Characterization and Processing of Low-Grade Middle Group 2 Chromite Ore by Gravity Shaking Table and a Comparative SLon Magnetic Separation: A Case Study

Chromite is considered a strategic mineral in the global economy. It is mainly used as an essential raw material in the production of stainless steel and other metal alloys due to its corrosion and heat resistance properties. High-grade chromite resources are gradually depleting; with the increasing chromite demand in metallurgical applications, studies have focused on exploring low-grade and alternative chromite sources. This study proposes a cost-effective processing flowsheet for the low-grade middle group 2 (MG2) chromite layer, a poorly explored chromatite seam within the South African bushveld igneous complex (BIC). The study involved mineralogical characterization followed by gravity and magnetic separation of the low-grade MG2 ore at 18.18% Cr2O3. Characterization by XRD and Auto-SEM revealed that the ore mainly consists of pyroxene, chromite, and feldspar, with other minerals in trace quantities. The gravity separation test by shaking table upgraded the chromite (Cr2O3) to 42.0% at high chromite recoveries, whereas the laboratory Slon wet high-intensity magnetic separation method (SLon WHIMS) upgraded the chromite in the feed to 42.95% grade at lower chromite recoveries. Desliming the sample before the gravity and magnetic separation tests significantly improved the separation. The magnetic separation tests further demonstrated that chromite within the MG2 layer is sensitive to magnetic separation due to its high iron content. The adapted flowsheet is proposed as a cost-effective flowsheet for processing the low-grade MG2 layer. The flow sheet can be optimized by conducting the SLon WHIMS tests at high intensities followed by fine gravity tests by spiral circuits to maximize the chromite recovery while achieving commercial chromite grades and a Cr:Fe ratio greater than 1.5.