Process Development of Clear Hills Iron Ore

The Federal Mines Branch in Ottawa, believing the Clear Hills iron ore would respond well to a process developed by R-N Corporation, excavated a 5,286 ton bulk sample from beneath 15m of overburden in the Swift Creek (now Rambling Creek) segment of the deposit which was shipped to the R-N pilot plant in Birmingham, Alabama in the early 1960s.

The pilot plant successfully produced, after a 5-day kiln reduction, 111 dry tons of iron (90% Fe) in hot briquette form (HBI). In 1962 C. S. Samis and J. Gregory published the results of the work in a paper titled “The Reduction of Clear Hills Iron Ore by the R-N Process”. 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 generated low rates of return.

The Alberta Research Council (ARC) and CANMET was contracted in the early 70s to refine the earlier reduction work on the Clear Hills iron ore and lower energy requirements. Known as the Grain Enlargement process, 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 (97% Fe, 0.48% acid solubles) and was considered suitable for use in a basic oxygen furnace or an electric arc furnace for making steel.

Of note, the GE Process reduced the energy usage by 75% compared to the R-N process, considerably improving the economics. In addition, phosphorus levels were lowered to within allowable limits after reduction. The results of the work were published by the ARC in 1984 by E. F. Bertram titled “Direct Reduction Beneficiation Process for Fine Grained Iron Ores”.

Pilot Plant Development

Ironstone has identified several “direct smelting” processes that are suitable for producing metallic iron (DRI/HBI/MPI) for sale to the global steel market. The company is evaluating the most technologically advanced processes developed by industry leaders and has engaged the world’s most authoritative iron ore engineering process consulting firm to lead the company’s pilot plant development work throughout 2011.

Ironstone iron ore stockpile on its Hines Creek site. Ore will be used in processing trials and pilot plant trials.

The results of this pilot work will enable the Ironstone to select a process which will create premium products while demonstrating the commercial viability of a mine and mill operation in the Clear Hills.