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Iron ore and its final product, steel, are arguably the most historically social and economically significant commodity of the last three millennia. Matched with the increased demand for higher grade material, changes in the economic viability of iron ore deposits have seen iron ore production shift from early, low-grade bog iron ore and marine ironstones to the gigantic BIF-hosted deposits and locally the terrestrial Phanerozoic ironstones

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Despite their significance and the abundant literature devoted to these deposits, questions still remain regarding their genesis and their relationship with past global and/or local events. For instance, BIF geochemistry has been reasonably well studied, whereas only very few studies are concerned with the geochemistry of high-grade BIF-hosted deposits

China and the United States of America are still the dominant force in the production of magnetite-hosted BIF deposits, but Australia and Brazil are currently developing these deposit types. The BIF-hosted martite-microplaty hematite deposits represent the bulk of high-grade iron ores. The BIF-hosted martite-goethite and terrestrial ironstones, locally called CID, now hold primary importance in the Australian iron ore industry while the significance of the martite-microplaty hematite ores has decreased through depletion of natural reserves. Although the European and North American marine ooidal deposits have been geochemically well characterized in the past, their economic significance has decreased. It is the new, giant terrestrial ooidal deposits of Western Australia, which had previously received little international interest, that now represent economically significant examples of this iron ore type. Now, the developing Chinese economy and the predicted emergence of India will provide the impetus for the discovery and exploitation of new deposits and ore types worldwide, and will see the importance of iron ore as a foundation for economic growth to continue for years to come

Iron ore minerals, particularly hematite and goethite, are beneficiated by a combination of size fraction, preconcentration, and flotation in stages (Fig. 13.45). Iron ore requires removal of silicate impurities of a finer size by flotation for higher-grade products of +60% Fe. ROM ore at 400–600 mm is fed to a primary crusher with product set at –40 mm. The crushed product is screened in two stages. The overflow of the first screen (+40 mm) is recrushed. The underflow of the first and overflow of the second screen, i.e., –40 and +10 mm size, are directly sent for loading as blast furnace grade. The underflow (−10 mm) is passed through a classifier. Undersized particles of −1 mm are sent to a tailing pond. The overflow of −10 and +1 mm is grinded in a ball mill to produce 200 μm product size. The pulp is subjected to hydrocyclones for separation of slimes and removal of silica. Collectors such as amines, oleates, sulfonates, or sulfates are used for the flotation of silica. Magnetic or gravity separation is introduced at any suitable stage for preconcentration. The final iron ore fines are converted to pellets

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Iron ore was sampled before stock piling with a stacker. One hundred samples taken from the stacker-conveyor showed a standard deviation in the iron assay of ± 0.5 %. The ore assayed, on average, 59 % Fe. Sieve analysis of the samples showed that the largest size was less than 5 mm and the liberation of Fe was maximum in the size range, −400 + 300 μm. Given that the specific gravity of the ore was 5.3 and the specific gravity of the gangue was 2.6, estimate the minimum mass of sample required representing the stack

Iron ore has been smelted in crude furnaces in the Indian subcontinent for at least the last 3000 years, but the history of its modern iron and steel industry is short. The arrival of a fully integrated steel mill on modern lines dates back only to the end of the nineteenth century when the Bengal Iron and Steel Company was set up at Kulti in present-day West Bengal. In 1907 the Tata Iron and Steel Company (TISCO) was formed at Jamshedpur in present-day Jharkhand. In 1918 the Indian Iron & Steel Company (IISCO) was established by merging with the Bengal Iron and Steel Company resulting in production of 450,000 t of salable steel per annum. In the same year, the first public sector steel unit under the name of Mysore Iron and Steel Limited (MISL) was founded at Bhadravati in present-day Karnataka. The total production of hot metal in the country was only 1.5 Mt per annum on the eve of independence (1946–1947)

Development of the steel industry was intensified just after independence (1947) by increasing the output of steel to 3.77 Mt per annum brought about by modernization and expansion of the three units already mentioned. Three new public sector integrated steel plants (ISPs) at Durgapur, Rourkela, and Bhilai commenced construction in 1954 under the aegis of Hindustan Steel Limited (now the Steel Authority of India Limited, SAIL). A decade later, an ISP at Bokaro was set up. The Alloy Steel Plant was founded at Durgapur in 1965. The management of IISCO was taken over by the government in 1972, and the Salem Steel Plant was founded in the same year. The Visakhapatnam or Vizag Steel Plant was commissioned in 1983 by Rashtriya Ispat Nigam Ltd. (RINL). In 1997, Kalyani Steel (an ISP) was established at Hospet and opted to follow the mini blast furnace (MBF) route. There is a program for massive expansion of the steel industry by setting up new steel plants and increasing the capacity of existing plants. There are a large number of mini steel plants in the country with medium or small-sized furnaces that use scrap as raw material. MBFs are going to play an important role in bringing the production plan for steel to fruition. Table 2.1 gives chronological milestones showing how the steel industry has expanded

