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Roasting Followed by Magnetic Separation: A Process

for Beneficiation of Titano-Magnetite Ore
a a a a a a
M. S. Jena , H. K. Tripathy , J. K. Mohanty , J. N. Mohanty , S. K. Das & P. S. R. Reddy
a
CSIR-Institute of Minerals & Materials Technology, Bhubaneswar, India
Accepted author version posted online: 04 Nov 2014.

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To cite this article: M. S. Jena, H. K. Tripathy, J. K. Mohanty, J. N. Mohanty, S. K. Das & P. S. R. Reddy (2015) Roasting
Followed by Magnetic Separation: A Process for Beneficiation of Titano-Magnetite Ore, Separation Science and Technology,
50:8, 1221-1229, DOI: 10.1080/01496395.2014.965834

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 Separation Science and Technology, 50: 1221–1229, 2015
Copyright © Taylor & Francis Group, LLC
ISSN: 0149-6395 print / 1520-5754 online
DOI: 10.1080/01496395.2014.965834
Roasting Followed by Magnetic Separation: A Process
for Beneficiation of Titano-Magnetite Ore
M. S. Jena, H. K. Tripathy, J. K. Mohanty, J. N. Mohanty, S. K. Das, and P. S. R. Reddy
CSIR-Institute of Minerals & Materials Technology, Bhubaneswar, India
Titano-magnetite is an ore of iron and titanium, and is
highly magnetic. Magnetite and ilmenite are two major miner-
als. Ilmenite exhibits various textural dispositions. Widmanstatten
and granular exsolution textures are important ones exhibited by
Downloaded by [New York University] at 22:38 18 May 2015
the constituent mineral. Reduction roasting followed by two-stage
LIMS gives a magnetic concentrate of 65.74% Fe at a yield
of 61.22% with 78.07% Fe recovery. Also, a by-product having
28.76% TiO2 at a yield of 20.08% with 36.78% TiO2 recovery
is produced. The concentrate (rich in magnetite) can be used as
heavy media in coal washeries whereas the middling fraction can
be taken for Ti recovery.
Keywords titano-magnetite; reduction roasting; magnetic separation
INTRODUCTION
Magnetic separation is a process usually adopted for con-
centrating the iron bearing minerals from the raw ore (1–5).
Also, it has potential applications in pollution control, biotech-
nology, chemical processing, and beneficiation of both other
ferrous and non-ferrous mineral industries, etc. (6). The most
commonly used beneficiation methods for iron ores are the
gravity and magnetic separation techniques, as they are sim-
ple, inexpensive, and non-destructive. Magnetic separation may
be preferred solely or in combination with gravity separa-
tion, depending on the ore characteristics (7–9). Selection
of magnetic separation techniques depends on many factors
like ore mineralogy, mineral liberation size, their correspond-
ing magnetic susceptibility, process economics, etc. Magnetic
separation takes advantage of differences in the magnetic prop-
erties of minerals. Minerals generally fall into one of three
magnetic properties: ferromagnetic, paramagnetic, and diamag-
netic. Based on the magnetic susceptibility of the minerals,
the selection of high or low intensity magnetic separator
Received 7 April 2014; accepted 11 September 2014.
Address correspondence to M. S. Jena, CSIR-Institute of
Minerals & Materials Technology, Bhubaneswar, 751013, India.
E-mail: msjena@immt.res.in
Color versions of one or more of the figures in the article can be
found online at www.tandfonline.com/lsst.
1221
may be determined. Ferromagnetic minerals are themselves
magnetic (i.e., magnetite and pyrrhotite) and can be easily
separated from other minerals by a low intensity magnetic sep-
arator. Conventional magnetic separation devices are generally
restricted to separating strongly magnetic materials, such as
iron and magnetite. A number of different types of devices have
