Search Results (90)

The mineral processing of a low-grade tungsten-molybdenum ore (LGTMO) was investigated to assess the potential of recovering molybdenum (Mo) and tungsten (W). Techniques such as Polarizing Microscope (PM), Scanning Electron Microscopy-Energy Dispersive Spectroscopy (SEM-EDS), Mineral Liberation Analysis (MLA), and Advanced Mineral Identification and Characterization System (AMICS) were employed. The recoverable metals in the ore are Mo (0.158% ± 0.03%) and W (0.076% ± 0.02%). Mo exists in two forms: 63.30% as molybdenite and 36.7% as powellite (CaMo_xW_1−xO₄). W is present as 75.26% scheelite and 24.74% powellite. The complete dissociation rates of molybdenite and scheelite-powellite are 27.14% and 88.87%, respectively. Particles of scheelite-powellite with a diameter less than 10 µm account for 34.61%, while molybdenite particles with a diameter below 10 µm make up 72.73%. Scheelite-powellite is mainly associated with olivine and dolomite, while molybdenite is mainly associated with pyroxene, calcite, and hornblende. Based on the process mineralogy, the mineralogical factors influencing the flotation recovery of molybdenite and scheelite-powellite were analyzed. Finally, a complete hydrometallurgical leaching test was carried out. The optimal experimental conditions are as follows: liquid-solid ratio of 6 mL/g, KMnO₄ concentration of 0.015 mol/L, Na₂CO₃ concentration of 0.12 mol/L, NaHCO₃ concentration of 0.024 mol/L, leaching time of 4 h, and leaching temperature of 85 °C. Under these conditions, the leaching efficiencies of Mo and W reach 79.23% and 41.41%, respectively. This study presents a novel approach for the recovery of refractory W and Mo resources in LGTMO while simultaneously providing a theoretical basis for the high-efficiency utilization of these resources. Full article

Natural phosphate ores frequently contain calcium–magnesium carbonate minerals as gangue components. Their separation from target phosphate minerals poses significant challenges due to analogous surface characteristics. The flotation differentiation between fluorapatite and dolomite remains a key research focus in mineral processing. In conventional collector systems, selective depressants critically govern separation efficiency, as their interfacial specificity directly determines beneficiation outcomes. The selective depression behavior of fulvic acid (FA) in modulating fluorapatite–dolomite separation efficiency within oleate-dominated flotation systems was elucidated through micro-flotation experiments, complemented by zeta potential measurements, contact angle analysis, Fourier-transform infrared spectroscopy (FTIR), and molecular dynamics (MD) simulations. The findings revealed that fluorapatite and dolomite both exhibit high floatability under NaOl-mediated collector systems in the absence of depressant additives, leading to negligible selectivity in the differential separation of the mineral pair. However, the float of fluorapatite particles in weakly acidic conditions was strongly depressed when a small amount of FA was added as a depressant, while exerting minimal impact on dolomite’s floatability. In binary artificial mixed-mineral flotation systems, under optimized flotation conditions (pH 5.0, 60 mg/L NaOl, and 15 mg/L FA), the concentrate achieved a P₂O₅ grade of 33.86% with a fluorapatite recovery rate of 92.36%, demonstrating significant selective separation of fluorapatite from dolomite. Subsequent analysis revealed that FA competitively chemisorbs with NaOl on fluorapatite surfaces, selectively reducing the hydrophobicity of the fluorapatite surface and suppressing fluorapatite floatability, thereby enabling effective differential liberation of the mineral pair. Full article

The selection of grinding media significantly impacts the resulting mineral’s liberation degree and grinding quality; this is particularly impactful for granite pegmatite-type quartz. Accordingly, in this study, we investigate the effects of different grinding media on the breakage characteristics of muscovite granite pegmatite-type quartz, focusing also on quartz mineral flotation. An analysis of scanning electron microscope images reveals distinct fracture characteristics among different minerals. Notably, the fractal dimension of mineral fracture roughness in ball-milled products is larger compared to that of rod-milled products, which exhibit a smaller fractal dimension. This fractal dimension serves as a quantitative measure of the microscopic morphology of mineral fractures in the grinding products, establishing a relationship between the roughness of the fractures and the type of grinding medium used. Further analysis of particle size distribution and mineral dissociation indicates that the rod mill produces a higher yield of coarse fractions compared to both ceramic and steel balls, while the fine fraction yield is significantly lower than that of the rod mill and steel balls. Importantly, the rod mill enhances the dissociation degree of quartz, suggesting that it can improve the liberation of mineral monomers and increase the yield of qualified fractions during the grinding process while effectively reducing the phenomenon of overgrinding. Our flotation experiments demonstrate that the recovery rate of quartz using the rod mill is 2.59% and 5.07% higher than that achieved with the ball mill and ceramic mill, respectively. These findings provide theoretical support for the optimization of grinding media and enhancement of mineral flotation recovery. Full article

