Search Results (144)

As a consequence of the gradual exhaustion of apatite ore reserves, intensive comminution has been implemented in mineral processing operations to enhance phosphorus liberation. Consequently, improving the flotation efficiency of fine particles has remained a persistent challenge within the phosphate industry. The performance of flotation columns is strongly affected by the interaction between gas (bubble) and particle. The present research was designed to evaluate how certain process variables and chemical dosages influence gas holdup and its correlation with the column flotation performance of fine particles derived from a low-grade apatite ore. Column flotation experiments were conducted employing a factorial experimental approach to evaluate the effects of air flow rate, surfactant concentration, collector dosage, and depressant dosage on gas holdup, P₂O₅ grade, and recovery. The results made it possible to identify the levels of gas holdup that lead to appropriate values of P₂O₅ grade and recovery simultaneously, and their relation with the operating variables and reagent dosage. Gas holdup values higher than 23.5% led to the desired values of P₂O₅ grade (>30%) and recovery (>60%) simultaneously. Statistical models were developed with high correlation coefficients (R² > 0.98) to predict P₂O₅ grade and recovery as functions of the operating variables. This research provides a comprehensive framework of the gas holdup effect on column flotation systems, offering significant potential for improving the economic viability of low-grade phosphate ore processing. Full article

This study proposes considering the effective re–benefication of coal middlings and other such considered waste materials as a way to ensure that clean coal in coal by–products can be extracted and effectively utilized, saving costs and reducing coal waste. To quantify the clean–coal yield and ash reduction that can be achieved by re–beneficiating four typical by–product streams from the Guobei Coal Preparation Plant (6 Mt a⁻¹) were used for the study. Coking–coal middlings, flotation tailings, and pressure–filter cakes from preparation plants still contain 30–60% combustible matter. Re–beneficiation techniques have been considered to recover this often-wasted coal, reduce waste rock disposal, and cut greenhouse–gas emissions per ton of clean coal produced. Representative samples (n = 4) were collected, sample size–classified as (fine coal particles ≤0.5 mm and coarse particles ≥) and subjected to (i) magnetite removal, (ii) laboratory froth flotation (diesel 507 g t⁻¹, sec–octanol 103 g t⁻¹), and (iii) fine and large particle density separation at 1.3–1.8 g cm⁻³ ZnCO₃ media. Clean–coal yield and ash were measured for each stream and the coal’s particle liberation was examined by SEM. Crushing, grinding and liberation equipment and techniques that aid in the treatment of coal and the re–beneficiation of coal middlings and tailings. The key findings recorded during the experiment are as follows: Flotation of <0.5 mm fractions delivered 46.9–58.3% clean–coal yield at 10.3–17.0% ash. Density separation of 0.5–1.0 mm middlings peaked at 1.4–1.5 g cm⁻³, yielding 34.2% clean coal at 15–18.4% ash. Scanning Electron Microscope analysis confirmed partial liberation as results from re–grinding + second flotation which increased yield by a further 8–12%. A calculated theoretical examination of the preliminary cost–benefit analysis indicates ≈36 CNY t⁻¹≈9 million CNY a⁻¹ in saved disposal costs alone. savings in disposal and 0.25 Mt a⁻¹ additional clean coal for the Guobei plant. The research presented in this paper highlights the current work by Anhui University of Science and technology in collaboration with Guobei coal preparation plant and the results therein achieved. Full article

Developments of new research tools in flotation studies, including bubble–particle attachment time efficiency and dynamic froth analysis, can help improve our understanding of particle–bubble interactions in flotation processes. In particular, the selection of new collectors and frothers, and their mixtures can provide a wide distribution of bubble sizes at their respective concentrations. In the literature, several studies have reported the effect of different frothers and collector mixtures on bubble characteristics like bubble size and critical coalescence concentration (CCC). The general trend obtained from these studies showed that the addition of frothers, along with collectors, which also act as frothers during flotation, resulted in finer bubbles and required lower concentrations of frothers, which in turn positively affected the flotation recoveries. In this study, an attempt was made to study fine-sized magnesite in the presence of sodium oleate (NaOL) and five different types of frothers (PPG600, PPG400, BTPG, BDPG, and MIBC). Bubble–particle attachment time with different sized capillary tubes and dynamic froth analysis values in a liquid–air system, along with flotation recoveries in a micro-flotation cell, were interpreted to show possible correlations and provide an optimum bubble/particle size ratio in the presence of different frothers. Full article

