O3, 84.95% total chromite, and the tailing had 16.89% Cr2O3, 29.61% total chromite.
The concentrate is coarse grained (98.79% is >0.038 mm size) while the tailings is fine
grained (44.69% is <0.038 mm size). The tailing was cleaned in ball mill and treated in
tabling to obtain a concentrate with 51.8% Cr2O3. The bulk rejects in the experiments was
fine grained (50.51% is <0.038 mm size), contained 10.56% Cr2O3 and 16.47% chromite
values out of which 11.10% is distributed in minus 0.038 mm size fractions.

Key words: Mineralogy, Beneficiation, Chromite, Sukinda

INTRODUCTION friable ores and during mining

The estimated reserve of chromite
in India is of the order 187 million tones.
The bulk of reserves (about 98%) are
located in the Sukinda valley (21o00’-
21o04’N:85o40’-86o00’E) of Orissa. The
main criteria for classifying the chromite
ores into different industrial grades, viz.,
metallurgical (low and high carbon
ferrochrome, silico-ferrochrome and
charge chrome), refractory and chemical
are the Cr2O3 content, Cr:Fe ratio and
friable/compact nature of the ore. More
than eighty percent of the production from
Sukinda valley constitutes powdery and
considerable quantities of low grade ores
(Cr2O3 < 40%) are also handled. The low
grade ores are beneficiated in chrome ore
beneficiation plants to obtain high grade
ores (>45% Cr2O3). Efficient design and
control of mineral treatment plants to
minimize the target mineral loss require
information on size distribution, mineral
quantities, mineral chemistry, bulk
chemical analysis and degree of liberation
of target mineral. This paper reports the
findings on mineralogical and chemical
characteristics of the tailings (Cr2O3=
21.16%) of a chrome ore beneficiation
plant of Sukinda and the different
beneficiated products obtained by
laboratory experiments.
MATERIALS AND METHODS
In the laboratory, the flow sheet
adopted for beneficiation of chromite
tailings (R-1) is: (a) two stage
hydrocyclone to remove the slimes as
overflows, (b) tabling of hydrocyclone
underflow to obtain concentrate (R-3) and
coarse tailings (R-4) and (c) coarse tailings
was cleaned in ball mill and treated in
table to obtain concentrate and tailings.
The final tailing (R-2) is a mixtures of
hydrocyclone overflows and tailings of
tabling experiments. The different samples
were wet sieved into size fractions
(micrometre), viz., -1000+700, -700+500,
-500+350, -350+250, 250+125, -125+63,
63+38 and -38 µm. Each size fraction was
cold mounted in epoxy resin and polished
by standard polish section preparation
methods. The polished sections were
studied under reflected light microscope.
Minerals were quantified by counting the
particles which were grouped into
following categories: free chromite, free
hematite+goethite, free quartz and locked
chromite particles. Liberation percent
(wt.) of chromite was calculated by the
formula: free chromiteX100/total
chromite. Chemical analyses of the
samples were obtained by making pressed
pellets and using Philips XRF unit pre-
calibrated with appropriate standards.
RESULTS AND DISCUSSION
Granulometric studies: Size analysis
data (Tables 1 to 4) indicated the
following results: (a) Feed (Sample- R-1):
59.87% of the particles are between 350
and 38 µm sizes and 27.66% particles are
less than 38 µm size. (b) Concentrate: The
concentrate sample is coarse grained with
97.88% of sample between 350 and 38 µm
sizes. (c) Both tailing (R-2 and R-4)
samples are fine grained; R-2 and R-4
samples contain 50.51% and 44.69%
particles of less than 38 µm size.
Microscopic studies
The mineralogical, textural and
chemical characteristics of hard lumpy and
friable chromite ores of Sukinda have been
published by a number of authors (Sahoo,
1974; Chakraborty and Chakraborty,
1984). In the bulk ores and concentrate
samples, chromite is the major constituent
with accessory minerals of goethite,
hematite, gibbsite and quartz. Chromite
occurs as euhedral and subhedral grains
(Figs. 1 and 2). The chromite grains are
occasionally fractured exhibiting
cataclastic texture. Angular and elongated
grains of chromite are formed due to
granulation of the large chromite grains.
