Modeling and Optimisation of Multigravity Separator for Recovery of Iron Values from Sub Grade Iron Ore Using Three Level Three Factor Box Behnken Design

Gottumukkala Venkateswara Rao; Ravvala Markandeya; Rajan Kumar

doi:doi:10.11648/j.ijmpem.20170204.12

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Modeling and Optimisation of Multigravity Separator for Recovery of Iron Values from Sub Grade Iron Ore Using Three Level Three Factor Box Behnken Design

Gottumukkala Venkateswara Rao, Ravvala Markandeya, Rajan Kumar

Published in International Journal of Mineral Processing and Extractive Metallurgy (Volume 2, Issue 4)

Received: 30 May 2017 Accepted: 7 July 2017 Published: 26 September 2017

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Abstract

In this study, a three level, three factor Box- Behnken factorial design combined with Response Surface Methodology (RSM) for modeling of process parameters of Multi Gravity Separator (MGS) for recovery Iron values from sub grade iron ore, Deposit No. 5, Bailadila complex has been developed. The three significant operational parameters of MGS, Drum rotational speed, Drum inclination and wash water Flow rate were considered in the experimental work and all other parameters like feed percent solids, shake frequency and shake amplitude were maintained constant. The ‘as received’ sub grade iron ore sample is admixture of lump and fines and chemically assayed 40.80% Fe, 40.90% SiO₂, 0.24% Al₂O₃ and 0.22% Loss on Ignition (LOI). Experiments were conducted with representative sample ground to -100 mesh (0.152mm) as per the design matrix. The obtained results were evaluated with the Box-Behnken factorial design, RSM and also Quadratic programming (QP). Second order response functions were developed for grade (%Fe) and recovery (% yield) of the concentrate fraction. Taking advantage of quadratic programming (QP), it was observed that maximum grade of 64.00% Fe achieved at a drum inclination of 3 degrees, wash water flow rate of 6 Liters Per Minute (LPM) and at a drum rotational speed of 175 Revolutions Per Minute (RPM). Similarly a maximum concentrate recovery (Yield) of 67.87% by weight could be achieved at 5 degrees drum inclination, 2 LPM wash water flow rate and at a drum rotational speed of 225 RPM. Predicted values of responses obtained using model equations were in good agreement with the experimental values. The influence of the process variables of multi gravity separator on concentrate grade and recovery were discussed.

Published in	International Journal of Mineral Processing and Extractive Metallurgy (Volume 2, Issue 4)
DOI	10.11648/j.ijmpem.20170204.12
Page(s)	46-56
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2017. Published by Science Publishing Group

Keywords

Response Surface Methodology, Box-Behnken Model, Optimisation, Multi Gravity Separator, Modeling, Bailadila and Sub Grade Iron Ore

References

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[2]	Aslan, N, H Kaya, 2009. “Beneficiation of chromite concentration waste by multi gravity separator and high intensity induced roll magnetic separator”, The Arabian journal for Science and Engineering, 34 (2B) pp 285-297.
[3]	Aslan, N, 2008a, “Multi-objective optimization of some process parameters of a multi gravity separator for chromite concentration”, Separation and Purification Technology, 64, pp 237-241.
[4]	Aslan,N., 2008 ”Application of response surface methodology and central composite rotatable design for modelling and optimisation of multi gravity separator for chromite concentration”, Powder Technology, 185, pp80-86.
[5]	Bandopadyaya, A., 2000. “Multi gravity separator – An equipment for separation of fines”, Processing of Fines (2), NML Jamshedpur, pp 81-92.
[6]	Bhaskar K U, B. Govindarajan, J P Barnwal, R Venugopal, M R Jakhu, T C Rao, “Performance and modeling studies of an MGS for graphite rejection in a lead concentrate”, International Journal of Mineral Processing., 67 (1-4) (2002), 59-70.
[7]	Chan B S, Mozley R H and Childs G J C “Extended trails with the High Tonnage Multi Gravity Separator”, Minerals Engineering 4(1991), pp 489-496.
[8]	Chan B S, Mozley R H and Childs G J C, “ The Multi Gravity separator (MGS): A Mine scale Machine”, Richard Mozley Limited, 1993
[9]	Çiçek T, and I. Cöcen, “Applicability of Mozley Multi-Gravity Separator (MGS) to Fine chromite Tailings of Turkish Chromite Concentrating Plants”, Minerals Engineering, 15(2002), pp. 91–93.
[10]	Gunaraj,V & Murugan, N, 1999, “Application of Response Surface Methodology for predicting weld base quality in submerged arc welding of pipes”, Journal of Materials Processing Technology, Vol. 88, pp 266-275.
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[14]	Patil, D. P., Govindarajan, B., Rao, T. C., Kohad, V. P., Gaur, R. K., Plant trials with the multi-gravity separator for reduction of graphite. Minerals Engineering, 2000, 12, 1127-1131.
[15]	Rao, G. V. et al., 2012, “Process amenability studies of sub grade iron ore from Bacheli complex, Bailadila sector, India”, XXVI IMPC 2012 Proceedings, New Delhi, India. Paper No.793, pp 1842-1860.
[16]	Rao, G. V et al, 2010, “Beneficiation of BHQ from Bacheli, Bailadila, Chattisgarh, India” XI International Seminar on Mineral Processing Technology (MPT-2010), NML Jamshedpur, December 2010.
[17]	Raissi, S, 2009, “Developing New processes and optimizing performance using Response Surface Methodology”, World Academy of science, Engineering and Technology, Vol 49, pp1039-1042.
[18]	Roy, S., 2009, “Recovery improvement of fine iron ore particles by multi gravity separation”, The Open Mineral Processing Journal, 2, pp 17-30.
[19]	Singh R, Bhattacharyya P, Bhattacharyya KK, “ Studies on recovery of mineral values using an enhanced gravity separator”, Advanced Gravity Seoaration (AGS), NML Pub, pp 47-56.
[20]	Sunil Kumar Tripathy, Yanamandra Rama Murthy, Vilas Tathavadkar and Mark Bernad Denys, “Efficacy of Multi Gravity Separator for concentrating Ferruginous chromite ore, Journal of Mining and Metallurgy, 48A (1) (2012) 39-49.
[21]	Yerriswamy P, J. P. Barnwal, B. Govindarajan, B K Gupta and T C Rao, “Influence of variables of multigravity separator on rejection of graphite from a lead concentrate”, Mineral Processing and Extractive Metallurgy, 111 (3) (2002), 156-159.