This study explores Bayesian Ridge Regression and PyMC-based probabilistic modelling to predict the cumulative grade of gold based on key operational variables in gold flotation. By integrating prior knowledge and quantifying uncertainty, the Bayesian approach enhances both interpretability and predictive accuracy. The dataset includes variables such as crusher type, particle size, power, time, head grade, and collector type. Comparative analysis reveals that PyMC outperforms traditional Sklearn models, achieving an R² of 0.92 and an MSE of 102.37. These findings highlight the potential of Bayesian models for robust, data-driven process optimization in mineral processing. The higher cumulative gold grade observed for VSI products and PAX collector usage may be attributed to the superior liberation efficiency of VSI, which produces more angular and cleanly fractured particles, enhancing collector attachment. PAX, being a strong xanthate, shows high affinity for sulphide mineral surfaces, particularly under the flotation conditions used, thereby improving selectivity and recovery. Full article

Slags containing critical minerals concentrated in artificial phases, so-called engineered artificial minerals (EnAMs), are a novel source of critical raw materials. To liberate the EnAMs, the slags need to be comminuted, reducing the size of the particles. This work investigated the dependence of the breakage behavior on particle size and mineral structure during the comminution of an EnAM-containing slag. Piston-die experiments were performed for particles in the 3 mm to 5 mm size range. Nanoindentation and two-roller breakage tester experiments were performed for those in the 50 µm to 200 µm size range. The investigations were accompanied by X-ray computed tomography (XCT) and scanning electron microscope/energy dispersive X-ray spectroscopy (SEM/EDX) measurements as well as a micro X-ray fluorescence analysis to examine the mineral microstructure. It was found that the commonly assumed exponential connection between particle size and strength differed in the two size ranges. This behavior can be linked to different grain and cluster sizes, which were found in the investigation of the mineral microstructure. In addition to particle size, it was found that mineral structure plays an important role when characterizing the breakage behavior. Full article

Mining is a crucial sector in the global economy, providing essential materials for various industries, including construction, electronics, and energy. However, traditional mining practices often have significant negative impacts on the environment. Therefore, integrating sustainable practices into mining has become vital. Grinding is a crucial stage in the mineral processing industry, essential in liberating valuable minerals from ore. However, it is also one of the most energy-intensive processes in mining operations, consuming a substantial amount of electricity. Understanding and optimising electricity consumption in the grinding process is essential for enhancing energy efficiency and reducing operational costs. The relationship between electricity consumption in the grinding process and the Bond Work Index (BWI) is a crucial aspect of mineral processing and energy management in the mining industry. Understanding this relationship helps optimise grinding operations and improve energy efficiency. This review paper continues a previous work, where possible alternative modified methods for estimating the BWI in a Bond ball mill are presented. An analysis of selected methods is also provided to assess and obtain an accurate value of the BWI, which is essential in the grinding process. The methods for estimating the BWI using the wet method are presented. It is shown how the BWI can be estimated using dynamic elastic parameters and how changes in the Bond ball mill affect the BWI value. New equations for calculating the BWI and alternative procedures for evaluating the BWI in samples of non-standard size are proposed. The paper presents a comparative analysis of all presented methods. Full article

Greece has mineral resources in which strategic elements such as nickel (Ni) and cobalt (Co) are present. In this study, characterizations of the metal concentrations of three laterite deposits, as well as minerals from a kiln originating from a mineral processing plant, were carried out. The aim of this research was to integrate technological characterization data on the quantities of cobalt (Co) and nickel (Ni) present in the lateritic profiles of three mineral deposits from Greece and in kiln dust. The study was conducted at the Mineral Processing Laboratory of UPC/Bases Manresa. Aliquots were constituted for particle-size distribution tests by wet sieving followed by laser granulometry. Scanning electron microscopy (SEM) was used to determine the mineralogical compositions. Sink–float tests were conducted to estimate the particle liberation. Mineral liberation analysis (MLA) was performed to understand the liberation and the association of minerals in the samples. Full article

