Search Results (7)

Olivine-type lithium iron phosphate (LiFePO₄, LFP) lithium-ion batteries (LIBs) have become a popular choice for electric vehicles (EVs) and stationary energy storage systems. In the context of recycling, this study addresses the complex challenge of separating black mass of spent LFP batteries from its main composing materials to allow for direct recycling. In this study, 71% copper and 81% aluminium foil impurities were removed by sieving black mass to <250 µm. Next, the application of froth flotation as a separation technique was explored, examining the influence of chemical agents, pre-treatment, and multi-step processes. Frother agent addition improved material recovery in the froth, while collector addition influenced the separation efficiency and enhanced graphite recovery. Pre-treatment, particularly sonication, was found to break down agglomerates and further improve separation. Multi-step flotation increased the purity of recovered fractions. The optimized process for a black mass < 250 µm, involving sonication pre-treatment and double flotation, resulted in enriched carbonaceous material (80.3 mol%) in froth fractions and high LFP concentration (81.9 mol%) in tailings fractions. The recovered spent LFP cathode material contained 37.20 wt% Fe₂P₂O₇, a degradation product of LiFePO₄. This research offers valuable insights for the development of efficient battery recycling methods for LFP batteries. Full article

Magnetite ores are among the most important sources of iron, which is in high demand in the global economy. Metallurgical properties of the magnetite concentrate significantly depend on impurities of silicon- and aluminum-bearing minerals. These impurities have to be separated from ore by magnetic separation and flotation techniques. Reverse column flotation is one of the methods applied for reducing the content of impurities in magnetite concentrate. This method allows recovering impurities from ore in the froth product (flotation tailings). However, the efficiency of this method significantly decreases with the decrease in particle size. As previously demonstrated, the effectiveness of fine particle column flotation can be increased if, before feeding the pulp into a column, fine bubbles are introduced into the pulp and the pulp is then passed through a tubular reactor. The major purpose of this study was to define the effectiveness of the reverse column flotation performance of ultrafine magnetite from the mixture with fine glass beads (ballotini) when, before the pulp is fed into the flotation column, it is mixed with fine air-in-water dispersion, and the mixture is then passed through a tubular flotation reactor (TFR). The obtained experimental findings allowed the definition of the optimal conditions of the mixture treatment in TFR that ensured high concentrate grade and iron recovery for the initial iron content in the mixture of 63.76%. These conditions were defined as follows: treatment time of the mixture in the TFR—7.5 s; average flow shear rate inside the TFR—1000 s⁻¹; volume dosage of fine bubbles per solid mass unit—0.032 or 0.21 mL/g. At the fine bubble dosage of 0.032 mL/g, the iron recovery and the concentrate grade were, respectively, 88.1% and 68.3% Fe, and at the dosage of 0.21 mL/g, the iron recovery reached 89.4% for the concentrate grade of 68.7% Fe. Full article

We examined greenhouse gas (GHG) production upon the addition of ammonium and phosphate to mature fine tailing (MFT) samples from Alberta’s Pond 2/3 (at 5 and 15 m) and Pond 7 (12.5 m) in microcosm studies. The methane production rate in unamended Pond 2/3 MFT correlated with sample age; the production rate was higher in the less dense, more recently discharged MFT samples and lower in the denser, deeper sample. Adding small amounts of naphtha increased methane production, but there was no correlation with increasing naphtha, indicating that naphtha may partition into bitumen, reducing its bioavailability. Although non-detectable phosphate and low ammonium in the pore water indicate that these nutrients were potentially limiting microbial activity, their addition did not significantly affect methanogenesis but somewhat enhanced sulphate and nitrate reduction. Neither ammonium nor phosphate were detected in the pore water when added at low concentrations, but when added at high concentrations, 25–35% phosphate and 30–45% ammonium were lost. These ions likely sorbed to MFT minerals such as kaolinite, which have microbial activity governed by phosphate/ammonium desorption. Hence, multiple limitations affected microbial activity. Sulphate was less effective than nitrate was in inhibiting methanogenesis because H₂S may be a less effective inhibitor than NO_x⁻ intermediates are, and/or H₂S may be more easily abiotically removed. With nitrate reduction, N₂O, a potent GHG was produced but eventually metabolized. Full article

