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1. Presentation on
THRESHOLD VALUE OF IRON ORE
P.Ramesh Babu (DGM-Geology)
S.Manoj Kumar (SM – Ore Dressing)

2. CONTENTS
oIron ore formation and deposits
o Distribution and occurrence
oSAIL Iron ore mines overview
oCaptive Mines of Bhilai Steel Plant
o Profile of Dalli-Rajhara Mines
oData Modeling of Dalli-Rajhara Mines
oThreshold value-issues & limitations
o Mineralogy of Dalli-Rajhara
oBeneficiability
oConclusion
o References

4. Magnetite Hematite
Goethite Limonite

5. SAIL – Iron Ore Mines Overview
SL.
NO MINE State YOC
Rated
capacity
Original
Reserves
Remaining
(As on
Apr`2017) Quality
Iron Ore Fe% SiO2 Al2O3
1.Kiriburu Jharkhand 1964 5.5 33 27.25 62.97 3.51 2.57
2.Meghahataburu Jharkhand 1985 6.5 22.5 11.41 61.52 4.58 2.73
3.Bolani Orissa 1960 10 143.5 57.68 62.95 2.83 3.03
4.Barsua/Taldih Orissa 1960 3 74.25 30.11 61.77 2.88 3.76
5.Kalta Orissa 1966 2.5 66.8 20.68 62.50 2.97 3.26
6.Gua Jharkhand 1919 10 140.75 67.38 61.93 3.40 2.90
7.
Manoharpur
(Chiria)
Jharkhand 1907 5 1200 966 62.14 2.68 2.74
8.Dalli-Rajhara Chattisgarh 1958 9 301.95 93.76 62.32 7.02 1.86
9
Rowghat Chattisgarh
2021* 14 511 511 63 3
1.5

6. To ensure continuous supply of Quality Raw Materials to Bhilai Steel
Plant in tune with the growth plan of Hot Metal on a sustainable
basis.
THE VISION
MINES ORGANISATION - BHILAI STEEL PLANT

7. BSP MINES LOCATIONS
25 km
100 km
135 km 275 km
198 km

8. MINING LEASES OF IRON ORE DEPOSITS
BHILAI STEEL PLANT
NAME OF
MINES / LEASE
MINERAL
PRESENT MINING LEASE STATUS
LEASE AREA (Ha.) VALIDITY
RAJHARA MECH Iron Ore 220.42 27-Apr-2023
DALLI MECH, J/DALLI &
KOKAN EAST
Iron Ore 719.60 31-May-2023
DALLI MANUAL Iron Ore 100.00 20-Aug-2023
MAHAMAYA & DULKI Iron Ore 1522.67 03-Nov-2021
KALWAR (NEW) Iron Ore 938.06
Deemed renewed up
to 31/3/2025
ROWGHAT Iron Ore 2028.797 22-Sep-2029

9. IRON ORE RESERVES & THEIR
DEPLETION
NAME OF MINE
INITIAL
RESERVE
(MT)
BALANCE
RESERVE as
on 01.04.2017
(MT)
Fe% SiO2 %
RAJHARA 75.79 40.42 64.44 5.11
DALLI 118.85 22.11 61.60 8.40
JHARANDALLI 42.50 11.76 58.35 10.9
DALLI MNL 33.00 0.6 59.38 10.4
M/MAYA 23.19 10.25 59.48 9.50
DULKI (D-1) 8.62 8.62 63.26 3.95
TOTAL 301.95 93.76 62.32 7.02

10. 7261 7219 7304
6904 6982
7156 7216 7302
7172
6742
4000
5000
6000
7000
8000
9000
2013-14 2014-15 2015-16 2016-17 2017-18(PR)
PRODUCTION DISPATCH
PRODUCTION & DISPATCH OF IRON ORE
‘ 000 T
* Production & Dispatch for 2017-18 has been taken on pro rata basis on
present performance level and is likely to improve

11. 7.303
7.909 7.926
7.169
7.685
2.149
2.655
7.66
6.072
4.349
9.452
10.564
15.586
13.241
12.034
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
2013-14 2014-15 2015-16 2016-17 2017-18(PR)
ORE WASTE TOTAL
EXCAVATION OF ORE & WASTE MT

