In the paper, a new technology was developed to improve the beneficiation of copper and iron components from copper slag, by modifying the molten slag to promote the mineralization of valuable minerals and to induce the growth of mineral grains. Various parameters, including binary basicity, dosage of compound additive, modification temperature, cooling rate and the end point temperature of slow cooling were investigated. Meanwhile, optical microscope, scanning electron microscope and energy dispersive spectrometer (SEM-EDS) was employed to determine the mineralogy of the modified and unmodified slag, as well as to reveal the mechanisms of enhancing beneficiation. The results show that under the proper conditions, the copper grade of rougher copper concentrate was increased from 6.43% to 11.04%, iron recovery of magnetic separation was increased significantly from 32.40% to 63.26%, and other evaluation indexes were changed slightly, in comparison with unmodified copper slag. Moreover, matte and magnetite grains in the modified slag aggregated together and grew obviously to the mean size of over 50 μm, resulting in an improvement of beneficiation of copper and iron.

In this paper, an effective method was developed to remove phosphorus and upgrade iron from high phosphorus oolitic hematite ore by high temperature flash reduction—a wet magnetic separation process. A thermodynamic analysis of iron and phosphorus mineral reactions and experiments with Fe-P separation process were performed, and the mechanism of phosphorus removal and beneficiation of iron is discussed as well. The results show that under the proper conditions, a final metallic iron powder assaying over 91% Fe and 0.25% P was obtained with iron recovery of 90% and phosphorus removal rate of 91.79% using the new process, indicating that the high temperature flash reduction process is a feasible and efficient way to process this kind of complex and refractory iron ore. Moreover, sodium sulfate is found to be capable of improving the removal of phosphorus and the upgrading of iron, as well as enhancing the growth of metallic iron grains significantly for higher recovery of iron.

This study investigated the solid-state reduction characteristics of natural chromite ore and the effect of iron powder on the solid-state reduction characteristics of natural chromite ore under isothermal conditions below 1200 °C. The enhancement mechanism of iron powder on the solid-state reduction of natural chromite ore was revealed using optical microscopy, X-ray diffraction (XRD), and scanning electron microscopy–energy dispersive spectroscopy (SEM-EDS). The iron metallization rate of chromite ore exhibited a trend of increasing first and then decreasing with the addition of iron powder, and the optimal iron powder addition was determined to be 30%. The multi-step reaction gradually transforms into a single-step reaction with the increase in the dosage of iron powder. Iron powder facilitates the generation of a low-melting Fe-C alloy liquid phase and accelerates the speed of the solid-state reduction reaction of chromite ore and the disintegration of chromite spinel particles. When the iron powder dosage exceeds 30%, most of the multi-step reduction reaction of chromite ore is transformed into the single-step reduction reaction, which reduces the disintegration of chromite spinel particles and weakens the enhancement effect of iron powder on the solid-state reduction of chromite ore.