IITs' breakthrough in iron ore mining sustainability: Transforming waste to wealth

In a groundbreaking initiative, researchers from the Indian Institutes of Technology (IITs) Madras and Kanpur, in collaboration with NMDC and JSW Steel, have pioneered a revolutionary process to repurpose waste generated from iron ore mining. This innovative approach not only addresses environmental concerns but also introduces a cost-effective and sustainable solution for the steel industry.

The research teams have successfully developed a microwave-assisted beneficiation process to convert iron ore mining waste, known as "slime," into iron-rich materials suitable for blast furnace charging.

From slime ponds to sustainable resources

Iron ore processing typically generates particles smaller than 0.15 mm, discarded as slime, constituting 20-25% of the total iron ore feed. Over the years, vast slime ponds have formed, holding millions of tonnes of locked iron content. The conventional approach involves exporting these slimes as low-grade iron ore, contributing to environmental degradation. The new process, however, transforms this waste into a valuable resource.

Ajay Kumar Shukla, associate professor and head of the Centre for Pyrometallurgy at IIT Madras, highlighted the project's impact on infrastructure development. The initiative led to the creation of a state-of-the-art lab at IIT Madras, named the Centre for Pyrometallurgy, equipped with facilities funded by IMPRINT INDIA. This lab enables further research into high-temperature processes involving reduction roasting or smelting.

 

 Industry-academia collaboration for a sustainable future

The collaboration between academia and industry giants like NMDC and JSW Steel demonstrates a proactive approach to addressing raw material challenges faced by the steel industry in India. The project, conducted under the IMPRINT INDIA initiative of the union education ministry, signifies the importance of fostering partnerships for impactful research and innovation.

Anish Upadhyaya from the Department of Materials Science and Engineering at IIT Kanpur emphasised the breakthrough's significance in processing lean quality fine iron ores on a large scale, offering a cost-effective and environmentally friendly solution. Vibuti Roshan, deputy general manager at NMDC, praised the work as an "innovative, cost-effective, and energy-efficient way" that holds potential for upscaling to beneficiate lean quality iron ores.

 

Tackling slime challenges across the industry

Beyond the IITs' initiative, major players in the Indian Steel/Mining Industry are actively engaging in slime beneficiation projects. Companies like SAIL, Tata Steel, Essar Steel, JSW, NMDC, NML, and IMMT are investing in research and development to find effective ways to beneficiate and utilise slimes, minimising environmental impact and maximising resource utilisation.

 

Paving the way for sustainable resource management

With India's steel industry experiencing rapid growth, there is a burgeoning demand for iron ore and coal. As high-grade iron ore reserves deplete, the focus on recovering additional iron values from slimes becomes imperative. The collaborative efforts between academia, industry, and government initiatives underscore a collective commitment to sustainable resource management and environmental stewardship.

In essence, the IITs' breakthrough not only transforms waste into valuable resources but also sets a precedent for collaborative, sustainable practices in the mining and steel industry—a crucial step towards a more environmentally conscious and resource-efficient future.