Impact of quality of iron ore lumps on sustainability of mining operations in the Quadrilatero Ferrifero Area

• Decreasing cut-off grade of a mine helps to maximize reserve recovery volume.
• Iron ore lumps (>16 mm) were processed in jig and log washers.
• Improved Fe content lead to a 20% increase in reserve volume.
• A geometallurgical model will be developed to optimize production process.

The quality of lumps may have a significant impact in iron ore mining systems with implications for mineral reserve recovery rates. Improving the quality of lump ore, through a simple yet innovative mineral processing, can maximize recovery of reserves, decrease waste generation, and increase the productivity and sustainability of mines by allowing transition to lower quality iron ores. An example of the application of such principle is described here in which both siliceous and dolomitic banded iron formation rocks (BIFs) were subjected to chemical, physical, and mineralogical characterization before undergoing beneficiation processes in pneumatic jigs and log washer equipment. These processes were found to increase product quality and reduce the levels of contaminants, including SiO2, Al2O3, and fines. The gain in quality led to a reduction in the cut-off grade, from 60% to 58% Fe, while maintaining products specifications. Consequently, a 20% increase in the lump ore reserves was achieved, contributing to the sustainability of the mining system.