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Bog iron ores are found associated with peat deposits in swampy conditions. Typically they contain hydrated ferric-oxide and manganese-oxide cements but, below the water table, they may be cemented by siderite. It has been suggested that microbial activity in tropical climates particularly promotes the direct precipitation of siderite

A possible present-day analogue of ancient ooidal ironstones appears to be the verdine facies. In this facies, iron-rich aluminous green clay minerals replace bioclasts and pellets. Ferruginous peloids, in many cases altered faecal pellets, are known to be forming today in sediments deposited in front of equatorial deltas, such as those on the continental shelves off Senegal, Guinea, Nigeria, Gabon, Sarawak, and east Kalimantan. Present-day examples of ferruginous ooid accumulation are rare. In the interior of Africa, along the southernmost parts of Lake Malawi, amorphous ferric-oxide ooids have been found associated with geothermal springs, and, in the brackish open water of southern Lake Chad, goethitic brown ooids are being formed. In the shallow seas of northern Venezuela, berthierine-rich green-brown muddy ooidal sediments with peloids have been discovered

Coal and iron ore formed the basis of the steel industry in Liège in present Belgium. Coal mining rights were granted in Liège in 1195 (or 1198?) by the Prince Bishop. At about the same time, the Holyrood Abbey in Scotland was granted coal mining rights. A typical medieval situation involved abbeys or cloisters driving technology. In France, a 13th-century real estate document established property limits defined by a coal quarry. The earliest reliable written documentation in Germany appears to be a 1302 real estate transaction that included rights to mine coal. The transaction covered land near Dortmund in the heart of the Ruhr

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Coal use started before it was documented in writing. Religious orders tended to keep and preserve written materials more reliably than others. It seems reasonable to postulate that coal use began no later than the 12th century in several West European countries. Documented evidence remains anecdotal for several more centuries but indicates that coal use increased steadily from the 12th century on. England led in coal production until late in the 19th century. Contributing to this sustained leadership were that wood (and hence charcoal) shortages developed earlier and more acutely there than in other countries, there was ready access to shipping by water (sea and navigable rivers), and large coal deposits were present close to the surface

By the 13th century, London imported significant amounts of coal, primarily sea-coal, shipped from Newcastle-upon-Tyne. The use of coal grew steadily, even though it was controversial, for what now would be called environmental impact reasons. Smoke, soot, sulfurous odors, and health concerns made it undesirable. From the 13th century on, ordinances were passed to control, reduce, or prevent its use. None of these succeeded, presumably because the only alternatives, wood and charcoal, had become too expensive, if available at all. Critical for the acceptance of coal was the development of chimneys and improved fire places. By the early 1600s, sea-coal was the general fuel in the city. The population of the city grew from 50,000 in 1500 to more than 500,000 by 1700, the coal imported from less than 10,000 tons per year to more than 500,000 tons

Early coal use was stimulated by industrial applications: salt production (by brine evaporation), lime burning (for cement for building construction), metal working, brewing, and lesser uses. By the late Middle Ages, Newcastle exported coal to Flanders, Holland, France, and Scotland

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By the early 16th century, coal was mined in several regions in France. In Saint Étienne, long the dominant coal producer, coal was the common household fuel, and the city was surrounded by metals and weapons manufacturing based on its coal. Legal and transportation constraints were major factors in the slower development of coal on the European continent compared to England. In the latter, surface ownership also gave subsurface coal ownership. In the former, the state owned subsurface minerals. Notwithstanding royal incentives, France found it difficult to promulgate coal development on typically small real estate properties under complex and frequently changing government regulations. Only late in the 17th century did domestic coal become competitive with English coal in Paris, as a result both of the digging of new canals and of the imposition of stiff tariffs on imported coal. Coal mining remained artisanal, with primitive exploitation “technology” of shallow outcrops, notably in comparison with the by this time highly developed underground metal mining

The earliest coal mining proceeded by simple strip mining: the overburden was stripped off the coal and the coal dug out. As the thickness of the overburden increased, underground mines were dug into the sides of hills, the development of drift mines. Mining uphill, strongly preferred, allowed free water drainage and facilitated coal haulage. Some workings in down-dipping seams were drained by driving excavations below the mined seams

Shafts were sunk to deeper coal formations. When coal was reached, it was mined out around the shaft, resulting in typical bell pits. Coal was carried out in baskets, on ladders, or pulled out on a rope. Where necessary, shafts were lined with timber

