Search Results (60)

Phosphorite, or phosphate rock, has garnered increasing attention in recent years as a promising unconventional resource for rare earth elements (REEs). This paper presents a processing scheme aimed at recovering both REEs and phosphate values from amine flotation tailings generated during phosphate beneficiation in Florida. In these tailings, REEs are primarily present as monazite and xenotime, often associated with heavy minerals. The proposed flowsheet includes gravity separation to pre-concentrate REE- and phosphate-bearing minerals, followed by flotation to further upgrade both REEs and phosphate, and finally sulfuric acid leaching to extract REEs and phosphate from the flotation concentrate. Gravity separation using a shaking table increased the total REE content from approximately 202 ppm to 657 ppm, with a concentrate yield of 12.51%, REE recovery of around 41%, and P₂O₅ recovery of 33%. Fatty acid flotation of the shaking table concentrate produced a final concentrate containing 1106 ppm REEs and 14.90% P₂O₅, with recoveries of approximately 86% for REEs and 90% for P₂O₅. Subsequent pyrolysis with concentrated sulfuric acid followed by water leaching achieved recoveries of about 85% for REEs and 93% for P₂O₅. While the process demonstrated effective concentration and leaching of REE minerals and apatite, the major challenge to further improving separation and extraction efficiency lies in the fine-grained nature of the valuable minerals and their interlocking with gangue minerals. Full article

While traditional disposal of solid waste from the global wine industry causes significant environmental burden and hazards, a range of value-added by-products can be produced from the grape marc. This review focuses therefore on crucial sustainability-enhancing technologies for pomace dewatering and separation, which constitute a mandatory stage in obtaining storage-stable by-products and final value-added commodities. A number of dryers and separators were considered for pre-treatment of wet grape marc and analysed in terms of their design characteristics, functionality, feasibility, throughput and efficiency. A multi-criteria decision analysis was carried out to compare, rank and select the equipment which is most suitable for the purpose. It was found out that the rotary drum dryer and the drum screen separator with internal blade rotor are the best candidates to fulfil the technology requirements, while the flowsheet that includes an initial separation followed by drying of the resulting fractions is a rather attractive option. Valorising grape waste worldwide contributes substantially to achieving the United Nations Sustainable Development Goals for responsible consumption and production, mitigating climate change, caring for health and well-being, preserving land life and combating hunger. Full article

The present study is part of the Horizon Europe-START project, which aims to recover tetrahedrite-group minerals present in mine dumps to be used as raw materials for the manufacture of thermoelectric devices. The aim of this work is to identify the mining waste facilities selected in Spain for the recovery of tetrahedrite and to outline the mineral processing operations performed on samples from each site to separate and concentrate this mineral. Ore deposits across Spain were selected based on the potential presence of tetrahedrite in their mining waste. A total of five deposits have been sampled, at which subsequent mineral separation and concentration tests have been conducted. A separation flowsheet is proposed in order to extract a high-purity tetrahedrite concentrate. Experimental results indicate two distinct options for separation approaches, depending on a key parameter that proves decisive in the processing of this mineral, which is whether the mineral paragenesis includes siderite. This study has demonstrated the technical feasibility of concentrating minerals of the tetrahedrite group through simple, cost-effective physical separation techniques—specifically magnetic and gravity separation—where the liberation size of the tetrahedrite exceeds 0.063 mm. Full article

As a critical mineral, magnesite plays a vital role in industries such as steelmaking, construction, and advanced technologies due to its high thermal stability and chemical resistance. However, the beneficiation of low-grade magnesite ores (~38.36% MgO) remains challenging due to the presence of iron, silica, and calcium-bearing impurities. This study proposes an integrated beneficiation strategy combining medium-intensity magnetic separation and flotation techniques to upgrade a low-grade magnesite ore. After grinding to 75 µm (d₈₀), the sample was subjected to two-stage magnetic separation at 5000 Gauss to remove Fe-bearing minerals, reducing Fe₂O₃ below 0.5%. The non-magnetic fraction was then treated through a two-stage reverse flotation process using dodecylamine (350 g/t) and diesel oil (60 g/t) at pH 7 to reject silicate gangue. This was followed by a four-stage direct flotation using sodium oleate (250 g/t), sodium silicate (350 g/t), and SHMP (100 g/t) at pH 10 to selectively recover magnesite while suppressing Ca-bearing minerals. The optimized flowsheet achieved a final concentrate with MgO > 46.5%, SiO₂ ≈ 1.05%, Fe₂O₃ ≈ 0.44%, and CaO ≈ 0.73%, meeting the specifications for refractory-grade magnesite. These results highlight the effectiveness of a combined magnetic–flotation route in upgrading complex, low-grade magnesite deposits for commercial use. Full article