This study investigates the beneficiation of finely grinded rutile ore utilizing a combination of flocculation and flotation methods. Rutile, a Ti-bearing mineral with industrial significance, is often associated with heavy minerals found in coastal and metamorphic environments. A rutile ore sample from Azıtepe (Alaşehir, Türkiye) was reduced to −63 µm and enriched under varying pH conditions (2.5–12) using different reagent combinations and was used for our investigation of both flocculation and flotation processes using reagents such as Aero801(SIPX), Aero825, tannic acid (TA), and pomace oil. The best results were achieved at pH: 8 using Aero801(SIPX) and pomace oil during flocculation, and Aero801(SIPX), Aero825, and Aerofroth88 during flotation, yielding a concentrate with an 8.99% TiO₂ grade and an 89.5% recovery rate. Meanwhile, a 7.00% TiO₂ grade concentrate was obtained with a recovery rate of 71.92% at neutral pH. This study found that pH and reagent selection had an important effect on TiO₂ enrichment efficiency in fine size, low-grade rutile ores. Future research is recommended to investigate selective depressants and multi-stage cleaning to improve separation. Full article

This study investigates the impact of two comminution technologies—Vertical Shaft Impactors (VSI) and High-Pressure Grinding Rolls (HPGR)—on gold flotation performance, using ore samples from the Ballarat Gold Mine, Australia. The motivation stems from the growing need to improve energy efficiency and flotation recovery in mineral processing, particularly under increasing economic and environmental constraints. Despite the widespread use of HPGR and VSI in the industry, limited comparative studies have explored their effects on downstream flotation behavior. Laboratory-scale experiments were conducted across particle size fractions (300–600 µm) using two collector types—Potassium Amyl Xanthate (PAX) and DSP002 (a proprietary dithiophosphate collector) to assess differences in flotation recovery, concentrate grade, and specific energy consumption. The results reveal that HPGR produces more fines and micro-cracks, enhancing liberation but also increasing gangue entrainment and energy demand. Conversely, VSI produces coarser, cubical particles with fewer slimes, achieving higher flotation grades and recoveries at lower energy input. VSI at 600 µm demonstrated the highest flotation efficiency (4241) with only 9.79 kWh/t energy input. These findings support the development of hybrid or tailored comminution strategies for improved flotation selectivity and sustainable processing. Full article

The efficient separation of antimonate minerals from quartz remains a significant challenge in mineral processing due to their similar surface properties and strong hydrophilicity. This study explored the application of sodium dodecyl sulfonate (SDS) as a selective collector for antimonate–quartz flotation separation. Micro-flotation tests demonstrated that SDS achieved optimal recovery of antimonate minerals (90.25%) at pH 8 with a dosage of 70 mg/L, while quartz recovery remained below 10%. Contact angle measurements revealed a significant increase in the hydrophobicity of antimonate minerals after SDS treatment, whereas quartz remained highly hydrophilic. FTIR and XPS analyses confirmed the selective chemisorption of SDS on antimonate mineral surfaces through Sb-O-S bond formation, while negligible adsorption occurred on quartz. Adsorption isotherms further showed the higher SDS uptake on antimonate minerals compared to quartz. These findings collectively demonstrate the effectiveness of SDS as a selective collector for the flotation of antimonate minerals, providing a promising approach to enhancing the recovery of fine antimonate particles. Full article

This study examines the influence of particle size on the flotation kinetics parameters of both raw and waste fine coal originating from the anthracite mine “Vrška Čuka”, Serbia. Flotation kinetics modeling was performed using MATLAB for nonlinear regression analysis, based on coal flotation test data. The correlation between total combustible recovery and flotation time was determined using the following models: Classical, Klimpel, Kelsall, Modified Kelsall, and Fully Mixed. The coefficients of determination range from 0.9724 (the Klimpel model) to 1 (the modified Kelsall model) for raw coal and from 0.8609 (the Klimpel model) to 0.9981 (the modified Kelsall model) for waste coal. Although both the Classical and Modified Kelsall models demonstrated a good correlation with the experimental data, the Modified Kelsall model provided a slightly better fit. The maximum values of the flotation rate constant (k) for both coals were obtained for the particle size-class (−0.1 + 0.053) mm for the Classical model and (−0.2 + 0.1) mm for the modified Kelsall model. The relation between flotation kinetics constant (k) and average particle size value (d_sr) was estimated for the Classical model and the modified Kelsall model. It was observed that the flotation kinetics constant (k) for coal particle size could be predicted satisfactorily. 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

