Australia's iron ore industry is entering a challenging period with the development of new orebodies, the introduction of new products and the push for further downstream processing. In addition, the recent price reductions for iron ore exports have intensified the focus on reducing capital and operating costs. To assist in these areas, CSIRO is expanding its research capabilities, including the incorporation into CSIRO of the Mineral Processing Laboratories in Perth, which were previously managed by the WA Department of Minerals and Energy. In addition, a large part of the $24.4 million expansion of CSIRO's Pinjarra Hills laboratories in Brisbane will be devoted to enhancing iron ore processing research, providing purpose built laboratories and large process bays. Research is being conducted in a wide range of areas, including ore characterisation, beneficiation, sintering, pelletising, process instrumentation, quality control and development of international standards. A key aspect of current research is the characterisation of iron ores and prediction of downstream processing performance using optical microscopy and computer-based image analysis techniques, backed up by a wide range of complementary techniques such as electron microscopy and electron microprobe analysis. The breakage properties of large rocks up to about 100 mm diameter are also being determined either using a Hopkinson bar or in situ in a laboratory crusher to assist with optimisation of comminution performance, and new capabilities in both wet and dry beneficiation have been developed for treating lower grade ore deposits and producing high-grade concentrates for direct reduction processes. A significant component of the beneficiation research includes the development of a range of novel techniques for dry concentration of iron ores and the removal of deleterious elements such as phosphorus. Further down the processing chain, batches of sinter and pellets are prepared under conditions simulating industrial practice using a pot-grate facility to determine how ore characteristics affect productivity and quality. Development of nuclear, microwave and ultrasonic techniques for on-line analysis of the chemical and physical characteristics of iron ore continues, and better standards are being developed for sampling, analysis and physical testing of iron ores and reduced products to improve quality control procedures and optimise the life of ore resources.
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