Rarely chromite exhibits zonal alteration
to ferrit chromit. Chromite grains also
exhibit irregular and corroded grain
boundaries developed during
serpentinisation and /or by partial
dissolution during weathering processes
(see Fig. 2). Frequently chromite grains
occur as inclusions within goethite
forming locked grains (Fig. 3).
Goethite is the major constituent of
tailing samples. Goethite is of two types
viz., vitreous and ochreous (limonite) and
the later is more abundant (Fig. 4).
Vitreous goethite is grey to dark grey in
colour, occurs as massive mass, colloform
bands, botroids and fibrous aggregates.
Earthy goethite (limonite) is friable,
clayey and constituted of ultrafine
crystallites. Often vitreous and ochreous
goethites are intimately admixed. Hematite
occurs as irregular masses, colloform
bands, streaks, needles and laths intimately
associated with goethite. Goethite and
hematite occur as narrow fracture filling
veins and partly replace chromite.
Occasionally small needles and rounded
silicates grains (serpentine) occur as
inclusions in chromite grains. Gibbsite
grains are also noticed and often
intimately associated with ochreous
goethite. Quartz is fine as well coarse
grained.
Quantitative mineralogical studies
(a) Bulk/feed sample (sample- R-1): The
feed sample has 37.34% (wt.) total
chromite; 29.86% free chromite particles,
Cr2O3 and Fe2O3 contents of 21.16% and
39.25% respectively (Table 1). Fig. 5
shows the plots of size fractions vs. wt.%
retained and total chromite distribution
patterns. The bulk/feed ore contains
considerable amounts of fine particles
(27.66 wt.% is < 38 µm size). Chromite
particles (both free and locked) are mostly
concentrated within the size range between
350 and 38 µm and small amount (6.82%)
is distributed in <38 µm size. Degree of
liberation of chromite is about 89% below
125 µm size. The data indicate that the
free chromite grains and finer locked
particles with high chromite percents can
be separated by suitable concentration
processes.
(b) Concentrates (Sample- R-3): The
concentrate sample was obtained by
tabling experiment of hydrocyclone
underflow. The chromite concentrate is
coarse grained with negligible amounts of
fines (1.21% is <38 µm), contains 84.95%
chromite, 50.97% Cr2O3, 22.96% Fe2O3
(Table 2; Fig. 5). The mineralogical and
chemical data indicate that chromite
concentrate is high grade and is suitable
for use in metallurgical industries.
(c) Tailings: The Tailings R2 and R4
contain 16.47 and 29.61% chromite and
10.56% and 16.89% Cr2O3 respectively.
Fig. 5 shows the plots of size fractions vs.
wt.% retained and total chromite
distribution patterns in the tailing
samples.. The final tailings sample (R2) is
fine grained (50.51% is <38 µm size and
the bulk of chromite particles (11.10%) are
present in <38 µm size (Table 4).
Compared to final tailings, the tabling
tailing sample is relatively coarse grained
(44.69% is <38 µm size) with 14.65% of
chromite in <38 µm size (Table 3). The
high amounts of chromite particles in
Tabling tailing sample (R-3) necessitated
further beneficiation. The sample was
cleaned in ball mill followed by second
stage tabling experiment to obtain
chromite ore concentrate with high Cr2O3
content (51.8%). The final tailings (R-2)
(Table 4) is rejected as it contains ultrafine
chromite grains and the grade is low.
CONCLUSIONS
1. The chrome ore beneficiation plant
tailings is a low grade ferrugeneous
chromite ore having 37.34% chromite,
21.16% Cr2O3 and Cr:Fe ratio of 0.53. The
mineralogical studies indicated high
amounts of free chromite particles at
coarse sizes.
2. Tabling of the hydrocyclone underflow
gave a products of high quality chromite
ores with 50.97% Cr2O3 and Cr:Fe ratio
of 2.18.
3. The final tailing is fine grained (50.51%
<38 micron size), low grade (Cr2O3 =
10.65) and chromite particles are
distributed in fine size suggesting rejection
of the sample.
4. The entire flow sheet gave following
results for concentrates: Yield- 26%,
Grade – 49% and Recovery - 63%).
Acknowledgements: The authors thank Prof. B.K. Mishra, Director, Institute of Minerals
and Materials Technology, Bhubaneswar for kind permission to publish this paper.

