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Iron processing: Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. Included in this article also is a discussion of the mining of iron and of its preparation for smelting.

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The biggest iron ore expansion project currently under progress is Vale’s S11D project, located in the Carajás mining district in the Para region of Brazil. The S11D project should increase the mining and processing capacity at Vale’s Carajás mining complex by 90 million tons per year to 450 million tons.

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M a ny iron ore producers are facing challenging times due to price uncertainty and the need to process crude material with increasing levels of impurities. Upgrading the ore through beneficiation processes, particularly washing (scrubbing), to earn more per shipped tonne can be the key to improving project economics.

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Mineralisation and Ore Type

Magnetite ore has lower iron content (34-36% Fe) than hematite ore (58-64% Fe). It must be upgraded by a complex ore treatment process (beneficiation) to produce a high-grade (+65% Fe) concentrate for steelmaking.

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