Nsude iron ore for sustainability Development

1. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
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Enhancement of Nusde Iron Ore for Metal
Industry Sustainability Development
Ocheri C & C.N. Mbah
Department. of Metallurgical and Materials Engineering,
University of Nigeria, Nsukka, Enugu State, Nigeria
Department. of Metallurgical and Materials Engineering,
Enugu State University of Science & Technology ( ESUT) ,
Agbani Enugu Nigeria.
Corresponding Author: Ocheri C.
Email: cyril.ocheri@unn.edu.ng
Phone no: +2348051793922

2. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
Introduction
Analytical
Techniques
X- ray
diffraction
Scanning Electron
Microscopy /EDS
X-ray
fluorescence
Fourier Transform
Infrared Spectroscopy
(FTIR) techniques.
Physical &
Chemical analyses
…Metallurgical Assessment
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3. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
Figure : 1 Blast Furnace 99% Completed
STATEMENT OF PROBLEM
• Ajaokuta Steel Plant has
capacity to produce 1.3 million
tonnes of steel per annum
• There fore about 2.135 million
tonnes of iron concentrate will
be genetaed from Itakpe iron
project
• This is conservatively estimated
to last for about 25 years which
is negligible for a life of a nation.
• The discovery and processing of
the Nsude iron ore will increase
the capacity & requirement of
the Blast Furnace need.
FACTS
Blast Furnace 99% Completed

4. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
Significance of the Study
Technology
Engineering
Innovation
Industrial and
Technological
Transformation
•Nsude is a rural
community which
does not have so
basic social amenities
for the growth and
development of her
people
•Technology: key to unlock the potential of the
Nsude community and its environs , 4

5. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
SINTER PLANT
COAL YARD
COKE OVEN
BLAST FURNACE
RAW MATERIAL:
IRON ORE, LIMESTONE,
DOLOMITE ETC.
COKE
SINTER
POWER PLANT
NATURAL GAS
POWER FOR
SALE
POWER FOR
INTERNAL USE
STEAM
TURBO BLOWER
BLAST AIR
PIG IRON
PIG CASTER
PIG IRON FOR
SALE
OXYGEN
PLANT
LIME
OXYGEN
HOT
METAL
STEEL MAKING
SHOP
LIQUID
STEEL
CONTNUOUS
CASTER
BLOOMS MEDIUM SECTION
STRL MILL
BILLETS
WIRE ROD
MILL
LIGHT SECTION
MILL
BILLETS
WIRE RODS, COILS etc
ROUNDS, SQUARES
HEXAGONS, ANGLES
BEAMS, CHANNELs
BILLET
MILL
Alumino-Silicate
Refractory Plant
Engineering Shops
Complex
Tar Bonded Dolomite
Refractory Plant
Value Chain Activities in Iron and Steel Producing Industries
Slabs
LIME Plant
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6. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
MATERIALS
The iron ores were sourced at Nsude Hill at Udi
Local Government Area, Enugu State .
Figure : 2 Nsude Iron Ore
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7. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
Comminution
• Jaw crusher –
• Gyratory crusher –
• Hammer crusher
• Edge mill –
• Ball or rod mill –
Method : Mineral Processing
OUTBOUND
INBOUND
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8. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
Method : Mineral Processing
•Mineral Ore
Charged into
Magnetic
separator
Product
•Ore Concentrate
•Tailings
OUTBOUND
INBOUND
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9. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
Methods
The ore sample was processes at the National Metallurgical Development Centre Jos, Plateau State, Nigeria
 A mixture of 5kg of ground iron ore
and 5 liters of water was prepared to
form a slurry.
 This slurry was then fed into the
Wilfley shaking table's deck tilted at
an angle of 32 degrees, at a feed rate
of 30 liters per hour.
 The water flow rate was maintained
constant throughout the process.
 The resulting products, including the
concentrated ore (realized
concentrate) .
 The tailing, were allowed to settle
before the water was decanted and
the products dried.
Figure : 3 Gravity Concentration
Figure 3 shows the Shaking Table as
was used to perform the
experiments on the three iron ore
samples. 9

10. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
X-Ray Diffraction (XRD )- Nsude Iron Ore
Figure 4: XRD ( Major Compounds)
Figure 5 : XRD with Major and Minor
Compound
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11. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
Scanning Electron Micrscopy (SEM)
Before Beneficiation Process After the Beneficiation Process
Figure : 6 Before Beneficiation Figure : 7 Gravity Concentrataion
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12. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
Energy Dispersive Spectroscopy (EDX)
• Before Beneficiation Before Beneficiation
Figure 8: EDX before Beneification Figure 9: EDX of Gravity Concentration
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13. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
Elemental Analysis - XRD & XRF
Crude Iron ore Gravity Separation
Elements Wt(%) Elements Wt(%)
O 22.1 O 10.40
C 2.04 Mg 0.5
Mn 2.40 Cu 3.33
Ti 4.40 Ca 0.23
Fe 60.40 Fe 70.10
Si 6.20 Si 12.22
Al 2.10 Na 3.22
Nsude Crude Iron ore Gravity Separation
S/NO Compounds % %
1 SiO2 28.76 19.55
2 Al2O3 4.80 2.11
3 Fe2O3 60.40 70.75
4 TiO2 0.30 0.19
5 CaO 0.11 0.11
6 P2O5 1.10 0.25
7 K2O Nd 0.03
8 MnO 0.12 0.70
9 MgO 0.14 0.21
10 Na2O 0.05 0.33
11 Cu 0.04 0.05
12 Zn 0.05 Nd
13 Rb 0.03 0.07
14 Zr 0.08 Nd
15 Br Nd 0.07
16 Cr 0.12 0.10
17 LOI 3.30 5.44
18 Total 100 100
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14. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
Fourier Transform Infrared Spectroscopy (FTIR) of
Nsude Iron Ore
 The most prominent peaks in the FTIR
spectrum of hematite are at 622 cm-1
, 530 cm-1
,
and 452 cm-1
.
These peaks correspond to the vibrations of
the Fe-O bonds in the crystal structure of
hematite.
There are also some smaller peaks that can
be observed in the FTIR spectrum of hematite,
such as the peaks at 2,350 cm-1
and 1,650 cm-1
.
These peaks correspond to water and
hydrox.
 The functional groups that are typically
observed in the FTIR spectrum of hematite are
the Fe-O, Fe-OH, and Fe-H bonds.
The Fe-O bond has the strongest and most
prominent peak, while the Fe-OH and Fe-H
bonds are much weaker and more difficult to
detect.
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Figure : 10 FTIR

15. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
•Hot Metal
•Pig iron
•Slag
•Blast furnace gases
RAW MATERIAL:
• IRON ORE,
• LIMESTONE,
•DOLOMITE ETC
• SINTER PLANT
• COKE
• BLAST AIR
OUTBOUND
INBOUND
Nsude Iron Ore …… Production iron Ore
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16. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
Figure 12 : Wire Rods produced from Wire Rod
Mill
PRODUCTS FROM THE WIRE ROD & LIGHT SECTION MILL & THE
FOUNDRY SHOP OF THE AJAOKUTA STEEL COMPANY LIMITED IN
AJAOKUTA , KOGI STATE
Figure 11 : Wire Rod Mill in Operations
Figure 13 : Light Section Mill in Operations
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Figure 14 : Products from Foundry Shop

17. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
STEEL
SECTOR
EMPLOYMENT &
EMPOWERMENT
AGRICULTURAL
SECTOR
TRANSPORTATION
SECTOR
COMMUNICATION
INDUSTRY
DEFENCE SECTOR
HUMAN RESOURCES
DEVELOPMENT
HUMAN APPLIANCES
INDUSTRY
SPORTS AND
RECREATION
ELECTRONIC &
ELECTRICAL
APPLIANCES
MINING INDUSTRY
SMALL SCALE &
MEDIUM
ENTERPRISES
POWER SECTOR
REVENUE GENERATION
METALLURGY
CONSTRUCTION
INDUSTRY
WATER, FOOD &
BEVERAGE
INDUSTRY
HEALTHCARE
SECTOR
EDUCATION
SECTOR
INDUSTRIAL
DEVELOPMENT
PETROLEUM
SECTOR
TEXTILE & LEATHER
INDUSTRY
FABRICATION
INDUSTRY
PULP, PAPER &
PRINTING
INDUSTRY
STEEL PLANTS &
ALLIED INDUSTRY
EFFECT OF STEEL ON THE ECONOMY
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18. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
Conclusion
The study on gravity concentartion improves iron recovery and quality.
 With notable impurity reductions, the optimised process produces a
high-grade iron concentrate that is appropriate for use in metallurgical
operations for the metal industry for sustainability development.
 The beneficiation procedure enhanced iron recovery by 85.9%,
according to the study's major results.
1. The iron content(Fe) increased to 70.10% Fe from 60.4%.
2. The Hemeatite Fe2O3 increased from 60.4% to 70.50%
3. Significant reductions in the amounts of impurities (silica, alumina,
and other elements).
4. Increasing the value of the iron ore resources in Nsude ore adds to the
growth of Nigeria's iron and steel industry.
5. Offering a structure for optimising the gravity concentration .
6. Providing information to policymakers on the operationalization of the
metal industry for sustainability development for economic growth .
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19. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
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20. 04/13/2025 Engr Ocheri C & Prof . Mbah C.N.
THANK YOU FOR
YOUR ATTENTION
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