In recent decades, the attention of researchers has been directed towards the study of the dehydration of isopropanol (IPA) through different techniques. Besides its multiple uses in the chemical industry, IPA is also a potential bio-component in eco-friendly gasolines. Extractive distillation is a successful technique for separating IPA from a minimum boiling azeotrope with water. However, the major challenge is the production of fuel-grade IPA (minimum 99.92 mol%) with low expenses. As a consequent step in the investigation of IPA dehydration with propylene glycol as extractive solvent, the present study compares its efficiency and economic viability with two other extractive solvents, namely ethylene glycol (EG) and dimethyl sulfoxide (DMSO). A systematic and comprehensive methodology was developed to design a three-column extractive distillation (TCED) for each investigated solvent. A techno-economic assessment of all the investigated processes concluded that ethylene glycol, followed by propylene glycol, seems to be the most promising solvent in the IPA dehydration process. Further, the heat integration of hot streams (SH flowsheets) demonstrated improvements over 17% in the case of ethylene glycol solvent, around 16% in the case of propylene glycol (PG) solvent, and only 10% (in the case of DMSO solvent) reduction in utility consumption, improving the energy efficiency of TCED processes. Furthermore, SH flowsheets yield a 14% cost saving obtained in terms of total annualized cost (TAC) and, respectively, 8.69%, by comparison with TCED processes. In the case of DMSO solvent, the TAC reduction is only 3.54% due to the capital cost, which has an increase of 3% mainly due to the high solvent cost. Full article

Until now, neurodegenerative diseases like Alzheimer’s and Parkinson’s have been studied separately in biochemistry and therapeutic drug development, and no causal link has ever been established between them. This study has developed a Unified Theory, which establishes that the regulation of axon and dendrite-specific 4E-BP2 deamidation rates controls the occurrence and progression of neurodegenerative diseases. This is based on identifying axon-specific 4E-BP2 deamidation as a universal denominator for the biochemical processes of deamidation, translational control, oxidative stress, and neurodegeneration. This was achieved by conducting a thorough and critical review of 224 scientific publications regarding (a) deamidation, (b) translational control in protein synthesis initiation, (c) neurodegeneration and (d) oxidative stress, and by applying my discovery of the fundamental neurobiological mechanism behind neuron-specific 4E-BP2 deamidation to practical applications in medicine. Based on this newly developed Unified Theory and my critical review of the scientific literature, I also designed three biochemical flowsheets of (1) in-vivo deamidation, (2) protein synthesis initiation and translational control, and (3) 4E-BP2 deamidation as a control system of the four biochemical processes. The Unified Theory of Neurodegeneration Pathogenesis based on axon deamidation, developed in this work, paves the way to controlling the occurrence and progression of neurodegenerative diseases such as Alzheimer’s and Parkinson’s through a unique, neuron-specific regulatory system that is 4E-BP2 deamidation, caused by the proteasome-poor environment in neuronal projections, consisting mainly of axons. Full article

The two-stage process for the treatment of rare earth phosphate minerals, involving an oxalic acid conversion leach and subsequent EDTA dissolution, has been demonstrated as a promising alternative to conventional extraction methods. To underpin a more detailed understanding, this work serves to further develop knowledge of the linkage between the stages and key practical aspects of the operation of the EDTA dissolution. A more detailed treatment of the phenomena observed in the EDTA treatment, characteristics of the solids, mass loss in dissolution, and the impact of parameter alterations in both stages provide greater holistic knowledge of the proposed flowsheet and considerations that will need to be addressed when increasing scale. Acid production (indicated by a pH decrease) in the EDTA dissolution stage was shown to be a feature of the reaction and not of residual acid associated with the solids from the oxalic acid stage. The consistency with which the rare earths were dissolved with respect to the phosphorus provided greater confidence that Nd and Pr (greater dissolution than P) are recovered at a higher efficiency than Ce and La (poorer dissolution than P). This was only not the case at high solids loading across both tests, leading to both oxalate and EDTA-deficient systems, respectively. Under high conversion conditions, it was demonstrated that Nd and Pr recoveries into solution approaching 70% were achieved. This equated to in excess of 17 gL⁻¹ of total rare earths in solution. Solid/liquid separation was shown to be a significant challenge, created by both the fine particle size distribution of the leached residue and the dispersant nature of EDTA. Full article