Fine spodumene particles are challenging to treat by froth flotation and are often discarded. An approach to recover the lithium-bearing mineral is to selectively aggregate fine spodumene into larger sizes that are amenable to recovery by flotation. This research investigated the aggregation behaviour of spodumene and the gangue minerals K-feldspar and quartz, using commercially available anionic polyacrylamide flocculants. Calcium ions were used as activators that facilitated the selective adsorption of the carboxylate groups in the anionic flocculants onto the spodumene surface. The calcium ions decreased the magnitude of the negative zeta potential and reversed the zeta potential to positive for spodumene and K-feldspar, but not for quartz, below pH 10. Calcium concentrations of 312.5 g/t enhanced the adsorption of anionic polymers onto spodumene and K-feldspar, inducing aggregation, while quartz was aggregated only above 5000 g/t. Increasing the polymer concentration increased the aggregate size for spodumene and K-feldspar, but had little effect on quartz. In situ sizing and turbidity measurements indicated the optimal conditions for spodumene aggregation were 625 g/t of calcium and 63–84 g/t of the 58% anionic-charged polyacrylamide at pH 8.5. The sedimentation results showed limited separation due to quartz entrapment in the aggregates. Anionic polyacrylamide flocculants with calcium activators can aggregate fine spodumene particles. Full article

The co-occurring relationships between ilmenite and gangue minerals in ilmenite deposits, as well as fine mineral embedding particle sizes, are complex. During the beneficiation process, grinding ilmenite finely is necessary to achieve sufficient individual mineral dissociation and the efficient recovery of ilmenite. During this process, a large number of fine-grained minerals can easily be generated, which adversely affects flotation separation. Micro–nanobubbles have been proven to effectively enhance the flotation separation efficiency of fine-grained minerals, as their cavitation characteristics are closely related to the flotation performance of the minerals. In order to fully understand the cavitation characteristics of micro–nanobubbles and their impact on the flotation recovery of fine-grained ilmenite, a series of experiments were conducted using methods such as the bubble cavitation property test, micro-flotation experiments, zeta potential analysis, the contact angle test, adsorption capacity detection, and PBM monitoring. The results indicate that during the process of slurry cavitation, appropriate concentrations of 2-octanol, cycle treatment times, and external inflation volume are conducive to the formation of micro–nanobubbles. Compared with deionized water without cavitation, cavitated micro–nanobubble water is more beneficial for the flotation separation of fine particulate ilmenite, titanaugite, and olivine. The presence of micro–nanobubbles can effectively promote the adsorption of combined collectors on mineral surfaces, significantly enhancing the hydrophobicity of the minerals, with an even stronger promoting effect observed under the treatment of 2-octanol. Micro–nanobubbles can adsorb a portion of the collectors originally attached to the mineral surfaces, thereby decreasing the absolute value of the surface potential of the minerals, which is beneficial for mineral aggregation. The introduction of micro–nanobubbles promotes the aggregation of fine ilmenite iron ore particles into flocculent bodies. 2-Octanol can reduce the size of the micro–nanobubbles generated during the cavitation process of the mineral slurry and, to a certain extent, weaken the phenomenon of bubble coalescence, so they demonstrate a greater advantage in facilitating the aggregation phenomenon. Full article

The processing of low-grade, lead-containing practical ores requires fine grinding to liberate galena and enhance flotation recovery. The ball mill is still one of the most common approaches used in industry for fine grinding. This study investigated the effect of the grinding parameters in a ball mill on the fine grinding product of galena and on flotation performance. The grinding product had a particle size below 30 μm, which was classified into +25 μm, −25 + 10 μm, and −10 μm fractions. Grinding experiments showed that modifications to the grinding concentration, media proportion, and filling ratio exerted significant effects on the yields of the +25 μm and −10 μm fractions. Flotation experiments showed that the yield of −10 μm particles negatively affected the flotation performance of galena. Discrete element method simulation results revealed that an increase in the motion velocity of the media group enhanced attrition effects during fine grinding, promoting the generation of −10 μm particles. The higher yield of −10 μm particles facilitated a smaller contact angle and smaller agglomerate size, resulting in lower recovery. To optimize the particle size distribution and improve fine-grained galena flotation recovery, it is essential to reduce the attrition of the grinding media on the mineral. Full article