For over a century, cyanidation has been a highly effective method for extracting gold from gold-bearing sources. However, due to environmental, health, and safety concerns associated with this process, considerable efforts have been devoted to exploring the use of alternative, less toxic, and environmentally friendly reagents. In this study, a comparative cyanide and ethaline deep eutectic solvent (DES) leaching study of gold from the Witwatersrand gold tailings was undertaken. A Statistical Design of Experiments (DOE) was used for the screening and optimization of significant process factors to achieve optimal gold extraction. The factors investigated include the reagent concentration, leaching time, pulp density, and solution temperature. The subsequent gold recovery from leach solutions was undertaken using activated carbon (AC). Mineralogical analysis by X–ray diffraction (XRD) showed that the tailings consisted of quartz (72.13%), muscovite (7.49%), chlorite (2.65%), pyrophyllite (1.50%), clinochlore (1.30%), and other trace minerals. Mineral liberation analysis (MLA) employing the Sparse Liberation–Dual Zoom (SPL-DZ) method showed that gold was associated with iron oxides (Fe₂O₃, Fe₃O₄). Fire assay analysis (FAA) showed that the bulk tailings had a grade of 0.32 g/t Au. Ethaline was found to be the most efficient reagent, achieving up to 71.9% gold extraction, thereby exceeding the 46.9% gold extraction obtained via the cyanidation process. Moreover, gold recovery using AC from ethaline leach solution was 75%. The high gold extraction from tailings using ethaline suggests a potentially feasible alternative to the traditional cyanidation process, particularly for the processing of gold locked in iron oxide phases, offering the advantages of low toxicity, cost-effectiveness, and ease of preparation. Full article

Antimony is one of the world’s scarcest metals and is listed as a Critical Raw Material (CRM) for the European Union. To meet the increasing demand for metals in a sustainable way, one of the strategies that could be implemented would be the recovery of metals as by-products. This would decrease the amount of hazardous materials filling mining dumps. The present study investigates the potential for producing antimony as a by-product at the Olympias separation plant in Northern Greece. This plant works a skarn mineralization that shows interesting amounts of Sb. Boulangerite (Pb₅Sb₄S₁₁) reports on Pb concentrate levels reached 8% in the analyzed product. This pre-enrichment is favorable in terms of boulangerite recovery since it can be separated from galena through froth flotation. Boulangerite distribution in the primary ore is quite heterogeneous in terms of the inclusion relationships and grain size. However, a qualitative assessment shows that the current Pb concentrate grain size is too coarse to successfully liberate a good amount of boulangerite. The use of image analysis and textural assessments is pivotal in determining shape factors and crystal size, which is essential for the targeting of flotation parameters during separation. The extraction of antimony as a by-product is possible through a two-step process; namely, (i) the preliminary concentration of boulangerite, followed by (ii) the hydrometallurgical extraction of the antimony from the boulangerite concentrate. The Olympias enrichment plant could therefore set a positive example by promoting the benefits of targeted Sb extraction as a by-product within similar sulfide deposits within the European territory. Full article