been developed, but they reflect a tendency to give less attention
to maximizing the magnetic forces than to refining mechanical
operation for various feeds (10–11).
Roasting is a metallurgical process involving gas-solid reac-
tions at elevated temperatures with the goal of purifying the
metal component(s). It is the process of preparing ores or
ore concentrates for subsequent enrichment, nodulizing, or
smelting. Roasting changes the physical properties or chem-
ical composition of ore, converts the useful components into
extractable form, and removes impurities. The temperature to
which the ore is heated depends on the specific ore and on the
purpose of roasting. Iron ore can be subjected to roasting, which
is usually reductive and converts iron oxides into the highly
magnetic form for subsequent enrichment. Oxidative roasting
is used to remove sulfur, carbon dioxide from carbonates, and
moisture from hydrates. The extent of industrial roasting of
ferrous ores is limited.
Titano-magnetite represents a valuable raw material for the
production of magnetite and titanium. In several countries they
are already processed whereby the treatment is adjusted to the
content of the components to be recovered. Upgrading is rather
simple for all types of titano-magnetites and can mainly be
achieved by magnetic separation after suitable grinding (12).
The most widely used titanium product is titanium dioxide
(TiO2 ), being used as pigment, as filler in paper, plastics and
rubber industries, and as flux in glass manufacture. Only about
6% is used to produce metallic titanium (13–14). The main
titanium containing minerals are ilmenite, rutile, and leucoxene.
Ilmenite supplies about 91% of the world’s demand for titanium
minerals (14–16). Magnetite is a dense medium solid com-
monly used in heavy/dense medium separation process for coal
preparation. Most of the magnetite is produced as a by-product
of iron ore processing. Demand for magnetite is expected to
increase continuously and the increasing cost of magnetite has
led to a growing interest in recovering magnetite from alternate
 1222 M. S. JENA ET AL.
sources. Considering the cost and demand, it is now necessary
to beneficiate the low grade magnetite ore to improve the qual-
ity for proper utilization (17–18). This paper discusses about
the processing of low grade titano-magnetite sample through
roasting followed by magnetic separation.
MATERIALS AND METHOD
Sample Preparation
About 500 kg of low grade titano-magnetite ore (∼ −40 mm
size) sample is collected from a mine of Gondia district,
Maharashtra, India and used for these present investigations.
The whole “as received” sample is thoroughly mixed and some
representative samples are drawn for characterization studies.
The rest of the material is classified at 6 mm screen and the
oversize material is stage crushed (by jaw crusher followed
by roll crusher) to pass through the 6 mm screen. Three rep-
resentative samples from this −6 mm size material are taken
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for magnetic separation, oxidation roasting followed by mag-
netic separation, and reduction roasting followed by magnetic
separation studies, respectively. For beneficiation by magnetic
separation (WHIMS and LIMS), the −6 mm raw ore as well
as −6 mm roasted (oxidation/reduction) ore are ground in a
closed circuit ball mill to pass through the 53 micron sieve.
The coke breeze, containing about 1.27% moisture, 11.47%
ash, 1.36% volatile matter, and 85.9% fixed carbon, is ground
in a ball mill and then classified to produce −500 + 300 micron
size material, which is used for reduction roasting studies.
Characterization Studies
Size and Chemical Analysis
The detail chemical analysis of “as received” low grade