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Gottumukkala Venkateswara Rao, Ravvala Markandeya, Rajan Kumar. (2017). Modeling and Optimisation of Multigravity Separator for Recovery of Iron Values from Sub Grade Iron Ore Using Three Level Three Factor Box Behnken Design. International Journal of Mineral Processing and Extractive Metallurgy, 2(4), 46-56. https://doi.org/10.11648/j.ijmpem.20170204.12

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ACS Style

Gottumukkala Venkateswara Rao; Ravvala Markandeya; Rajan Kumar. Modeling and Optimisation of Multigravity Separator for Recovery of Iron Values from Sub Grade Iron Ore Using Three Level Three Factor Box Behnken Design. Int. J. Miner. Process. Extr. Metall. 2017, 2(4), 46-56. doi: 10.11648/j.ijmpem.20170204.12

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AMA Style

Gottumukkala Venkateswara Rao, Ravvala Markandeya, Rajan Kumar. Modeling and Optimisation of Multigravity Separator for Recovery of Iron Values from Sub Grade Iron Ore Using Three Level Three Factor Box Behnken Design. Int J Miner Process Extr Metall. 2017;2(4):46-56. doi: 10.11648/j.ijmpem.20170204.12

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@article{10.11648/j.ijmpem.20170204.12,
  author = {Gottumukkala Venkateswara Rao and Ravvala Markandeya and Rajan Kumar},
  title = {Modeling and Optimisation of Multigravity Separator for Recovery of Iron Values from Sub Grade Iron Ore Using Three Level Three Factor Box Behnken Design},
  journal = {International Journal of Mineral Processing and Extractive Metallurgy},
  volume = {2},
  number = {4},
  pages = {46-56},
  doi = {10.11648/j.ijmpem.20170204.12},
  url = {https://doi.org/10.11648/j.ijmpem.20170204.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmpem.20170204.12},
  abstract = {In this study, a three level, three factor Box- Behnken factorial design combined with Response Surface Methodology (RSM) for modeling of process parameters of Multi Gravity Separator (MGS) for recovery Iron values from sub grade iron ore, Deposit No. 5, Bailadila complex has been developed. The three significant operational parameters of MGS, Drum rotational speed, Drum inclination and wash water Flow rate were considered in the experimental work and all other parameters like feed percent solids, shake frequency and shake amplitude were maintained constant. The ‘as received’ sub grade iron ore sample is admixture of lump and fines and chemically assayed 40.80% Fe, 40.90% SiO2, 0.24% Al2O3 and 0.22% Loss on Ignition (LOI). Experiments were conducted with representative sample ground to -100 mesh (0.152mm) as per the design matrix. The obtained results were evaluated with the Box-Behnken factorial design, RSM and also Quadratic programming (QP). Second order response functions were developed for grade (%Fe) and recovery (% yield) of the concentrate fraction. Taking advantage of quadratic programming (QP), it was observed that maximum grade of 64.00% Fe achieved at a drum inclination of 3 degrees, wash water flow rate of 6 Liters Per Minute (LPM) and at a drum rotational speed of 175 Revolutions Per Minute (RPM). Similarly a maximum concentrate recovery (Yield) of 67.87% by weight could be achieved at 5 degrees drum inclination, 2 LPM wash water flow rate and at a drum rotational speed of 225 RPM. Predicted values of responses obtained using model equations were in good agreement with the experimental values. The influence of the process variables of multi gravity separator on concentrate grade and recovery were discussed.},
 year = {2017}
}

