Interview & Timeline

Interview: Coming Clean

Project to demonstrate potential of new mining technology

The M100 - Magnetic Elutriator, a new "taconite washing machine" developed by St. Paul-based 5R Research Inc., could put a whole new spin on separating iron ore from waste rock. The Iron Range Resources and Rehabilitation Board and others are funding a commercial-scale test of this new mining technology, which could extend and improve the productivity of northeastern Minnesota's mines.

If successful, the $1.4 million pilot test of the unit could open the door to a faster, cheaper and more environmentally friendly way to recover iron ore particles from taconite.

In magnetic elutriation, electromagnets and carefully controlled water pressure agitate taconite slurry to separate ore from silica and other waste materials, similar to the way a washing machine's agitator action loosens dirt from clothing. This would replace the two-step system of magnetic drum separators and chemical-laden flotation units currently used at most Iron Range mines.

John McGaa, president of 5R Research, estimates that elutriation could save the mines $1 per ton in energy and chemical costs and could increase production by up to 10 percent. "This is basically a $1 million experiment that, if it works, will be a super project for the mining industry on the environmental and economic fronts," he said.

EVTAC Mining will be the first to test the M-100 magnetic elutriator— a 60-foot tall, 500-horsepower fiberglass tube outfitted with an electromagnet that will process 100 tons of slurry per hour. Construction will begin this summer; McGaa hopes to have the unit running by January 2001.

Pilot tests have shown that elutriation can recover more ore and produce a higher-quality product than traditional ore processing. Silica levels have averaged 3.5 percent, compared to EVTAC's normal levels of 5.5 percent, and could be as low as 2 percent. Levels this low also could make direct-reduced iron (DRI) production feasible on the Iron Range. Ore recovery from elutriation has been about 99 percent.

Figures like these convinced the IRRRB to provide a $500,000 loan that could later be converted to stock in 5R Research.

"If this all works out, it'll be a home run for the industry," said Brian Hiti, the IRRRB's manager of mining and natural resources development. "It's a more productive way to do what they're already doing, and it could make Iron Range ore acceptable for DRI."

5R Research also was one of eight companies nationwide to receive a $500,000 grant from the Department of Energy through its National Industrial Competitiveness for Energy, Environment and Efficiency (NICE3) program. EVTAC is kicking in $280,000 and 5R has about $100,000 into the project.

A paradigm shift

Other aggregate production processes such as gravel-sorting have used elutriation for years. McGaa first applied it to mining while researching ways to recover the lead and iron in steelmakers dust — the vapor released from boiling steel. Ironically, his discovery was made using a demagnetizer, a unit that uses an electromagnet to demagnetize regular magnets. "In effect, magnetic elutriation works because we tried a demagnetizer," McGaa said. "Nobody had thought about using a 'demagnetizer' to magnetize things."

In the M100, an electromagnetic zone will magnetize the slurry just long enough to separate ore from waste products.

The taconite industry's traditionally conservative approach to technology has slowed the acceptance of magnetic elutriation. Mines can be reluctant to make capital investments in new, unproven technology. "Wherever we went, early in the process, there was a little bit of disbelief. The feeling at the mines was that you couldn't do separation as a one-step, single-pass process," McGaa said.

This attitude makes 5R's alliance with EVTAC all the more significant. "This project is unique because both the industry partner and the entrepreneur are very interested in commercial-scale testing," Hiti said. "With these two elements and the DOE grant, we were able to come in with key support to help it succeed."

Proving the potential

EVTAC's management is optimistic about the project's success. Two smaller elutriator pilot units have been tested at the plant during the last three years; each has run for a long time. "We're comfortable with the technology, we just need to know if it will run at the scale we need," said Howard Hilshorst, president of EVTAC.

Well-known industry vendors, including Westinghouse, Foxboro, GPI and Saloman Electric, are building the structure. Some of the components will be specially designed. "Electromagnets of this size have never been made for mining before," said Gary Saari, senior facility engineer at EVTAC. "We all believe it should work, but there are always bugs to work out when new technology moves from small-scale to large-scale use."

At least one of two units being installed will run 24 hours a day, seven days a week for about 18 months, starting in January; the other will be a back-up.