12. 7.303
7.909 7.926
7.169
7.685
2.149
2.655
7.66
6.072
4.349
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
2013-14 2014-15 2015-16 2016-17 2017-18(PR)
ORE WASTE stripping ratio sub-grade stock
Ratio ore : waste

13. The Rajhara Iron Mine of Balod district in the Indian state of Chhattisgarh

14. Mining Profile
(X-Sec -DMM 480 RL)

15. Mining Profile
(X-Sec -RMM 415 RL)

16. Modeling – Data Analysis
CATEGORY TONNES RFE RSIO2 RAL2O3 [Waste]
>55 19483498 62.86 6.77 1.76
>45 22627495 61.20 8.83 1.97 20700900
>35 23129770 60.79 9.38 1.99 20198626
>55 37383256 65.34 4.03 1.15
>45 40771569 64.09 5.33 1.32 2701875
>35 42609725 63.09 6.54 1.39 863719
>55 8845975 61.02 7.46 2.26
>45 11891805 58.44 10.71 2.67 5917518
>35 12195498 58.02 11.26 2.71 5613826

17. 0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18
Fe %(R) SiO2%(R) Al2O3%(R) Fe %(L)
SiO2%(L) Al2O3%(L) Fe %(F) SiO2%(F)
Al2O3%(F) Fe %(S) SiO2%(S) Al2O3%(S)
Quality Profile

18. 0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 2017-18
Fe %(R) SiO2%(R) Fe %(L) SiO2%(L)
Fe %(F) SiO2%(F) Fe %(S) SiO2%(S)
Quality Profile(Fe & SiO2))

19. PURPORT

20. "Rule 12(7)-Indian Bureau of Mines shall review the threshold
values of minerals periodically in consultation with the stake
holders."
In view of the above comments and suggestions are hereby
invited from all the stake holders including general public on
the following aspects:
1.Inclusion or deletion of any major mineral from the list of
minerals for which threshold value was notified in 2009,
2.Changes in the threshold value of the major minerals
values of which were notified in 2009, with justifications,.
3.Suggested threshold value for the new major minerals
proposed to be included in the list with justification.

21. • MINISTRY OF MINES INDIAN BUREAU OF MINES
NOTIFICATION NAGPUR ,THE 16TH OCTOBER,
2009 No.T-45031/CGBM/2007(PF)
• THRESHOLD VALUE OF MINERALS FOR
IMPLEMENTATION
• IRON ORE
(i)HEMATITIC IRON ORE: 45% Fe(MIN)
(ii) HEMATITIC SILICEOUS ORE (FOR ORE OF GOAN
ORIGIN): 35% Fe(MIN)

22. "Threshold Value of minerals" means limit
prescribed by the Indian Bureau of Mines from
time to time based on the Beneficiability and or
marketability of a mineral for a given region and
a given time, below which a mineral obtained
after mining can he discarded as waste."

23. ISSUE
The mine owners are directed to comply with following.
1. All the non-saleable/un-usable minerals/ ores above the
limit prescribed in the threshold values are required to be
stacked separately in the area earmarked for the purpose.
2. The mineral/ ore stock above the limit prescribed in the
threshold values of minerals should be properly maintained in
a bound register indicating the quantity and quality of
material stacked. The month wise inventory of such materials
shall be updated.
3. The overburden and waste material obtained during
mining operation shall not be allowed to be mixed with the
materials above the threshold values of minerals stacked.

24. Limitations
We have certain limitations like
• SAIL mines in this region were started operations before 1980’s with
large broken area out of total lease area.
• Due to non availability of space ; it is very difficult to extend the area
both laterally as well as vertically.
• MoEF insists to backfill the existing broken area and surrender for
fresh area clearances.
• Hence, area for dumping of waste and sub-grade ore is major
constraint in all mines.