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TY  - JOUR
T1  - Modeling and Optimisation of Multigravity Separator for Recovery of Iron Values from Sub Grade Iron Ore Using Three Level Three Factor Box Behnken Design
AU  - Gottumukkala Venkateswara Rao
AU  - Ravvala Markandeya
AU  - Rajan Kumar
Y1  - 2017/09/26
PY  - 2017
N1  - https://doi.org/10.11648/j.ijmpem.20170204.12
DO  - 10.11648/j.ijmpem.20170204.12
T2  - International Journal of Mineral Processing and Extractive Metallurgy
JF  - International Journal of Mineral Processing and Extractive Metallurgy
JO  - International Journal of Mineral Processing and Extractive Metallurgy
SP  - 46
EP  - 56
PB  - Science Publishing Group
SN  - 2575-1859
UR  - https://doi.org/10.11648/j.ijmpem.20170204.12
AB  - In this study, a three level, three factor Box- Behnken factorial design combined with Response Surface Methodology (RSM) for modeling of process parameters of Multi Gravity Separator (MGS) for recovery Iron values from sub grade iron ore, Deposit No. 5, Bailadila complex has been developed. The three significant operational parameters of MGS, Drum rotational speed, Drum inclination and wash water Flow rate were considered in the experimental work and all other parameters like feed percent solids, shake frequency and shake amplitude were maintained constant. The ‘as received’ sub grade iron ore sample is admixture of lump and fines and chemically assayed 40.80% Fe, 40.90% SiO2, 0.24% Al2O3 and 0.22% Loss on Ignition (LOI). Experiments were conducted with representative sample ground to -100 mesh (0.152mm) as per the design matrix. The obtained results were evaluated with the Box-Behnken factorial design, RSM and also Quadratic programming (QP). Second order response functions were developed for grade (%Fe) and recovery (% yield) of the concentrate fraction. Taking advantage of quadratic programming (QP), it was observed that maximum grade of 64.00% Fe achieved at a drum inclination of 3 degrees, wash water flow rate of 6 Liters Per Minute (LPM) and at a drum rotational speed of 175 Revolutions Per Minute (RPM). Similarly a maximum concentrate recovery (Yield) of 67.87% by weight could be achieved at 5 degrees drum inclination, 2 LPM wash water flow rate and at a drum rotational speed of 225 RPM. Predicted values of responses obtained using model equations were in good agreement with the experimental values. The influence of the process variables of multi gravity separator on concentrate grade and recovery were discussed.
VL  - 2
IS  - 4
ER  -

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Author Information

Gottumukkala Venkateswara Rao

R&D Centre, NMDC Limited, Hyderabad, India
Ravvala Markandeya

Principal, JNTUH College of Engineering, Manthani, India
Rajan Kumar

R&D Centre, NMDC Limited, Hyderabad, India

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APA Style

Gottumukkala Venkateswara Rao, Ravvala Markandeya, Rajan Kumar. (2017). Modeling and Optimisation of Multigravity Separator for Recovery of Iron Values from Sub Grade Iron Ore Using Three Level Three Factor Box Behnken Design. International Journal of Mineral Processing and Extractive Metallurgy, 2(4), 46-56. https://doi.org/10.11648/j.ijmpem.20170204.12

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ACS Style

Gottumukkala Venkateswara Rao; Ravvala Markandeya; Rajan Kumar. Modeling and Optimisation of Multigravity Separator for Recovery of Iron Values from Sub Grade Iron Ore Using Three Level Three Factor Box Behnken Design. Int. J. Miner. Process. Extr. Metall. 2017, 2(4), 46-56. doi: 10.11648/j.ijmpem.20170204.12

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AMA Style

Gottumukkala Venkateswara Rao, Ravvala Markandeya, Rajan Kumar. Modeling and Optimisation of Multigravity Separator for Recovery of Iron Values from Sub Grade Iron Ore Using Three Level Three Factor Box Behnken Design. Int J Miner Process Extr Metall. 2017;2(4):46-56. doi: 10.11648/j.ijmpem.20170204.12