In the present work, Combined Heat and Mass Exchanger Networks (CHAMENs) with multiple utilities were synthesized using the pinch technology, the Microsoft Excel and GAMS programs for comparing process flowsheets. Due to the lack of information about streams that can transfer heat and mass, these were generated by combining streams that can only transfer heat and streams that can only transfer mass. On one hand, energy balances and mass balances were made when a common value of an open interval was bounded by source and target values of a stream and, on the other hand, by an open interval bounded by values based on information from the dataset. The CHAMEN formulation was resolved using the Generalized Reduced Gradient method from Microsoft Excel^® and the DICOPT solver from GAMS. When there were problems in convergence of a solution, initial values for solving the problem using the Solver Tool were obtained by changing the solving method or resolving the Heat Exchanger Network and the Mass Exchanger Network models separately. Heat and mass transfer per interval bounded by values based on information from the dataset can be used in designing the CHAMEN by hand. Six examples are presented in this work and they include streams exchanging heat and mass jointly and streams exchanging them separately. Two of the six examples presented were designed at the threshold–temperature and threshold–composition difference. For the first time using a mixed-integer linear programming framework, the heating of a stream with its own energy after cooling for the mass transferring process is reported. Full article

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. Full article

The extractive distillation process using propylene glycol (IUPAC name: 1,2 propanediol) as an extractive agent for the separation of the isopropanol–water system was investigated in this work. A systematic procedure was set out to obtain the optimal design and process conditions for extractive distillation and solvent recovery columns using the PRO/II process simulator. Four thermally integrated flowsheets were proposed, implying the recovery of the sensible heat and latent heat from the hot streams in the process. To establish the economic feasibility of the proposed process, we calculated the total annual cost for all the simulated versions, and the proposed fully thermally integrated flowsheets could save up to 43.13% in terms of the utility costs and up to 15.57% in terms of the TAC compared to the conventional design. Thus, propylene glycol (PG) is found to be suitable as a new solvent for isopropanol dehydration, being comparable with other classical solvents used for the dehydration of alcohols. Full article

This study introduces a straightforward and effective amorphous ZrP/polyacrylonitrile composite ion exchange method for separating Li from the leachate of spent Li-ion batteries (NMC 111). The cathode materials were leached with a series of optimized experiments. The influence of operating variables, including the H₂SO₄ concentration, temperature, H₂O₂ concentration, and pulp density, on leaching efficiency was examined to determine the optimal conditions for sorption experiments. The leaching efficiencies of Li, Co, Ni, and Mn were found to be 99.9%, 99.5%, 98.8%, and 99.9%, respectively. Subsequently, batch sorption experiments were performed by using am-ZrP/PAN, including the determination of the effect of pH, sorption kinetics, and the sorption isotherm. The effect of pH on adsorption was examined in 1 mmol/L equimolar solutions of Li, Ni, Mn, and Co. Li was separated from Mn, Co, and Ni in the leaching liquor. The adsorbent for Mn, Co, and Ni sorption better fitted pseudo-second-order kinetics. High selectivity for Li was observed, even at the higher solution concentration of 15 mM Li, Ni, Co and Mn. In addition, the column loading process demonstrated selectivity for Li over Co, Ni, and Mn metal ions. The preliminary evaluation of the whole process with mass flow demonstrated that it would be feasible to achieve full separation and metal recovery by integrating a combined hydrometallurgical method in future studies. However, much work is still needed to develop a practical separation flowsheet. Full article

