Ore Beneficiation Research Articles (Page 1)

Introducion: Ore beneficiation applied to industrial minerals, specifically high-purity quartz and feldspars, especially for use in the manufacture of porcelain tiles, poses challenges in terms of energy demand and efficiency. Due to the dry nature of the operations, it has the potential to disperse large volumes of particulate matter into the environment. Objective: This study aimed to analyze quartz and feldspar beneficiation operations at two mineral processing units located in Rio Grande do Norte, focusing on energy consumption and dust dispersion reduction. Method: For each processing unit visited, the crushing, screening, grinding, and classification variables were observed and evaluated, generating a process flowchart for comparison and identification of operational bottlenecks. Energy estimation (Bond's Law) was applied for each mineral substance (quartz and feldspar) to determine the correlation between WI and feed (F80) and product (P80) particle size distributions. Results and Discussion: For feldspar, the WI is 11.67 kWh/t at both units, but energy consumption at the first was 11.44 kWh/t, while at the second it rose to 12.34 kWh/t, representing an increase of approximately 7.9%. In the case of quartz, with a WI of 12.77 kWh/t, consumption was 12.52 kWh/t at Unit 1 and 13.49 kWh/t at the second, an increase of approximately 7.7%. From an environmental perspective, the need for equipment encapsulation, especially in the VSI crusher and screening, is highlighted, as a fundamental strategy for controlling particulate matter emissions in mining operations. Research Implications: The application of targeted research to assess energy efficiency in mineral processing plants proves essential to balance mining development with operating costs, and identifying potential impacts from the activity ensures the recommendation of environmental control measures. Originality/Value: The article presents a proposal for evaluating technical improvements in quartz and feldspar processing, highlighting trends such as the use of new crushers (HPGR) and changes in grinding parameters, ensuring reduced energy consumption and dust control measures.

Cho-Dien zinc oxide ore is characterized by strong weathering. The ore has a content of 6-10% zinc content. Zinc occurs mainly in hemimorphite (calamine), smithsonite and chalcophanite. The rocks are mainly goethite, clay and quartz. However, no feasibility study has been conducted to treat this ore in practical production. This paper presents the effects of different types of flotation reagents (collectors, depressants, dispersers, etc.) on the beneficiation process of zinc oxide ore. From there, the suitable flotation reagents dosages and regimes were given. The research result shows the concentrate has a content of 20-25 % Zn at a recovery ratio of 55-60%. These preliminary results suggest that developing a technically and economically feasible beneficiation technology for Cho-Dien zinc oxide ore is possible.

This article explores the current state and future directions in the processing and utilization of serpentinite waste generated during the mining and beneficiation of chrysotile-asbestos ores in Russia and Kazakhstan. Inefficient management of this waste leads to significant environmental impacts and deterioration of ecological conditions in industrial regions. A critical review of recent scientific publications and developments in the production of magnesium compounds from serpentinite is presented. Results. It is demonstrated that with proper technological approaches, serpentinite waste from chrysotile-asbestos processing can become a source of economic benefit. Examples are given of industrial production of high-purity chemical products derived from serpentinite waste. The article discusses the resource and economic efficiency of such processes, including research results obtained at M. Auezov South Kazakhstan University on the integrated processing of serpentinite waste from the Zhitikara deposit. Scientific novelty. The proposed technology involves an innovative approach using thermally activated serpentinite for the purification and neutralization of magnesium extraction solutions, enabling the production of high-purity magnesium compounds from low-grade mineral feedstock. The novelty lies in the combination of acid leaching with solid-phase reagents derived from the same waste, making the process more sustainable and economically efficient. Practical significance. The developed technologies can be implemented at chrysotile-asbestos mining enterprises to reduce environmental burden and meet the increasing demand for magnesium compounds in Kazakhstan’s industry. Utilization of serpentinite waste not only mitigates environmental impact but also supplies key industrial sectors with valuable magnesium-based products.