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@article{10.11648/j.ijmpem.20170204.12,
  author = {Gottumukkala Venkateswara Rao and Ravvala Markandeya and Rajan Kumar},
  title = {Modeling and Optimisation of Multigravity Separator for Recovery of Iron Values from Sub Grade Iron Ore Using Three Level Three Factor Box Behnken Design},
  journal = {International Journal of Mineral Processing and Extractive Metallurgy},
  volume = {2},
  number = {4},
  pages = {46-56},
  doi = {10.11648/j.ijmpem.20170204.12},
  url = {https://doi.org/10.11648/j.ijmpem.20170204.12},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmpem.20170204.12},
  abstract = {In this study, a three level, three factor Box- Behnken factorial design combined with Response Surface Methodology (RSM) for modeling of process parameters of Multi Gravity Separator (MGS) for recovery Iron values from sub grade iron ore, Deposit No. 5, Bailadila complex has been developed. The three significant operational parameters of MGS, Drum rotational speed, Drum inclination and wash water Flow rate were considered in the experimental work and all other parameters like feed percent solids, shake frequency and shake amplitude were maintained constant. The ‘as received’ sub grade iron ore sample is admixture of lump and fines and chemically assayed 40.80% Fe, 40.90% SiO2, 0.24% Al2O3 and 0.22% Loss on Ignition (LOI). Experiments were conducted with representative sample ground to -100 mesh (0.152mm) as per the design matrix. The obtained results were evaluated with the Box-Behnken factorial design, RSM and also Quadratic programming (QP). Second order response functions were developed for grade (%Fe) and recovery (% yield) of the concentrate fraction. Taking advantage of quadratic programming (QP), it was observed that maximum grade of 64.00% Fe achieved at a drum inclination of 3 degrees, wash water flow rate of 6 Liters Per Minute (LPM) and at a drum rotational speed of 175 Revolutions Per Minute (RPM). Similarly a maximum concentrate recovery (Yield) of 67.87% by weight could be achieved at 5 degrees drum inclination, 2 LPM wash water flow rate and at a drum rotational speed of 225 RPM. Predicted values of responses obtained using model equations were in good agreement with the experimental values. The influence of the process variables of multi gravity separator on concentrate grade and recovery were discussed.},
 year = {2017}
}

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TY  - JOUR
T1  - Modeling and Optimisation of Multigravity Separator for Recovery of Iron Values from Sub Grade Iron Ore Using Three Level Three Factor Box Behnken Design
AU  - Gottumukkala Venkateswara Rao
AU  - Ravvala Markandeya
AU  - Rajan Kumar
Y1  - 2017/09/26
PY  - 2017
N1  - https://doi.org/10.11648/j.ijmpem.20170204.12
DO  - 10.11648/j.ijmpem.20170204.12
T2  - International Journal of Mineral Processing and Extractive Metallurgy
JF  - International Journal of Mineral Processing and Extractive Metallurgy
JO  - International Journal of Mineral Processing and Extractive Metallurgy
SP  - 46
EP  - 56
PB  - Science Publishing Group
SN  - 2575-1859
UR  - https://doi.org/10.11648/j.ijmpem.20170204.12
AB  - In this study, a three level, three factor Box- Behnken factorial design combined with Response Surface Methodology (RSM) for modeling of process parameters of Multi Gravity Separator (MGS) for recovery Iron values from sub grade iron ore, Deposit No. 5, Bailadila complex has been developed. The three significant operational parameters of MGS, Drum rotational speed, Drum inclination and wash water Flow rate were considered in the experimental work and all other parameters like feed percent solids, shake frequency and shake amplitude were maintained constant. The ‘as received’ sub grade iron ore sample is admixture of lump and fines and chemically assayed 40.80% Fe, 40.90% SiO2, 0.24% Al2O3 and 0.22% Loss on Ignition (LOI). Experiments were conducted with representative sample ground to -100 mesh (0.152mm) as per the design matrix. The obtained results were evaluated with the Box-Behnken factorial design, RSM and also Quadratic programming (QP). Second order response functions were developed for grade (%Fe) and recovery (% yield) of the concentrate fraction. Taking advantage of quadratic programming (QP), it was observed that maximum grade of 64.00% Fe achieved at a drum inclination of 3 degrees, wash water flow rate of 6 Liters Per Minute (LPM) and at a drum rotational speed of 175 Revolutions Per Minute (RPM). Similarly a maximum concentrate recovery (Yield) of 67.87% by weight could be achieved at 5 degrees drum inclination, 2 LPM wash water flow rate and at a drum rotational speed of 225 RPM. Predicted values of responses obtained using model equations were in good agreement with the experimental values. The influence of the process variables of multi gravity separator on concentrate grade and recovery were discussed.
VL  - 2
IS  - 4
ER  -

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