Centrifugal contactors (CCs) are a technology candidate for the development of advanced reprocessing flowsheets. While they offer many advantages, such as process intensification, there are still uncertainties regarding their industrial deployment. The presence of particles in the process streams in particular may present a challenge to both performance and operability. Preliminary studies have been undertaken to evaluate the accumulation of particles in the contactors and the effect upon the extraction behaviour of nitric acid. Aluminium oxide (Al₂O₃) particles were suspended in the aqueous feed solution during the operation of a three-stage, 40 mm diameter CC cascade. The presence of insoluble solid particles in the aqueous feed, up to 7 g/L, were not observed to affect phase separation and entrainment under the experimental conditions investigated. The particles were centrifuged out of solution and accumulated as a thin cake/bed in the rotors of each stage. This work also illustrates that particles do entrain through the cascade. The predominant effect on the rate of accumulation was particle concentration in the aqueous feed solution, and increasing solids loading was observed to have an impact upon the extraction of nitric acid across the cascade. Full article

The paper shows the expediency of supplementing the balance simplex method by calculating the number of free variables of separation flowsheets containing recycle flows. The need to determine and set the free variables that provide lower energy consumption when calculating the material balance of flowsheets with recycling is justified. The problem of material balance multivariance is illustrated, and ways to solve it are shown with the example of separation flowsheets for two ternary mixtures: n-butanol + water + toluene and n-butanol + butyl acetate + water. Separation flowsheets containing three distillation columns and a liquid–liquid separator are proposed for both systems. The dependence of the recycle flow values and the energy consumption of distillation columns and separation flowsheets on the selection and setting of values of free variables in solving the balance problem is shown. The dependence of energy consumption on the composition of the original mixture is studied for an n-butanol + butyl acetate + water system. Recommendations for setting free variables for flowsheets of the separation of ternary mixtures with three binary (and one ternary) azeotropes are formulated. The technique of highlighting the region of separation flowsheet operability is illustrated. The column operating parameters that ensure the production of products of a given quality with minimal energy consumption are determined. It is shown that with the incorrect selection and setting of variables (during balance task solvation), the energy consumption for mixture separation can be overestimated by more than 40%. Full article

In the flotation separation process of a Cu-Mo-W polymetallic ore, the wastewater from the scheelite cleaning flowsheet contains large numbers of residual flocculants and metal ions, and the separation of chalcopyrite and molybdenite requires a large number of environmentally harmful depressants. Therefore, it is necessary to find new methods to reduce the environmental and cost pressures of wastewater treatment and the use of depressants. In this work, the flotation wastewater from the scheelite cleaning flowsheet for the separation of chalcopyrite and molybdenite by selective surface passivation was investigated for the first time. Flotations of single minerals and artificially mixed minerals with or without immersion pretreatment in the presence and absence of aeration were performed. The results showed that pulp pH had no effect on the flotation of either mineral, and a molybdenite recovery of 93.22% with a chalcopyrite recovery of 10.77% was achieved under the conditions of 10 days of immersion pretreatment with aeration, 350 mg/L of kerosene, and 100 mg/L of MIBC. By combining the electrochemical cyclic voltammetry analysis and characterization by XRD and SEM, the selective surface passivation mechanism of chalcopyrite was discussed, which could be due to the coverage of the insoluble oxidation products, especially jarosite. This work has simultaneously achieved the depressant-free flotation separation of molybdenite and chalcopyrite and the reuse of scheelite flotation wastewater, which is of great significance for environmental protection and cost saving. Full article

Biomass as a whole offers a more diverse potential for valorisation than any other renewable energy source. As one of the stages in the separation of bio-oil involves a liquid mixture of acetol and acetic acid, and as both components are particularly well suited for valorisation, a hybrid method was developed for their separation with a high purity level through an approach combining liquid–liquid extraction and distillation. In order to design and simulate the flowsheet, the ChemCAD 7.0 simulation software was used. Sensitivity analyses were carried out to investigate the influence of the different parameters in the distillation columns, such as the reflux ratio, the feed stage location, and the vapour/bottom molar flow ratio. The effect of different extractants and of their excess on the separation process, as well as the possibility of regenerating the extractant, was also studied. Tri-n-octylamine was accordingly selected as a separating agent that was fully recycled. The end result for separating an initial 48/52 wt% acetol/acetic acid liquid mixture was acetol with a purity of 99.4 wt% and acetic acid with a purity of 100 wt%. Full article