Variations in the recovery of platinum group metals (PGMs) are often attributed to mineralogical and other natural ore-type variations. To increase the recovery of PGMs by the flotation process, a comprehensive understanding of gangue and valuable minerals is essential for optimising the extraction and processing of metals. Recoveries may be improved if the questions of how, where, and why losses occur can be answered with a certain degree of confidence. A requirement is the availability of statistically reliable mineralogical data. The PGMs of MG-1–4 chromite tailings dumps of the western limb of the Bushveld complex (BC) were studied in detail to unravel the PGMs and the nature of the platinum group minerals in the sample. Characterisation of the chromite tailings via deportment analysis revealed that the sample contained a significant amount of 3E PGM + Au (Pt, Pd, Ru, and Au) and was concentrated in the -25 µm fraction. The results of automated mineralogical analysis showed that the sample was composed of the PGE-sulphides group, comprising 63.6 vol%, PGE-sulfarsenides 10.4 vol%, PGE-arsenides 1.3 vol%, PGE-bismuth tellurides 3.3 vol%, PGMs-alloy 4.1 vol%, and Laurite comprising 17.3 vol% of the total PGE population. The sample was composed of 66.5 vol% of liberated PGMs, 0.2 vol% attached to liberated BMS, 27.3 vol% of PGMs attached to or locked within silicate or oxide gangue composite particles, 0.2 vol% of PGMs associated with BMS attached to silicate or oxide gangue particles, and a low proportion (5.8 vol%) of PGMs reported being locked within gangue or oxide particles. The majority of PGM grains observed were reported in the fast-floating category (64.4 vol%), 27.6 vol% in the slow-floating 1 category, 2.2 vol% in the slow-floating 2 category, and 5.8 vol% to the non-floating category. The results of the study revealed that the PGMs of MG 1–4 chromite tailings were liberated; however, the low liberation index (<0.2) suggested that a significant portion of PGMs remained trapped within gangue, hindering their recovery. This highlights the need for effective comminution (crushing and grinding) to achieve better liberation. The sample contained fine particles that were more prone to being lost in the tailings and to lowering recovery due to the slimes coating valuable minerals. The recovery of the PGMs from this complex’s polymetallic bodies of low-grade and complex mineralogy will be insufficient with traditional methods and thus innovation is needed. Innovation like advanced comminution, novel flotation equipment or reagents, selective leaching and bioprocessing can overcome these challenges. Full article

As the global demand for tellurium (Te) increases, it is crucial to develop efficient recovery methods that consider existing supply streams. This research combines gravity separation and froth flotation processes to enhance the recovery of Te minerals from tailings produced during the beneficiation of copper porphyry ores. Prior to processing, a systematic and comprehensive characterization study of copper tailing (CT) samples was conducted to examine the deportment of Te minerals in different mineral phases and to understand their locking and liberation behavior. Characterization techniques included inductively coupled plasma mass spectrometry (ICP-MS) and TESCAN’s integrated mineral analysis (TIMA). Copper tailing characterization showed that minerals with gold (Au), silver (Ag), bismuth (Bi), and Te were present in various forms, including native Au, electrum, tellurides, and sulfosalts. TIMA revealed that >90% of these minerals were primarily hosted in pyrite as less than 10 µm inclusions in the CT. TIMA also revealed that Te minerals exhibited fine-grained liberation of less than 20 μm. Moreover, TIMA results showed that >80% of mica and other silicate minerals were concentrated in size fractions < 38 μm, suggesting that desliming processes would positively impact Te enrichment. The results from the processing tests showed a Te recovery rate of ~77% and a Te enrichment ratio of 13 when using the combination of gravity separation and froth flotation at 90 g/t xanthate collector and 50 g/t glycol frother. The findings from this study show a significant potential for Te recovery from unconventional sources if appropriate physical beneficiation approaches are adopted. Full article

Froth flotation predominantly separates particles according to their differences in wettability. However, other particle properties such as size, shape or density significantly influence the separation outcome as well. Froth flotation is most efficient for particles within a size range of about 20–200 μm, but challenges arise for very fine or coarse particles that are accompanied by low recoveries and poor selectivity. While the impact of particle size on the separation behavior in flotation is well known by now, the effect of particle shape is less studied and varies based on the investigated zone (suspension or froth) and separation apparatus used. Beyond these complexities, many particle properties are correlated, making it challenging to analyze the isolated impact of individual properties on the separation behavior. Therefore, a multidimensional perspective on the separation process, considering multiple particle properties, enhances the understanding of their collective influence. In this paper, the two-dimensional case is studied; i.e., a parametric modeling approach is applied to determine bivariate Tromp functions from scanning electron microscopy-based image data of the feed and the separated fractions. With these functions it is possible to characterize the separation behavior of particle systems. Using a model system of ultrafine (<10 μm) particles, consisting of either glass spheres or glass fragments with different wettability states as the floatable fraction and magnetite as the non-floatable fraction, allows for the investigation of the influence of descriptor vectors consisting of size, shape and wettability, on the separation. In this way, the present paper contributes to a better understanding of the complex interplay between certain descriptor vectors for the case of ultrafine particles. Furthermore, it demonstrates the benefits of using multivariate Tromp functions for evaluating separation processes and points out the limitations of SEM-based image measurements by means of mineral liberation analysis (MLA) for the studied particle size fraction. Full article

