Experimental modeling for upgrading of brown barite ore by different processing methods

Abstract

Barite powder as a weighting agent is the most important additive into drilling mud for the oil and gas extraction. In this study, production of brown barite powder (SG 4.065 g/cm3) was examined by flotation (direct and reverse) and magnetic separation for upgrading the quality of fine barite particles and receive it to the standard point for drilling applications (SG higher than 4.2 g/cm3). Mineralogy analysis showed that hematite was the main associated mineral, and particles were liberated below 200 µm. Thus wet high intensity magnetic separator (WHIMS) was used and results indicated that WHIMS could increase the quality of product to SG ~ 4.2 g/cm3. However, flotation separation was examined for the possible improvement in quality of the product. The Taguchi experimental modeling method was applied to scheme flotation tests, compute the various values of flotation parameters for upgrading the SG of products and determine their optimal values. Outcomes demonstrated that flotation can provide higher quality for products than WHIMS, S.G: 4.44 and 4.35 g/cm3 in direct and reverse flotation, respectively. Results indicated that Taguchi method can successfully be used for design of experiments in the manufacturing process; reduce risks and costs of industrial development. These outcomes illustrated that the Mehdiabad brown barite ore can be upgraded by direct flotation and meet the required quality for drilling.