Time will tell if magnetic elutriation is a technology whose time has come. Whatever the result, one thing remains clear: a new cycle of mining technology has begun. "Taconite has to change. If we don't get more efficient, we're going to go away. This technology looks like a very viable means of lowering our silica levels and our production costs," Hilshorst said.

Timeline

1996 – 5R Research Inc. formed as sole proprietorship, R&D proposals submitted to both AISI and State of Minnesota. Offer made to partner with the University of Minnesota.
1997 – AISI declines offer to partner. U of M declines offer to partner. State of Minnesota’s Office of Environmental Assistance agrees to underwrite small scale prototype Magnetic Elutriator. Scale-up begins and proves successful with the debut of a 1 ton-per-hour system known as the "M1 Prototype". First contract R&D "consulting" project begins.
1998 – R&D proposals submitted to Evtac Mining Company and to the Northland Technology Fund. Both agree to underwrite the cost of a 10 ton-per-hour system known as the "M10 Prototype". System completed in December and delivered to plant site in Eveleth Minnesota.
1999 – M10 Prototype is proven successful as designed; outstanding separation performance is obtained after the second major series of in-plant tests. System further modified to attempt a full range of trials which ultimately prove that the original design is in fact preferred. 5R’s engineering staff is relieved to conclusively prove that scale-up is based on a "volumetric basis". Preliminary design work begins on full-scale system known as the "M100". Consulting work continues and results in major R&D grant award from US Dept of Commerce to client company (computer plastic recycling).
2000 - Proposal submitted to the US Dept of Energy. The DOE agrees to underwrite approximately a third of the costs associated with demonstrating the commercial system, i.e. the M100 demonstration tests. DOE award contingent on State of Minnesota match. Letter of Intent obtained from the State’s IRRRB agency; formal partnership is initiated leading to signed contract from IRRRB agency. DOE releases first installment of funds and detailed engineering and design work begins.
2001 – Fabrication of M100 components begins. IRRRB unable to release funds for unclear reasons; however major fiscal problems with State and Iron Ore industry are apparent. DOE supports project to as great an extent possible; Minnesota Dept of Commerce provides considerable leadership, leading to continued DOE involvement despite no matching IRRRB funds. Detailed component-testing is performed and proves successful. M100 components delivered to plant site.
2002 – Construction phase begins at plant site. Heavy-duty concrete foundation is prepared and is rated for the fully loaded weight of M100 system, estimated steady-state weight is 40 to 50 tons.
2003 – Plant closes due to uncertainties in international marketplace, namely global economic slowdown coinciding with foreign producers placing excess capacity on international spot market; plant’s production cost exceed spot market price.
2004 – Plant brought back online with foreign ownership/investment, all R&D on hold.
2005 – Efforts to fund M100 project resume. Overtures made to all familiar state and federal R&D funding sources; all pertinent government research agencies found to be either defunct or without R&D funds; focus shifts to private investment.
2006 – 5R presents at the American Institute of Mining Engineers (AIME/SME) annual conference. Call made to pull industry together in joint partnership – industry leadership is receptive but acknowledge poor economic performance and therefore lack of financial ability to underwrite aggressive & expensive effort to prove experimental mining technology.
2007 – Overtures made to 5R by China’s largest steelmaker for design assistance and feasibility of magnetic elutriation of Chinese iron ores – feasibility study conducted & submitted to steelmaker.
2008, 2009 – Commodity prices for iron ore jump from $30/ton to $60/ton providing much needed relief to the struggling domestic mining industry. This relief is short lived however as a global economic slowdown reduces domestic production to the lowest levels in almost a century. Elsewhere the Chinese steel industry makes major investments in Australian iron ore properties - challenging global giants BHP, Vale and Rio Tinto.
2010 – Commodity prices for iron ore soar to $120/ton. 5R begins fielding inquiries from international mining operations looking for proven technology to upgrade production capacity.
2011/Present – Commodity prices for iron ore set a record of $175/ton. 5R fields an inquiry from a global manufacturing firm & leader in green technology for possible partnership in an aggressive effort to commercialize magnetic elutriation technology.