25. Beneficiation Inevitability

27. MINERALOGICAL STUDIES – ROM Fines

28. MINERALOGICAL STUDIES – ROM Fines
• fine size with size fractions of -1 to +12 mm with varying hues from yellow,
light to deep brown, there by physically suggesting moderate iron ore mineral
content.
• The sample is moderately enriched in ore mineral content out of which 78% of
them are ore minerals and the rest 22% is gangue content. The ore minerals
include Hematite (H) and Goethite (G) and the gangue minerals are Ferruginous
clay (Fcl) and Siliceous matrix ie Quartz(Q).
• Hematite is ubiquitous ore mineral by its contribution up to 72% followed by
scanty mounts of Goethite (G) whose contribution is approximately 6% by
area of their occurrence.
• Large and coarse-grained Hematite minerals do accommodate patches and
medium to fine size inclusions of Ferruginous clay as well as Quartz, where as few
of the coarse-grained and all most all the medium and fine size Hematite minerals
do contain thin superficial coatings of Ferruginous clay matrix.
• None of the ore mineral grains are seen to occur in ‘free-state’ and all moat all the
ore mineral grains either accommodate patches and/or inclusions of gangue
mineral content or superficial coatings or thin layers of Ferruginous clay matrix.

29. MINERALOGICAL STUDIES - slimes

30. MINERALOGICAL STUDIES - slimes
• The ore body showing characteristics of low to moderate grade ore
which comprises Hematite and Goethite as ore minerals and
Quartz, Pseudo Ore and Ferruginous Clay as gangue minerals.
• Ore minerals distribution is around 40% as a whole and gangue
minerals distribution is around 60% area as whole.
• Main ore mineral is Hematite with 25% area out of which around 9%
grains are in free-state and remaining 16% grains are in un-
liberated state. Around 7% un-liberated grains could be liberated at
25 micron size. Remaining un-liberated grains are in less than 15
micron size.
• Goethite covers around 15% area as a whole. All Goethite grains are
in less than 70 micron size. Out of 15% Goethite, around 6% grains
are in free-state and remaining 9% grains are in un-liberated state. All
un-liberated grains are in less than 20 micron size.

31. MINERALOGICAL STUDIES-Summary
Hematite
(H)
Goethite
(G)
Ferrugino
us clay
(Fcl)
Quartz(Q) Liberation
size
Area
Distribution
ROM
Fines
78% 22%
NA
72% 6%
Slimes
40% 60%
25% 15%
Liberated
9% 6% 15 µ

32. Generated
Fines
(-1mm)
(+1-8mm)
(+8mm)
(Non-Mags)
To Slime Unit
(Mags)
GF Beneficiation – Process Flow
(+0.15-1mm) (- 0.15 mm)
CB 14
(Float)
(sink)

33. Pellet concentrates (Mags)
Slime Beneficiation - Process
Slime from Dam
Running Slime
Hopper
Mixing Tank
From GF circuit
0.15 mm
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…
…

34. Tailing
1.19 Mtpa
Fe: 37.1
%
SiO2 : 22.5 %
Al2O3 : 9.5 %
Concentrate
1.11 Mtpa
Fe: 65.4 %
SiO2 : 3.0 %
Al2O3 : 1.4 %
GF Slime
0.57 Mtpa
Fe: 55.6 %
SiO2: 10.0 %
Al2O3: 6.0 %
Capacity 2.33 Mtpa
Hydro cyclones for
de-sliming
WHIMS
Dewatering Hydro
cyclones
Ball Mill
Concentrate
Thickener
Pressure Filtration
Plant for
Concentrate
Tails Thickener
Running slime
0.35 Mtpa
Fe: 41.0 %
SiO2 : 20.6 %
Al2O3 : 12.3%
Hitkasa slime
1.38 Mtpa
Fe: 55.5
%;
SiO2 : 12.5 %;
Al2O3 : 3.7 %.

35. OPINION
• Industrial scale beneficiation works with 70-80%
efficiency and practical assay gain of Fe content is only
4-4.5 unit.
• The problems associated with beneficiation of Iron ore
are many fold.
• Generation of Substantial proportion of ROM as fines.
• Generation of Tailing and slimes.
• Economic utilisation/disposal of tailings and the related
environmental pollution

36. As per the rule16 of MCDR’2017,the sub-grade
ore is to be mined out, but non-utilisability of
low-grade iron ore is causing hindrance for the
reclamation/rehabilitation of Pits as the total
cost of production of the ore is also rise high.

37. Considering the present conditions, the threshold
value of hematitic ore in Chattisgarh region may
kindly be maintained at 45% Fe level content
or alternatively
intensive R&D studies activities may be patronised
to find out economically viable beneficiation process
by which low grade iron ore can be upgraded as per
industrial specification with high yield .