Abstract:
In this work the nature of the Pudo iron ores in the Northern Region of Ghana and the
potential for producing premium grade iron nuggets from the ores is investigated using
carbonaceous materials generated from end-of-life rubber tyre (ELT) as reductant. Physical
analyses such as, specific gravity, particle size distribution and Bond Work and Abrasion
indices were performed on the as-received samples of the Pudo Titaniferous Magnetite ore.
Pulverised samples of the ores (magnetite and non-magnetic) were then characterised by
X-ray fluorescence (XRF) analysis, and Scanning Electron Microscopy-Energy Dispersive
Spectroscopy, (SEM/EDS) analyses. The results from the XRF and SEM analyses of the
representative sample showed that the Pudo non-magnetic iron ore is of a low-grade
hematite with an average Fe content of about 10.17 wt%, but an excellent fluxing material
since it has high amounts of magnesia and calcium oxide, with high amount of gangue
material (SiO2 + Al2O3) and no deleterious elements (sulphur and phosphorus). The Pudo
magnetite ore is a moderately high grade ore with an average grade of 80.918 wt% Fe2O3
(56.59 wt% Fe), with the presence of TiO2 (10.140 wt %) and (0.018 wt%) sulphur. Values
obtained from the abrasion and Bond Ball Mill Work Indices test showed that the Pudo
Titaniferous magnetite ore is a very hard ore with values of 0.254 and 23.535 kWh/t,
respectively. Carbonaceous materials were generated from ELT by pulverising charred
crumbs of ELT in a laboratory ball mill to -106 µm. Proximate analysis conducted on ELT
agrees with work done by previous researchers. Reduction studies were conducted on
composite pellets of mixed variants of the iron ore containing charred ELT in a domestic
microwave oven and the extent of reduction was calculated after microwave irradiation for
40 minutes. It was observed that premium grade metallic iron can be produced from
appropriate blends of the Pudo iron ores using ELT as reductant, with a measured extent of
reduction up to 103.8%