References

CHAKRABORTY, K.L. and of Fines and Its Technology,

CHAKRABORTY, T.L. (1984)
Geological features and origin of
the chromite deposits of Sukinda
Valley, Orissa, India. Min. Dep.,
v.219, pp.256-265.
DAS, B., RAO, R.B. and
NARASIMHAN, K.S. (1989)
Beneficiation of low grade chrome
ores for use in charge chrome
industry. Proc. Nat. Sem.
Ferroalloys Making, Organized by
IIM and RRL, Feb., pp 73-78.
KUMAR, R.C., SINGH, V. and RAO,
S.M. (2007) Beneficiation of
ferrugeneous chromite fines at
TATA STEEL: Problems and
Prospects. Int. Conf. Beneficiation
Organised by TATA STEEL and
IIME, Jamshedpur Chapter, Dec.,
2007. pp.49-55
REDDY, P.S.R., RAO, R.B. and MISRA,
V.N. (2004). Utilisation of low
grade chromite ores of Orissa.
Sem. Mineral Processing
Technology (MPT), Feb., pp 497-
507.
SAHOO, R.K. (1974) Mineralogical and
ore deposit studies of the Sukinda
ultramafic belt, Orissa, India with
special reference to the assocated
chromite and nickeliferous
laterites. Unpublisjhed Ph.D.
Thesis. Univ. of Heidelberg. 167 p.
 Table 1. Quantitative mineralogy of the bulk sample. Sample: R-1. Loc. –Locked. Ditn.-
Distribution. F.-Free. Lib.- Liberation

Minerals 1000X700 700X500 500X350 350X250 250X125 125X63 63X38 -38 Total
Free chromite 0.95 2.85 3.48 10.78 32.43 48.89 52.08 24.67 29.86
Free goethite 38.6 40.32 37.54 49.71 46.77 42.66 43.92 75.33 52.80
Free quartz 0.00 0.00 0.27 0.00 0.00 0.00 0.00 0.00 0.02
Loc. Chromite 60.45 56.83 58.71 39.52 20.80 8.44 4.00 0.00 17.33
Total 100 100 100.00 100.00 100.00 100.00 100.00 100.00 100.00
Wt.% 2.59 3.46 6.41 10.37 18.11 20.39 11.00 27.66 100.00
Total chromite 13.04 19.9 21.09 30.54 42.83 54.80 54.88 24.67
Chromite ditn. 0.34 0.69 1.35 3.17 7.76 11.17 6.04 6.82 37.34
F. Chromite 0.02 0.10 0.22 1.12 5.87 9.97 5.73 6.82 29.86
ditn.
Lib. Chromite % 7.29 14.32 16.48 35.29 75.22 89.22 94.96 100
Chemical Analysis (Wt. %)
Cr2O3 8.16 12.32 11.14 14.66 22.99 32.16 32.55 14.31 21.16
Fe2O3 ND ND 35.09 35.31 31.65 29.15 30.46 55.22 39.25
Cr:Fe ----- ----- 0.31 0.41 0.71 1.08 1.04 0.25 0.53

Table 2. Quantitative mineralogy of the concentrate sample. Sample: R-3

Minerals 500X350 350X250 250X125 125x63 63x38 -38 Total

Free chromite 53.96 64.86 79.54 85.46 92.08 60.64 83.13
Free goethite 18.45 15.76 14.68 12.67 7.92 39.36 13.24
Free quartz 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Locked Chromite 27.59 19.38 5.78 1.87 0.00 0.00 3.63
Total 100.00 100.00 100.00 100.00 100.00 100.00 100.00
Wt.% 0.91 3.39 29.39 54.54 10.57 1.21 100
Total chromite 67.76 74.55 82.43 86.40 92.08 60.64
Chromite distribution 0.61 2.53 24.22 47.12 9.73 0.73 84.95
Free Chromite 0.49 2.20 23.37 46.61 9.73 0.73 83.13
Liberation hromite% 79.63 87.00 96.49 98.91 100.00 100.00

