Reducing the need for tailings storage dams in the iron ore industry

An integrated process for recovering the valuable iron fraction from low grade iron ore, including the steps of:

• a) comminution of the iron ore in a comminution device,
• b) classification of the comminuted iron ore to obtain a classified fraction suitable for coarse flotation with a particle size range from 100 micron up to 1000 micron and classified fraction suitable for fine beneficiation with a particle size of less than 100 micron;
• c) subjecting the fraction suitable for coarse flotation to coarse flotation to obtain an intermediate iron concentrate and a coarse sand residue with a particle size range from 100 micron up to 1000 micron;
• d) grinding the intermediate concentrate to a size suitable for fine beneficiation with a particle size of less than 100 micron;
• and
• e) subjecting the fractions suitable for fine beneficiation from steps b) and d) to fine beneficiation and obtaining a final iron concentrate and a fine tailings;
• wherein:
• the coarse sand residue from step c) is dewatered to less than 20 percent water by weight, and the dewatered coarse residue is dry-stacked separately from the fine tailings.