In Alberta’s Athabasca oil sands region (AOSR), over 1.25 billion m³ of tailings waste from the bitumen extraction process are stored in tailings ponds. Fugitive emissions associated with residual hydrocarbons in tailings ponds pose an environmental concern and include greenhouse gases (GHGs), reduced sulphur compounds (RSCs), and volatile organic compounds (VOCs). Froth treatment tailings (FTT) are a specific type of tailings waste stream from the bitumen froth treatment process that contains bioavailable diluent: either naphtha or paraffins. Tailings ponds that receive FTT are associated with the highest levels of biogenic gas production, as diverse microbial communities biodegrade the residual diluent. In this review, current literature regarding the composition, chemical analysis, and microbial degradation of FTT and its constituents is presented in order to provide a more complete understanding of the complex chemistry and biological processes related to fugitive emissions from tailings ponds receiving FTT. Characterizing the composition and biodegradation of FTT is important from an environmental perspective to better predict emissions from tailings ponds and guide tailings pond management decisions. Full article

The low grade of copper deposits and the use of the froth flotation process have caused excessive tailing production. In recent years, experts have looked for new alternative methods to improve this situation. Black copper minerals are abundant resources not exploited by large-scale copper mining and possess high Mn concentrations. On the other hand, manganese nodules are submarine resources and show high concentrations of Cu, Ni, Fe, and, mainly, Mn. However, both mineral resources are refractory to conventional leaching processes, and so a reducing agent is necessary for their treatment. We studied the use of tailings obtained from the flotation of foundry slags with a high content of Fe₃O₄ as reducing agents at different MnO₂/tailings ratios and H₂SO₄ concentrations. Mn dissolution was compared in marine nodule and black copper minerals samples. It was found that higher Mn dissolutions are obtained from marine nodules, likely due to the acid consumption created by Cu dissolution from black copper minerals. The remnant elements in manganese nodules were leached under an oxidant condition. Full article

Porphyry copper deposits (PCDs) are some of the most important sources of copper (Cu) and molybdenum (Mo). Typically, the separation and recovery of chalcopyrite (CuFeS₂) and molybdenite (MoS₂), the major Cu and Mo minerals, respectively, in PCDs are achieved by two-step flotation involving (1) bulk flotation to separate Cu–Mo concentrates and tailings (e.g., pyrite, silicate, and aluminosilicate minerals) and (2) Cu–Mo flotation to separate chalcopyrite and molybdenite. In Cu–Mo flotation, chalcopyrite is depressed using Cu depressants, such as NaHS, Na₂S, Nokes reagent (P₂S₅ + NaOH), and NaCN, meaning that it is recovered as tailings, while molybdenite is floated and recovered as froth product. Although conventionally used depressants are effective in the separation of Cu and Mo, they have the potential to emit toxic and deadly gases such as H₂S and HCN when operating conditions are not properly controlled. To address these problems caused by the use of conventional depressants, many studies aimed to develop alternative methods of depressing either chalcopyrite or molybdenite. In this review, recent advances in chalcopyrite and molybdenite depressions for Cu–Mo flotation separation are reviewed, including alternative organic and inorganic depressants for Cu or Mo, as well as oxidation-treatment technologies, such as ozone (O₃), plasma, hydrogen peroxide (H₂O₂), and electrolysis, which create hydrophilic coatings on the mineral surface. Full article

This study investigates the flotation performance of a representative hard coal slime sample (d₈₀ particle size of minus 0.2 mm) obtained from the Prosper-Haniel coal preparation plant located in Bottrop, Germany. Flotation was carried out with a newly designed flotation cell refurbished from an old ultrasonic cleaning bath (2.5 L volume) equipped with a single frequency (35 kHz) and two different power levels (80–160 W) and a sub-aeration-type flotation machine operating at a stable impeller speed (1200 rpm) and air rate (2.5 L/min). The reagent combination for conventional and simultaneous ultrasonic coal flotation tests was Ekofol-440 at variable dosages (40–300 g/t) with controlling water temperature (20–25 °C) at natural pH (6.5–7.0). The batch coal flotation results were analyzed by comparing the combustible recovery (%) and separation efficiency (%) values, taking mass yield and ash concentrations of the froths and tailings into account. It was found that simultaneous ultrasonic coal flotation increased yield and recovery values of the floated products with lower ash values than the conventional flotation despite using similar reagent dosages. Furthermore, particle size distribution of the ultrasonically treated and untreated coals was measured. Finely distributed coal particles seemed to be agglomerated during the ultrasonic treatment, while ash-forming slimes were removed by hydrodynamic cavitation. Full article