This study developed a novel pulsation-fluidized bed system, and the device was integrated into a reflux classifier to enhance the preconcentration of antimony oxide ore. The diaphragm-based pulsation device converts a stable upward water flow into a vertically alternating pulsation flow. By precisely controlling the pulsation parameters and optimizing operational conditions, the density-based stratification of particles can be significantly enhanced, thereby improving bed layering and effectively reducing entrainment. An antimony oxide ore from flotation tailings with an Sb grade of 0.8% was used as the feed material to evaluate the performance of the pulsation reflux classifier (PRC). Under optimized conditions, the PRC produced a concentrate with an Sb grade of 5.48% and a recovery of 81.68%, corresponding to a high separation efficiency of 70.97%. The response surface statistical model revealed that the interaction between the fluidization rate and pulsation frequency significantly enhanced the Sb grade of the concentrate, while pulsation stroke was identified as the key factor influencing separation efficiency. Furthermore, the variation in bed profile parameters with changing pulsation characteristics elucidates the interplay between particle suspension, stratification, and fluid disturbances. This study demonstrates that pulsation fluidization significantly enhances the separation performance of the reflux classifier, offering a new approach for the efficient preconcentration of complex fine-grained minerals. Full article

Tin is a crucial strategic metal, extensively employed in aerospace, new energy materials, and other advanced fields. However, with the progressive depletion of high-grade tin ores, the utilization of low-grade tin ores for metal tin production has emerged as a significant trend. Nonetheless, low-grade tin ores present inherent challenges that hinder their direct application in tin extraction. Flotation remains an effective method to enhance ore grade, yet issues such as fine particle dispersion and ore complexity persist. In light of this, the present study provides a comprehensive review of cassiterite resource characteristics, surface chemistry, flotation reagents, and relevant case studies. By delving into the physicochemical properties of cassiterite, this paper elucidates its floatability and the distinctions among various flotation reagents. Furthermore, it identifies critical challenges in cassiterite flotation and proposes targeted, feasible strategies to support the efficient exploitation of tin resources, thereby fostering the sustainable development of the tin industry. Full article

Phosphate ores, which are regarded as critical mineral resources, play an important role in various industrial fields. Apatite is the main source of phosphate mineral resources and must be concentrated before it is processed into industrial products. Flotation is the most commonly employed method for apatite concentration. However, as the proportion of fine apatite increases, the challenge of separating it from gangue minerals intensifies, due to the resemblance in surface characteristics between apatite and gangue. Interfacial regulation during flotation is fundamental to the process, including the regulation of the mineral/water interface wettability by flotation reagents (collectors and modifiers), the control of interactions between mineral particles, and the regulation of interactions between mineral particles and bubbles. This article introduces the surface characteristics of apatite and its main gangue minerals. It discusses innovative work on flotation reagents (primarily collectors and depressants) and their action mechanisms on mineral surfaces. It reviews the current development of theories on the regulation of interactions between interparticles and between particles and bubbles. Finally, the study outlook the future research on interfacial regulation in apatite flotation. This study is intended to offer references for the continued advancement of apatite flotation. Full article

Lithium is a critical mineral resource. With the development of high-end manufacturing industry, the demand for high-performance lithium-containing chemical raw materials continues to grow. At present, lithium needs to be acquired from a large amount of lepidolite ore, constrained by the existing lithium resource supply limitation quandary, and the industry urgently needs to develop more efficient beneficiation and extraction methods for lepidolite. Findings have suggested mixed collectors (e.g., DDA/SDBS) achieve a 4.99% Li₂O grade and 98% recovery at neutral pH, reducing reagent use by 20–30%. Microwave-assisted roasting boosts Li recovery to 95.9% and cuts energy use by 26.9%. Bioleaching with Acidithiobacillus ferrooxidans (A.F.) and rhamnolipid releases 6.8 mg/L Li with a lower environmental impact. Sulfuric acid baking recovers Li (97.1%), Rb (96.0%), and Cs (95.1%) efficiently. Despite challenges in fine-particle recovery and reagent costs, integrated strategies like nanobubble flotation, green collectors, and AI optimization offer sustainable, high-efficiency extraction. This work provides insights for advancing lepidolite processing, balancing economics and environmental stewardship. Full article