The aim of this study is to analyze the representation of geological, mining, processing, and environmental processes in platform Minecraft. Based on a methodological comparison of in-platform mechanics with technological and geoscientific procedures, the article assesses the degree of accuracy, simplification, and didactic applicability of individual processes related to the extraction and use of mineral resources. The analysis is structured into seven main thematic areas covering the entire resource value chain—from geological exploration through mining, ore beneficiation and processing, to quantitative indicators (e.g., waste-to-ore ratio), fluid resources, and environmental impacts. Special attention is given to the potential of modifications that significantly enhance the complexity and accuracy of simulated processes. The results show that Minecraft, enriched with thematic mods, can serve as an accessible and flexible tool for the popularization and education of industrial and geoscientific processes, while engaging a wide range of audiences.

The increasing demand for lithium-ion batteries particularly for electric vehicles underscores the importance of improving the sustainability of lithium mining operations. The depletion of high-grade lithium ore deposits has necessitated the upgrading of medium to low-grade ores for lithium extraction. Spodumene is the most commercially exploited lithium-bearing mineral found in pegmatites due to its high lithium content. Ore sorting can be used for early rejection of up to 60% of gangue minerals prior to preconcentration. Dense media separation is a viable spodumene beneficiation method. However, as case studies have shown, flotation may still be required to process middlings and the undersized fraction, which falls outside the particle size range effective for dense media separation. Magnetic separation can be conducted during or after flotation to remove iron impurities in lithium concentrates. While fine particle flotation has historically achieved high recovery rates, their economic feasibility is increasingly questioned due to intensive comminution requirements. Coarse particle flotation in mechanical flotation cells for instance is inefficient due to turbulence-induced detachment of coarse particles. Coarse particle beneficiation using fluidized bed flotation cells can offer advantages such as reduced grind size and environmental footprint. Despite proven energy savings and recovery efficiencies in other mineral sectors, their application in lithium mining operations remains limited to pilot scale. Also, research in this area is underexplored. This review addresses this gap by evaluating the feasibility, potential benefits and challenges of integrating ore sorting, dense media separation, magnetic separation and fluidized bed flotation with the HydroFloat, NovaCell and Reflux cells into lithium ore beneficiation flowsheets. Key challenges identified include high water consumption and the inadvertent entrainment of fine particles requiring desliming steps. Furthermore, this review acknowledges the challenges in spodumene beneficiation due to the structural similarities among silicate minerals and highlights relevant pretreatment methods to improve selectivity, recovery and grade.

The increasing demand for critical raw materials such as copper and cobalt highlights the need for efficient beneficiation of low-grade ores. This study investigates a copper-cobalt sulfide ore (0.99% Cu, 0.028% Co) using froth flotation to produce high-grade concentrates. Various types of surfactants are applied in different ways, each serving an essential function such as acting as collectors, frothers, froth stabilizers, depressants, activators, pH modifiers, and more. A series of flotation tests employing different collectors (SIPX, PBX, AERO, DF 507B) and process conditions was conducted to optimize recovery and selectivity. Methyl isobutyl carbinol (MIBC) was consistently used as the foaming agent, and 700 g/L was used as the slurry density at 25 °C. Dosages of 30 and 100 g/t1 were used in all tests. Notably, adjusting the pH to ~4 using HCl significantly improved cobalt concentrate separation. The optimized flotation conditions yielded concentrates with over 15% Cu and metal recoveries exceeding 80%. Mineralogical characterization confirmed the selective enrichment of target metals in the concentrate. The results demonstrate the potential of this beneficiation approach to contribute to the European Union's supply of critical raw materials.