titano-magnetite ore is carried out to determine the contents of
Fe, FeO, TiO2 , Al2 O3 , SiO2 , and LOI present in the sample as
per the standard wet chemical analysis procedure.
The size analysis is carried out using standard BSS sieves by
wet method for the “as received” sample. Each size fractions
are then dried, weighed, and analyzed for Fe content.
Density Determination
The “as received” sample, crushed to −6 mm size, is pre-
pared for bulk density measurement by using standard test
procedure. The true density of “as received” as well as mag-
netic concentrate of reduced products is determined using
Quantachrome make Automatic Helium Gas Ultra Pycnometer
as per standard test method.
X-Ray Diffraction Study
The mineralogical compositions of the “as received” sample
is evaluated by XRD analysis using PANalytical, X’Pert-PRO
X-ray diffractometer with Cu Kα radiation (λ = 1.5418 Å).
Measurements were conducted at 40 kV voltage and 30 mA
current with scanning interval 2θ = 10-65◦ and a scan speed of
2◦ /min.
Microscopic Study
The samples taken from the “as received” low grade titano-
magnetite ore sample are polished and the polished sections are
prepared as per the standard procedure for mineralogical study
under microscope.
Beneficiation Studies
Magnetic Separation Study
The wet high intensity magnetic separation (WHIMS)
study is carried out using the laboratory model (Box Mag
Rapid) batch type WHIMS. In each case, around 100 gm of
−53 micron sample is taken for WHIMS study. The slurry of
100 gm sample with 2-3 liter of water is fed to the magnetic
separator. The concentrate is washed with fresh water before
disconnection of magnetic field. The current is varied at 2.5,
5.0, 7.5, 10.0, and 12.0 amp to create the magnetic intensities
of 4900, 7700, 11800, 13720, and 15400 gauss, respectively.
Both magnetic and non-magnetic fractions are collected and
again the magnetic fraction is subjected to WHIMS for second
stage separation to produce better grade magnetic product at the
same operating condition. The second stage non-magnetic frac-
tion is taken as middling. All the three products generated in
each of the experiments are dried, weighed, and analyzed for
Fe content.
The wet low intensity magnetic separation (LIMS) study is
carried out using the laboratory scale SALA make continuous
drum type LIMS, supplied by M/s Sala International, Sweden.
The experiments are conducted at a feed rate of 10.0 kg/hr with
20% solid concentration at a wash water flow rate of 2 lit/min
using the −53 micron size ground sample. The magnetic sepa-
ration is carried out at 2000 gauss magnetic intensity. The slurry
is fed to the LIMS after setting the current at appropriate posi-
tion. Additional water is added to wash the magnetic fraction.
Both magnetic and non-magnetic fractions are collected and
the magnetic fraction is again subjected to LIMS for second
stage sequential separation to produce better grade magnetic
concentrate at the same operating condition. The second stage
non-magnetic fraction is taken as middling, and then all the
three products are dried, weighed, and analyzed for Fe and TiO2
content.
Oxidation Roasting Followed by Magnetic Separation Study
Roasting in oxidative atmosphere is carried out at 950◦ C
in a muffle furnace. Around 1 kg of −6 mm “as received”
ground sample is kept inside the muffle furnace and then the
furnace temperature is raised. After raising the temperature to
950◦ C, the sample is kept for another 1 hour inside the fur-
nace. The sample is then taken out, cooled, and ground in a
ball mill to pass through 53 micron sieve. Subsequently, repre-
sentative samples are taken from this −53 micron size ground
 BENEFICIATION OF TITANO-MAGNETITE ORE 1223