Chemical analysis (wt.%)

Cr2O3 40.51 45.32 50.18 51.65 55.14 35.17 50.97
Fe2O3 ND ND 22.04 22.89 22.76 31.82 22.86
Cr:Fe ------ ------- 2.23 2.21 2.37 1.08 2.18
Table 3. Quantitative mineralogy of the sand tabling tail sample. Sample: R-4

700X500 500x350 350X250 250x125 125X63 63X38 -38 Total

Free chromite 0.58 1.52 2.06 4.79 15.22 43.30 32.79 28.37
Free goethite 78.86 72.8 77.10 84.62 79.45 52.70 67.21 67.25
Free quartz 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Locked Chromite 20.56 25.68 20.84 10.60 5.34 4.00 0.00 4.38
Total 100 100 100.00 100.00 100.00 100.00 100.00 100.00
Wt.% 1.13 2.95 4.72 4.92 16.67 24.92 44.69 100.00
Total chromite 2.63 4.08 4.14 6.91 17.89 45.30 32.79
Chromite distribution 0.03 0.12 0.20 0.34 2.98 11.29 14.65 29.61
Free Chromite 0.01 0.04 0.10 0.24 2.54 10.79 14.65 28.37
Liberation Chromite 22.05 37.25 49.76 69.26 85.06 95.58 100.00

Chemical analysis, Wt.%

Cr2O3 2.54 2.84 1.88 2.24 9.56 25.76 19.02 16.89
Fe2O3 ND 32.41 34.01 34.34 34.42 32.75 47.56 41.67
Cr:Fe ‘--------- 0.09 0.05 0.06 0.27 0.77 0.39 0.40

Table 4. Quantitative mineralogy of the final (composite) tail sample. Sample: R-2

350X250 250X125 125X63 63X38 -38 Total

Free chromite 1.20 2.78 5.16 26.77 21.97 15.77
Free goethite 80.39 81.91 90.54 71.23 78.03 79.31
Free quartz 0.00 0.00 0.00 0.00 0.00 0.00
Locked Chromite 18.41 15.31 4.30 2.00 0.00 4.92
Total 100 100.00 100.00 100.00 100.00 100.00
Wt.% 15.17 8.73 12.05 13.54 50.51 100.00
Total chromite 3.04 4.31 6.45 27.77 21.97
Chromite distribution 0.46 0.38 0.78 3.76 11.10 16.47
Free Chromite 0.18 0.24 0.62 3.62 11.10 15.77
Liberation Chromite% 39.47 64.42 80.04 96.38 100.00

Chemical analysis (wt.%)

Cr2O3 2.21 3.74 5.45 14.72 12.74 10.56
Fe2O3 ND 34.78 37.07 36.65 52.05 47.17
Cr:Fe ‘------ 0.11 0.14 0.39 0.24 0.22
 O-G

O-G

1 2

C
O-G

3 4

Fig. 1: Euhedral and anhedral chromite grains as inclusion within ochreous goethite (O-
G) mass forming locked grain. Feed ore. Fig. 2: Chromite grain is intensely
fractured showing cataclastic texture. The fractures are filled up by goethite.
Chromite is also partly replaced by goethite. Feed ore. Fig. 3: Euhedral free
chromite grains with smooth and irregular outlines. Concentrate. Fig. 4: The final
tailings are composed of mostly ochreous goethite (O-G) particles with hematite
strings and patches and minor amounts of free euhedral chromite grains (C).
 60

50

40
Wt.%

30

20

10

0
-1000+700 -700+500 -500+350 -350+250 -250+125 -125+63 -63+38 -38
Size, micrometre

Fig. 5. Diagram showing the variations of size vs. wt.% retained (filled symbols) and
total chromite distribution (open symbols) in feed, concentrate and tailings.
Rhombus shaped symbol – Feed/bulk ore; Square – Chromite concentrate; Circle
– Tailings of tabling experiment; Triangle – Final tailings/rejects.