Entropy analysis using particle discrete data: Application for the beneficiation of a tin bearing complex ore

Advances in microbial biosurfactants for mineral flotation: Towards sustainable phosphate ore beneficiation

Objectives: This study assesses the environmental impacts of primary nickel production in Brazil using Life Cycle Assessment (LCA). Theoretical Framework: Brazil has strategic potential in supplying minerals for the energy transition, and evaluating the environmental impacts of nickel production is crucial. Method: The LCA focuses on mining, ore beneficiation, and pyrometallurgy, using ReCiPe 2016 to quantify 18 impact categories, emphasizing Global Warming Potential (GWP), Stratospheric Ozone Depletion, and Terrestrial Acidification. Results and Discussion: GWP reached 3.28×10⁴ kg CO₂eq/t Nieq, mainly from pyrometallurgy (94.1%) due to energy use and fossil fuels. Ozone depletion (2.73×10⁻² kg CFC11eq/t Nieq) stemmed from electricity (56.5%) and ore processing (43.8%), while acidification (1.14×10² kg SO₂eq/t Nieq) came from coal/coke combustion. Pyrometallurgy was the main hotspot. Tailings from sulfide ore processing (4.56×10¹ t/t Nieq), Land use (2.81 ha·year/t Nieq) and water consumption (7.63×10² m³/t Nieq) were also quantified. Research Implications: The study establishes a baseline for future LCAs and identifies optimization opportunities for sustainability. Originality/Value: First comprehensive LCA of Brazilian nickel production, providing insights to reduce its environmental footprint.

Separation processes are critical to mining and mineral processing, through the purification and concentration of valuable elements. Maximizing metal recovery while reducing water and chemical usage are central to innovating mining, for applications ranging from primary metal extraction, value recovery from tailings or acid drainage, to the recycling of valuable resources from unconventional feedstocks.Electrochemical approaches are a promising pathway towards sustainable mining, through renewable-electron driven separations. Control of the redox electron-transfer at electrochemical interfaces allows for reversible binding and release of target molecules. First, we present the development of redox-electrochemical technologies for the recovery and purification of critical metals, including platinum group metals (PGMs) and rare-earth elements (REEs). Second, we highlight new electrodeposition approaches for battery and electronic waste recycling, targeting both noble metals as well as critical elements such as lithium, cobalt, and nickel. Finally, we demonstrate for the first time how redox-platforms can be translated to continuous and scalable metal extraction operations in an electrochemical liquid-liquid extraction (e-LLE) system, and integrated with energy-efficient electrowinning.In general, electrochemical processes can be an integral part of future sustainable mining framework, by coupling with upstream ore extraction, beneficiation, and sustainable hydrometallurgical techniques. On the long-term, we envision advances in molecular separations to be key for next-generation resource extraction and recycling platforms.

A modified dextrin-based copolymeric flocculant for the beneficiation of low-quality iron ore

ABSTRACT The mining and beneficiation of low-grade phosphate ores has become inevitable due to its increasing consumption for fertilizers. Controlling of ore grade through blending and beneficiation of low-grade ore requires extensive chemical analysis in each step for optimizing process parameters. To facilitate rapid analysis of phosphate ore a new analytical procedure has been developed using sequential WDXRF spectrometer. A set of international certified reference materials (CRMs) and well-characterized in-house standards of phosphatic siliceous dolostone of the Vempalle Formation, Cuddapah basin were utilized for calibration of the analytical signals. The newly developed analytical procedure has been tested by analyzing major oxides in four natural samples of phosphate ore from the Proterozoic Jhamarkotra rock phosphate deposit, Udaipur, Rajasthan. The analytical results indicate wide tolerance ranges of the calibration lines especially for CaO, P2O5, SiO2 and MgO. The results were subsequently validated with the data obtained on the same set of samples by Inductively Coupled Plasma-Optical Emission Spectrometric (ICP-OES) technique. The comparison shows that the precision and accuracy of WDXRFS data for CaO, P2O5, and SiO2 in phosphate ore are well within the statistically acceptable range i.e., <1% and 5–10% respectively, except for other major oxides at low (<1 wt.%) concentrations. This study reveals that WDXRFS can be used as a cost effective, rapid and eco-friendly technique for routine analysis of phosphate ore, containing significantly wide ranges of CaO, P2O5 as well as SiO2 and MgO impurities, for grade controlling during mining and optimizing process parameters during beneficiation and extraction.