sample and subjected to WHIMS as well as LIMS separately. 70

Weight, %
The WHIMS and LIMS studies are conducted as per the proce-
Grade (Fe), %
dures and conditions stated in previous section. All the products 60
are then dried, weighed, and analyzed for Fe and TiO2 content.
50
Reduction Roasting Followed by Magnetic Separation Study

Percentage, %
Reduction roasting is carried out at different temperature 40
ranging from 750◦ C to 1050◦ C in a muffle furnace using
coke breeze as reductant. Around 550 gm of the −6 mm “as 30
received” crushed sample is mixed thoroughly with 200 gm of
coke breeze (−500 + 300 micron). The mixture is further cov- 20
ered with additional coke breeze of about 150 gm to prevent
re-oxidation of top layer during the process of heating. The box 10
containing the mixture is kept inside the muffle furnace and the
furnace temperature is raised. After raising the temperature to 0
+40 +30 +22 +16 +10 +6 +3 +2 +1 –1
the desired level, the sample is kept for another 1 hour inside
Size, mm
the furnace. Then the sample is taken out, covered with addi-
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tional coke breeze (around 50 gm) over the hot roasted material
to prevent re-oxidation, and then cooled. This cooled roasted
product is subjected to dry PERMROLL magnetic separator,
supplied by M/s. Ore Sorters Limited, Australia, to separate
coke breeze and ash. Then the magnetic product is ground in
a ball mill to pass through 53 micron sieve. Subsequently, this
ground −53 micron sample is subjected to low intensity mag-
netic separator (LIMS) as per the procedures and conditions
stated in section 2.3.1. All three products, obtained from LIMS,
are dried, weighed, and analyzed for Fe and TiO2 content.
RESULTS AND DISCUSSION
Characterization Studies
Size and Chemical Analysis
The detail chemical analysis of the “as received” titano-
magnetite ore sample is given in Table 1. The ore contains
around 52.49% total iron and 16.84% TiO2 . It indicates that
the ore is rich in TiO2 content.
The size and size wise Fe analysis of “as received” sam-
ple is given in Fig. 1. It shows that the “as received” sample
contains only 2% of below 1 mm size material and the Fe
values are uniformly present in all the size fractions. This
indicates that simple classification or conventional methods
TABLE 1
Chemical analysis of “as received” sample
Constituents Percentage, %
Fe 52.49
FeO 8.86
TiO2 16.84
Al2 O3 5.05
SiO2 4.28
LOI 0.56
FIG. 1. Size and chemical analysis of ‘as received’ sample.
TABLE 2
True density of “as received” sample and concentrates
True density,
Details g/cc
As received sample 4.6869
Reduction roasted (850 ◦ C) magnetic 5.1202
concentrate
Reduction roasted (950 ◦ C) magnetic 5.3950
concentrate
Reduction roasted (1050 ◦ C) magnetic 5.7627
concentrate
of beneficiation techniques are not suitable for beneficiat-
ing this titano-magnetite ore sample. Hence, it is decided
to reduce the size of the “as received” sample to below
53 micron for beneficiation through magnetic separation as per
the mineralogical studies (19).
Density Determination
The bulk density is measured for the “as received” sample
crushed to −6 mm size and found to be 2.7 gm/cc.
The true density of the “as received” titano-magnetite ore
ground to below 53 micron and magnetic concentrate of
reduced product (at different temperatures) are measured and
tabulated in Table 2. It indicates that the true density increases
as the temperature of reduction roasting increases. It is found
that true density of magnetic concentrate of reduced product,
roasted at 1050◦ C, increases up to 5.7627 gm/cc.
X-Ray Diffraction Study
The X-Ray Diffraction study using Cu Kα target for the “as
received” sample is carried out and shown in Fig. 2, which
 1224
Downloaded by [New York University] at 22:38 18 May 2015
FIG. 2. X-Ray Diffraction patterns of ‘as received’ sample.
indicates that this ore contains mostly hematite, maghemite
(magnetite converting towards hematite), ilmenite, and kaolin-
ite as major mineral phases. XRD pattern of the sample also
revealed that maghemite is the major mineral followed by
hematite, ilmenite, and kaolinite.
Mineralogy
The polished sections of the “as received” sample are exam-
ined under microscope for mineralogical and textural attributes
of the ore. It indicates that the studied sample is a titanifer-