The effective separation of ore is based on two fundamental processes: liberation and separability. Liberation involves the reduction of size, yielding smaller particles with enhanced compositional homogeneity. Understanding liberation requires an understanding of rock breakage, as it impacts mineral liberation and helps identify ores suitable for pre-concentration. Non-random breakage, influenced by textural and mineral properties, introduces heterogeneity in mineral distribution across size fractions. Physical attributes, including ore and gangue mineralogy and texture, influence fractionation tendencies during breakage. Notably, the presence of mineralization in veins substantially assists early-stage liberation in mineral processing. The aim of this study is to develop a methodology that allows the prediction of natural fractionation tendencies based on geological, mineralogical, and textural data using Discrete Element Method (DEM) modeling. DEM simulations provide insights into granular material behavior, capturing phenomena such as crack initiation and propagation. The use of DEM, particularly with models such as the Flat Joint Model (FJM), enhances our understanding of rock damage mechanisms. In this paper, DEM is used to predict preferential grade by size deportment, and a numerical model is developed to reflect grade distributions across size fractions. A fragmentation analysis is conducted after rock breakage simulations using DEM to analyze the fragment sizes and grades and calculate the Response Rankings of synthetic specimens. Full article

For the effective comminution and subsequent enrichment of mineral ores, comprehensive knowledge of their mineralogical and physical properties is required. Using an integrated methodology, this study evaluated samples of polymetallic Ni-Cu ore from Zapolyarnoe, Russia. Several analytical techniques were utilised, including optical microscopy, microindentation with Vickers geometry, the Point Load Test, and Mineral Liberation Analysis (MLA). The purpose of this study was to determine mineral associations, physical features, and enrichment during jaw crusher comminution. The acquired properties included the Point Load Strength Index, Vickers Hardness Number, and fracture toughness. The MLA method characterised seven fractions in terms of particle size distribution, degree of liberation, association, and modal mineralogy. Magnetite, pyrrhotite, pentlandite, and chalcopyrite were calculated in terms of wt% and their textural features. The enrichment of each ore phase in fractions with particle sizes smaller than 400 µm was determined. The influence of this enrichment was discovered to be correlated with various textural and structural parameters, such as intergrowth, grain size, and crack morphologies after indentations. In addition, the chromium content of magnetite contributed to an increase in the fracture toughness values. Despite the complexities involved, even limited samples of materials provide valuable insights into processing behaviour, emphasising the importance of considering mineralogical parameters in comminution studies. Full article

In anticipation of future demands, a comprehensive understanding of the chemical and mineralogical characteristics of nickel-bearing minerals is a prerequisite to devising effective nickel beneficiation methods. Of particular importance are markers in the mineralogy of the flotation concentrate that inform beneficiation strategies to improve concentrate grades, increasing both the marketability and cost of refining. In this work, a detailed characterization of a complex nickel sulfide flotation concentrate from a Western Australian deposit was carried out to determine the mode of occurrence and distribution of nickel and the associated gangue minerals, with the view of identifying prudent beneficiation strategies to improve concentrate grades. The concentrate was characterized via particle, chemical, and mineralogical techniques. Particle size analysis of the concentrate showed that it consisted predominantly of fine and ultra-fine particles (<20 μm), with the nickel value concentrated in the finer size fractions. Nickel mineralization in the ore (by quantitative X-ray diffraction) was found to be within pentlandite, violarite, millerite, and gersdorffite. The sulfide gangue was predominantly pyrrhotite, pyrite, chalcopyrite, sphalerite, arsenopyrite, and galena. Quantitative evaluation of minerals by scanning microscopy (QEMSCAN) analysis revealed that nickel minerals are at least 91% liberated, and the remaining portion (around 7%) is locked within binary iron (Fe) sulfides and 2% within complex minerals. Based on these findings, potential processing options, such as magnetic separation, gravity separation, and froth flotation, for recovering and upgrading nickel from this concentrate are discussed. Notably, with the significant presence of ultrafine/fine pyrrhotite content, averaging around 52% in the minus 38 µm fraction, novel flotation cells, including the Jameson cell, column flotation cells, and Reflux flotation cell (RFC), have been identified as potential candidates for fine/ultrafine pentlandite recovery. Overall, the characterization study conducted suggests that acquiring knowledge about the mineralogical characteristics of existing mineral concentrates can serve as a pathway to improving future concentrate grades. Full article