The selective flotation of apatite and hematite in high-phosphorus oolitic iron ore is challenging due to the declining selectivity of reagents as the particle size decreases. This study explores pullulan as an eco-friendly depressant in combination with α-bromolauric acid (α-BLA) as a collector. Microflotation experiments showed that while α-BLA exhibited a strong collection ability, its selectivity was poor. Adding pullulan created a hydrophilic layer that suppressed hematite flotation while enhancing apatite recovery. Under optimal conditions (pH 9, α-BLA 28.57 mg/L, pullulan 1.43 mg/L), the phosphorus content in the concentrate decreased from 8.83 to 0.97%, while iron recovery reached 86.83%, confirming the effectiveness of this reagent combination. Interfacial characterization and extended Derjaguin-Landau-Verwey-Overbeek (E-DLVO) calculations revealed that pullulan preferentially adsorbs on hematite, altering its wettability and charge, simultaneously hindering α-BLA adsorption. Additionally, the active site density on the mineral surface influences reagent adsorption and bubble attachment. These results highlight the synergistic effect of α-BLA and pullulan, offering a sustainable phosphorus-containing iron ore beneficiation strategy.

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.

Soil contamination with potentially toxic elements (PTEs) not only poses potential ecological risks (RI) but also leads to human health risks (HI) through the uptake of potentially toxic elements by crops. However, most studies primarily focus on potentially toxic element contamination in either soil or crops, often neglecting the intrinsic connections between soil and crop contamination risks. In reality, some regions may exhibit severe soil PTE exceedances, yet the PTE levels in crops may not necessarily exceed regulatory limits, resulting in human health risks that are not uniformly high. This study investigated a typical area with severe soil PTE pollution caused by wastewater from electroplating, smelting, and ore beneficiation industries, and conducted risk assessments on soil and crops. The research aims to elucidate the differences in soil and crop PTE contamination risks and the correlations between PTE concentrations in soil and crops. Results showed that Cd was the most severe PTE contaminant in the soil in the study area, with an average concentration of 1.11 mg/kg and a maximum concentration of 7.30 mg/kg. However, the average concentrations of eight PTEs in crops were all below the standard limits for cereal crops specified in the Food Safety National Standard for Pollutant Limits in Foods (GB 2726-2022). Cd was identified as the most severe PTE contaminant in the soil, resulting in the highest RI (836) in the MY sub-region of the study area. However, Cr in crops contributed the most to health risk (63.5%), leading to the highest HI (7.1) in sub-region MY. Despite Cd being the most severely polluting PTE in soil, its contribution to human health risk through crops was relatively low, ranging from 2.82% to 9.90%. This discrepancy in pollution risks indicates that a PTE causing severe soil contamination may not necessarily result in significant human health risks via crop uptake. Correlation and regression analyses revealed that soil PTEs had the greatest impact on Cd levels in crops. Soil Ni, Cd, Cu, As, and Zn exhibited different synergistic or antagonistic effects on crop PTE uptake. Notably, soil Cd content showed a highly significant positive regression relationship with Cd, Cr, and Ni concentrations in crops. Overall, the influence of soil PTEs on crop PTEs varied significantly, and the spatial differentiation characteristics of PTEs in soil and crops differed. For PTEs with high spatial differentiation, localized and precise management measures should be implemented. Conversely, for PTEs with low spatial differentiation, unified risk management and control measures can be adopted.

Every year, a large amount of chrome ore is produced in our country. Dewatering of tailings generated during the beneficiation of these ores is one of the problems faced by the mineral processing industry. In this study, flocculation performance was investigated by using lignin in the dewatering of tailings obtained from chrome ore beneficiation. The sample used in the study was obtained from Burdur Yesilova chrome ore beneficiation plant tailings dam. The effects of flocculant dosage, stirring speed, pulp density and suspension pH value on turbidity were investigated. Experimental results using lignin showed that the optimum turbidity value was 24.4 NTU. Flocculation experiments showed that the optimal flocculation conditions were as follows: flocculant dosage of 50 g/t, stirring speed of 250 rpm, pulp density of 15% and pH 9.2. This study is important in terms of being carried out using tailings from actively operating chrome ore beneficiation plant and determining the flocculation properties of the tailings. By carrying out this study, it has been shown that dewatering these tailings can be done in an effective and environmentally friendly way in order to combat water scarcity and supply clean water for reuse in the plant.