ous magnetite (contains ilmenite and martitized magnetite), but
the magnetite is completely altered to martite/maghemite. The
sample contains minor amounts of silicate minerals; may be
hornblende, biotite, and feldspar. The ore exhibits various inter-
growth textures characteristics of titano-magnetite ores world-
wide. The ore exhibits common textures such as Widmanstatten
texture, granular exsolution, trellis intergrowth, and micro-
graphic intergrowth. Ilmenite lamellae occur at the octahedral
planes of magnetite giving rise to Widmanstatten texture as
shown in Fig. 3a. Sometimes large tabular ilmenite grains are
present along with ilmenite lamellae in the ore as observed
from Fig. 3b. The ore exhibits trellis intergrowth where the
ilmenite lamellae met with coarse ilmenite grains with tapered
ends as shown in Fig. 3c. The ore also exhibits external granular
exsolution where the ilmenite lamellae grow outwards from the
magnetite grain boundaries as observed from Fig. 3d. Figure 3e
shows ilmenite is also present as fine internal granules within
the magnetite/maghemite. The ore shows graphic intergrowth
texture where fine vermicular ilmenite grains are intimately
associated with magnetite as shown in Fig. 3f.
Ilmenite forms intricate intergrowths with magnetite.
Ilmenite plates/lamellae are max. 20 µ width but the length
may be max. 3 mm. Coarse granular aggregates of ilmenite are
M. S. JENA ET AL.
observed. The aggregates are at places about 3 mm in length.
Small ilmenite grains (max. 20 µ dia) are observed within
the magnetite. Also, ilmenite grains are found along the grain
boundaries of magnetite. These grains have a max. 100 µ dia.
Rounded ilmenite granules (max. 1 mm; av. 0.20 mm dia) are
found along the grain boundaries of magnetite. Large ilmenite
aggregates have 3 mm length and 0.8 mm width.
Because of the complex textural pattern and intimate
ilmenite-magnetite association, it is difficult to separate
ilmenite from magnetite and also both from other gangue.
However, coarse ilmenite grains and lamellae of around 50 µ
in size can be separated after grinding. Based on these find-
ings, the “as received” sample is ground to below 53 µ size for
recovery of iron values by magnetic separation technique.
Beneficiation Studies
Wet High Intensity Magnetic Separation (WHIMS)
The wet high intensity magnetic separation is carried out
on the “as received” titano-magnetite ore ground to below
53 micron size. The current is varied from 2.5 to 12.0 amp to
maintain the magnetic intensities from 4900 to 15400 gauss,
respectively. The results of the effects of magnetic intensity
on this ground ore are shown in Fig. 4. From the results, it is
observed that the yield of the magnetic concentrate increases
with the increase in magnetic intensity but simultaneously the
grade of the concentrate decreases. Though the percentage
recovery of Fe is increased but the grade of the concentrate is
not appreciable. In this study on the raw ore at 4900 gauss mag-
netic intensity, a concentrate of 49.67% yield with 55.48% Fe
recovery is produced with a grade of only 59.92% Fe.
Low Intensity Magnetic Separation (LIMS)
The low intensity magnetic separation for the below
53 micron ground raw ore is carried out at 2000 gauss mag-
netic intensity and the results are given in Table 3. Though the
LIMS study has given a better concentrate in terms of grade
but the yield and Fe recovery is very low. A concentrate of
16.74% yield with 20.77% Fe recovery at a grade of 64.68% Fe
is produced in two-stage magnetic separation. The grade of the
concentrate indicates the presence of magnetite. TiO2 content
in non-magnetic fraction is also slightly increased.
Oxidation Roasting Followed by Magnetic Separation
Oxidation roasting is undertaken at 950◦ C in a muffle fur-
nace on this “as received” titano-magnetite ore sample, crushed
to below 6 mm size (19). The wet high intensity magnetic sepa-
ration (WHIMS) is carried out on the roasted sample ground to
below 53 micron at similar conditions as in the case of raw ore.
The results of WHIMS study on the oxidation roasted sample
and the effects of varying magnetic intensities are depicted in
Fig. 5. The results indicate that the yield of the concentrate is
reduced drastically to 19.19% and also the grade is reduced by
2-3% in comparison with the raw ore taken for WHIMS study.
 BENEFICIATION OF TITANO-MAGNETITE ORE 1225