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In larger mines, once the coal was intersected by the shaft, “headings” were driven in several directions. From these, small coal faces were developed, typically about 10 ft wide, usually at right angles from the heading, and pillars, blocks of coal, were left in between these so-called bords, the mined-out sections. Pillar widths were selected to prevent roof, pillar, and overburden failure, which could endanger people and could lead to loss or abandonment of coal. Each working face was assigned to a hewer, who mined the coal, primarily with a pick. The hewer first undercut the coal face: he cut a groove along the floor as deep as possible. He then broke out the overhanging coal with picks, wedges, and hammers. Lump coal was hand loaded into baskets, usually by the hewer's helper. The baskets were pushed, dragged, or carried to and sometimes up the shaft. This haulage commonly was performed by women and children, usually the family of the hewer. The hewer operated as an independent contractor. He was paid according to the amount of coal he and his family delivered to the surface. Once established as a hewer, after multiple years of apprenticeship, the hewer was among the elite of workers in his community

In deeper or better equipped mines, the coal baskets or corves were hoisted up the shaft using a windlass, later horse-driven gins. These also were used for hoisting water filled baskets or buckets, to dewater wet mines. By the end of the 17th century, shaft depths reached 90 ft, occasionally deeper. Encountering water to the extent of having to abandon pits became frequent. Improving methods to cope with water was a major preoccupation for mine operators

Ventilation also posed major challenges. Larger mines sank at least two shafts, primarily to facilitate operations. It was recognized that this greatly improved air flow. On occasion shafts were sunk specifically to improve ventilation. During the 17th century, the use of fires, and sometimes chimneys, was introduced to enhance air updraft by heating the air at the bottom of one shaft. In “fiery” mines, firemen, crawling along the floor, heavily dressed in wetted down cloths, ignited and exploded gas accumulations with a lighted pole. This practice was well established in the Liège basin by the middle of the 16th century. As mines grew deeper, and production increased, explosions became more frequent, on occasion killing tens of people

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In North America, coal was reported on Cape Breton in 1672. Some coal was mined for the French garrison on the island, some was shipped to New England before 1700. Coal was found by Joliet, Marquette, and Father Hennepin, in 1673, along the Illinois river. It is possible that some was used at that time by the Algonquins in this area

Mineral deposits like iron ore, bauxite, chromite, copper, limestone, and magnesite are exposed to the surface and are easy to explore/mine. Significant deposits of Rampura-Agucha zinc-lead-silver, India, Red Dog zinc-lead, Alaska, OK Tedi copper-gold, Papua New Guinea, and Olympic Dam copper-gold-uranium-silver, Australia, have been discovered and exploited based on surface exposure. There are ample possibilities of finding new deposits under glacial or forest cover. Prospecting efforts should look for fresh rock exposure and newly derived boulders. Examples are Adi Nefas Zn–Cu–Au–Ag deposit, Madagascar, El Abra Cu deposit, Chile, and chromite deposits in Orissa, Tamil Nadu, India (Fig. 2.1)

Figure 2.1. Massive chromite orebody exposed to surface near Karungalpatti village at Sitampundi belt, Namakkal District, Tamil Nadu, India, (Finn Barrett, Goldstream Mining NL, Australia, during reconnaissance.)

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The direct reduction of iron-ore fines without an intermediate agglomeration stage has been an interesting challenge for process developers in the past. The constraining factor has been the so-called sticking tendency of reduced or metallized fines, which is particularly prevalent and difficult to control in the case of gas-based direct reduction. With most of the available iron ores, this phenomenon tends to appear already at a fairly low temperature threshold of ≥650 °C. For Outotec's gas-based Circored® DR process, which has been industrially proven at a 500,000 t/y HBI (hot briquetted iron) plant in Trinidad, hydrogen was selected as a single reducing agent. The main reasons for this choice were its superior low-temperature (∼600 °C) reduction reaction characteristics, the low conduciveness of the reduced material to sticking and avoid the low-temperature, high-pressure methanation tendency if CO were present. The principle of the Circored® preheater is applied for preheating and partial reduction of the iron ore fines for the HIsmelt® smelt-reduction plant at Kwinana, Western Australia, for a capacity of 800,000 t/y of hot metal

The Circofer® process uses fundamentally the same two-stage CFB/FB configuration for the core plant for obtaining highly metallized product as in the case of Circored®. The precursor of the coal-based Circofer® process of Outotec was the prereduction CFB reactor for the EIred smelting reduction pilot plant in Sweden, which operated for 3 years in the late 1970s. A heater for coal charring and circulatory material heating has been integrated into the CFB circuit, for which oxygen is injected into the heater. The process operates at 4 atm at a temperature of approximately 900 °C

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