Process Development
Ironstone has identified several “direct smelting” processes that may be suitable for producing metallic iron for sale to steel makers or as a scrap metal diluant.
Beneficiation work conducted by the Alberta Research Council (ARC) and CANMET in the mid-seventies built upon the R-N direct reduction process work done earlier, which successfully produced iron at high level of purity with high recovery ratios. Although the R-N process produced a high grade product suitable for steel making without processing in a blast furnace, high energy requirements and low iron prices at that time made it uneconomical.
ARC was contracted in the early 70s to develop a process (Grain Enlargement) more suitable for the Clear Hills iron ore. The work was progressed through the laboratory stage to a continuous lab pilot plant. Both recovery and purity of iron was at a very high level and was considered suitable for use in a basic oxygen furnace or an electric arc furnace for making steel. The energy usage was reduced by 75% compared to the R-N process making it more economic for this ore.
Ironstone has a team evaluating the most technologically advanced processes developed by industry leaders and the world’s most authoritative iron ore engineering processing consulting firms. This will enable the company to choose a process which will create a premium product while demonstrating the commercial viability of a mine and mill operation in the Clear Hills in light of the strong iron markets and its huge resource base.
The technical team is confident economic upgrading of Clear Hills iron ore to meet customer requirements will be achieved by modifications to existing equipment and processes.