Ilm

Ilm

Ilm

(a) (b)
Downloaded by [New York University] at 22:38 18 May 2015

100 µm

(c) (d)

(e) (f)

FIG. 3. (a) “Widmanstatten texture” due to orientation of ilmenite(Ilm) lamellae along the octahedral planes of titano-magnetite. (b) Coarse ilmenite grains (Ilm)
in the ore besides two sets of ilmenite lamellae (Ilm) perpendicular to each other within magnetite host. (c) Ilmenite lamellae showing trellis intergrowth. (d)
External granular exsolution of ilmenite in the ore. (e) Fine ilmenite granules within titano-magnetite host showing internal granule exsolution texture. (f) Graphic
intergrowth between magnetite and ilmenite.
 1226 M. S. JENA ET AL.

100 60 40 58

90
59 35
57
80

Grade (Fe), %
Recovery, %

Grade (Fe), %
58 30

Recovery, %
70 56

57 25
60

55
56
50 Weight recovery (Yield), % 20
Weight recovery (Yield), %
Fe recovery, %
Fe recovery, %
Grade (Fe), %
Grade (Fe), %
40 55
15 54
4000 6000 8000 10000 12000 14000 16000
4000 6000 8000 10000 12000 14000 16000
Magnetic intensity, gauss
Magnetic intensity, gauss
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FIG. 4. Effect of magnetic intensity in WHIMS study on ‘as received’ sample.

FIG. 5. Effect of magnetic intensity in WHIMS study on oxidation roasted
(950 ◦ C) sample.

As the magnetic intensity increases the yield and Fe recovery

53 micron at similar conditions as in the case of raw ore.
of the concentrate increases but the grade of the concentrate
The effects of reduction roasting temperature on low intensity
decreases, which is not acceptable.
magnetic separation are shown in Fig. 6. The results show a
The low intensity magnetic separation (LIMS) is carried out
drastically significant change in both yield as well as grade due
on the roasted sample ground to below 53 micron at similar
to sequential reduction of iron phase from Fe2 O3 → Fe3 O4 →
conditions as in the case of raw ore. The results of the LIMS
FeO → metallization (20). At 850◦ C, the maximum conver-
study on the oxidation roasted sample are given in Table 4. The
sion of iron phase towards Fe3 O4 and also slight liberation of
results indicate that separation by LIMS has given better con-
TiO2 from iron phase takes place and hence the yield, grade,
centrate in terms of grade than WHIMS on roasted sample but
and recovery of both Fe and TiO2 are increased. An appre-
the yield has been further reduced to 12.97%.
ciable better concentrate with 65.74% Fe content at a yield
From the above studies, it is observed that roasting at oxida-
of 61.22% with 78.07% Fe recovery is obtained, by two stage
tive atmosphere for this titano-magnetite ore has no positive
low intensity magnetic separation, with a by-product (middling)
effect in magnetic separation than raw ore. Also, it is seen
having 28.76% TiO2 content at a yield of 20.08% and 36.78%
that separation by low intensity magnetic separator (LIMS)
TiO2 recovery. The non-magnetic fraction may be considered
gives better results in terms of grade for both Fe and TiO2 .
as tailings, having low iron content, which may be rejected.
This indicates the presence of highly magnetic material like
While roasted at 950◦ C, the iron phase is reduced to FeO
magnetite/maghemite and ilmenite.
(non-magnetic), which is reported in non-magnetic fraction.
As TiO2 is mostly associated with iron phase, the non-magnetic
Reduction Roasting Followed by Magnetic Separation
fraction has become rich in TiO2 . At 1050◦ C, due to iron met-
Reduction roasting is undertaken at different temperature allization, again the yield and recovery of magnetic concentrate
ranging from 750◦ C to 1050◦ C in a muffle furnace on this raw is increased to some extent. The results of low intensity mag-
ore crushed to below 6 mm size. As per the earlier observa- netic separation (LIMS) studies conducted on raw, oxidized,
tions, only the low intensity magnetic separation (LIMS) is and reduced (at 850◦ C) ore are compared and given in Table 5.
carried out on the reduction roasted sample ground to below

TABLE 3
Results of LIMS study for “as received” sample
Details Yield, % Fe, % TiO2 , % Fe Rec., % TiO2 Rec., %
Magnetic 16.74 64.68 6.89 20.77 6.94
Middling 8.56 62.16 9.47 10.21 4.87
Non magnetic 74.70 48.16 19.61 69.02 88.19
Head 100.00 52.12 16.61 100.00 100.00
 BENEFICIATION OF TITANO-MAGNETITE ORE 1227