The tungsten deposits in Mongolia have the potential to be exploited as an alternative source to alleviate the risk due to the monopolization in the global production of such a critical metal. However, it is challenging to develop an efficient mineral processing method that can complement the supply based on the currently available energy resources in Mongolia. Therefore, the present study investigated the range of energy required for the beneficiation of tungsten ores, including theoretical assumptions and practical evaluation for two processes in Mongolia. The range of energy consumption was 0.12 to 2.21 kWh/t for crushing and 0.29 to 4.62 kWh/t for grinding regarding the range of Kick’s constant 0.2–0.6 kWh/t and Bond work index 7–17 kWh/t, respectively. The most dominant impact factor in the comminution was the product size. The evaluation of 18 different comminution–flotation circuits indicated a range of required energy from 362 kWh to 8298 kWh. The maximum values of energy consumption for mineral processing of Erdene-soum and Khovd Aimag tungsten ore were 6280 and 6355 kWh. An estimation regarding the energy demand (6355 kWh) and supply energy for the process of Khovd Aimag ore was conducted to propose a suitable system of renewable energy resources using the power pinch analysis method.

The aim of this study is to explore the feasibility of using flotation wastewater from copper-porphyry ore processing to synthesize a gel that serves as a precursor for a polymer nanocomposite used in supercapacitor electrode fabrication. These wastewaters-characterized by high acidity and elevated concentrations of metal cations (Cu, Ni, Zn, Fe), sulfates, and organic reagents such as xanthates, oil (20 g/t ore), flotation frother (methyl isobutyl carbinol), and pyrite depressant (CaO, 500-1000 g/t), along with residues from molybdenum flotation (sulfuric acid, sodium hydrosulfide, and kerosene)-are byproducts of copper-porphyry gold-bearing ore beneficiation. The reduction of Ni powder in the wastewater induces the degradation and formation of a gel that captures both residual metal ions and organic compounds-particularly xanthates-which play a crucial role in the subsequent steps. The resulting gel is incorporated during the oxidative polymerization of aniline, forming a nanocomposite with a polyaniline matrix and embedded xanthate-based compounds. An asymmetric supercapacitor was assembled using the synthesized material as the cathodic electrode. Electrochemical tests revealed remarkable capacitance and cycling stability, demonstrating the potential of this novel approach both for the valorization of industrial waste streams and for enhancing the performance of energy storage devices.

Experimental Study on Beneficiation of a Fine-grained Tantalum-Niobium Ore in Nei Mongol

This study focuses on optimizing the alkali roasting conditions for chromite beneficiation tailings with the goal of enhancing chromium oxide (Cr2O3) extraction. Within the experimental framework, the variables included roasting temperature, the amount of added Na2CO3, and reaction time. The results revealed that temperature is the most critical factor directly affecting the extraction efficiency. Increasing the amount of Na2CO3 contributed to an increase in Cr2O3 recovery, although excessive addition may not be economically justified. The optimal conditions—1000 °C, 120%–130% Na2CO3 (relative to tailings mass), and 120 min—enabled a Cr2O3 extraction rate of up to 98.6% through aqueous leaching. The phase transformation analysis confirmed the breakdown of the spinel structure and formation of water-soluble sodium chromate. Microanalysis observations and measurements validated the progressive destruction of chromite grains and sodium enrichment in the reaction zones. The remaining leaching residue consisted of inert Na2Mg2Si2O7 and MgO, suitable for further metal recovery. The proposed approach enables efficient detoxification of hazardous tailings and serves as a basis for integrated utilization of Cr-bearing industrial waste.