TABLE 4
Results of LIMS study at 2000 gauss for oxidation roasted (950◦ C) sample
Details Yield, % Fe, % TiO2 , % Fe Rec., % TiO2 Rec., %
Magnetic 12.97 60.03 12.13 14.98 10.02
Middling 45.36 50.26 17.62 43.83 50.85
Non magnetic 41.67 51.38 14.76 41.19 39.13
Head 100.00 51.99 15.72 100.00 100.00

80 70 intricate intergrowths of magnetite (converted to

maghemite/hematite) and ilmenite, it is difficult to
separate them by conventional beneficiation tech-
70
niques. Hence, the sample is ground to below
53 micron before subjecting to magnetic separation
60 65 based on the mineralogical studies.

Grade (Fe), %
Recovery, %
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Investigations carried out for beneficiation of this low grade

50 titano-magnetite ore reveals that
• This sample responds well to magnetic separation. The
40 60 magnetic separation by wet high intensity magnetic
separator (WHIMS) and low intensity magnetic sep-
30 Weight recovery (Yield), %
arator (LIMS) on the “as received” ore indicates that
Fe recovery, % LIMS, operated at 2000 gauss magnetic intensity, has
Grade (Fe), % given better performance than WHIMS for treating
20 55
700 800 900 1000 1100
this particular ore.
Temperature, °C • Oxidation roasting followed by magnetic separation
by WHIMS as well as LIMS has not shown any
FIG. 6. Effect of roasting temperature on LIMS study of reduction roasting positive effect for beneficiation of this ore.
sample.
• Reduction roasting followed by low intensity magnetic
separator (LIMS) has given a remarkable up-gradation
CONCLUSIONS for both Fe in concentrate and TiO2 in middling (by-
Characterization studies, carried out on this low grade titano- product) in terms of grade and recovery.
magnetite ore, reveal that • After reduction roasting of the ore at 850◦ C followed
by LIMS, a concentrate with 65.74% Fe content at a
• This sample contains around 52.49% Fe, 8.86% FeO, yield of 61.22% with 78.07% Fe recovery is obtained.
5.05% Al2 O3 , 4.28% SiO2 , 16.84% TiO2 , and 0.56% Simultaneously, a middling (by-product) with 28.76%
LOI. Size analysis of the “as received” sample shows TiO2 content at a yield of 20.08% with 36.78% TiO2
the uniform distribution of Fe values through out all recovery is produced. The magnetic product, which
the size fractions. has specific gravity more than 5, can be used as heavy
• Mineralogical studies indicate that this ore con- medium during the “Heavy Medium Separation” pro-
tains hematite, ilmenite, kaolinite, and maghemite cess in coal washeries. The TiO2 rich middling frac-
as major mineral phases. As there are fine and tion may be used for production of ferro-titanium

TABLE 5
Comparison of LIMS results at 2000 gauss on raw, oxidized, and reduced sample
Concentrate Fe By-product (Middling) TiO2

Sample Yield, % Grade, % Recovery, % Yield, % Grade, % Recovery, %

Raw 16.74 64.68 20.77 8.56 9.47 4.87
Oxidation roasted 12.97 60.03 14.98 45.36 17.62 50.85
Reduction roasted 61.22 65.74 78.07 20.08 28.76 36.78
 1228 M. S. JENA ET AL.
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FIG. 7. Process flowsheet for recovery of Fe and TiO2 values from low grade titano-magnetite ore.
after blending at a suitable proportion with high grade
ilmenite/rutile. The tailings generated during the pro-
cess having low Fe and TiO2 content may be rejected.
Further increase in reduction roasting temperature
leads towards formation of FeO or metallization.
• Based on these studies, a process flowsheet has been
developed to process this low grade titano-magnetite
ore for recovering iron values, as well as TiO2 values
as a by-product and shown in Fig. 7.
ACKNOWLEDGEMENTS
The authors are thankful to the Director, CSIR-IMMT,
Bhubaneswar for his kind permission to carry out this work at
CSIR-IMMT, Bhubaneswar.
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