Search Results (223)

This study systematically compares the crystal properties of fluorite (CaF₂) and dolomite [CaMg(CO₃)₂] through first-principle calculations. Density functional theory (DFT) simulations revealed fundamental differences in structural and electronic characteristics: fluorite exhibits purely ionic Ca-F bonds (Mulliken population: 0.08) with a wide bandgap; whereas dolomite demonstrates a hybrid bonding nature featuring ionic Ca-O/Mg-O bonds (populations: 0.09/0.18) and covalent C-O bonds (0.86), which are accompanied by a narrower bandgap. The charge density and density of states (DOS) analyses demonstrated fluorine’s dominant electronic reactivity in fluorite (F 2p states near Fermi level) versus the oxygen/calcium activity in dolomite. Cleavage studies identify preferential fracture planes, with fluorite’s {111} plane exhibiting higher unsaturated bond density (14.76 nm⁻¹) than dolomite’s {104} plane (10.55 nm⁻¹), which correlates with their distinct mechanical processing behaviors. This work establishes a theoretical foundation for developing selective separation strategies by exploiting crystal-specific surface properties. Full article

The novelty of this study lies in the first comparative characterisation of five carbonaceous materials: three monophase carbons (wood charcoal, carbon, graphite) and two ore-derived CM samples from polymetallic sulphide and oxidised lithium ores. The methodology included IR spectroscopy, XPS, acid–base adsorption centres identified by colour indicators, chemical composition analysis, and kinetic flotation tests. Bulk and surface compositions differed significantly: although the ash content of ore-derived CM reached 84.4%, XPS revealed carbon-enriched surfaces with thin films of about 1–2 nm. IR spectra confirmed multiphase structures with carbonate, silica, and aluminosilicate bands, and showed an identical composition of CM from different industrial ore types. Flotation kinetics confirmed high floatability (recoveries 80%–99%, k up to 1.95 min⁻¹). Even with sodium lignosulphonate at 500 mg/L, recovery only decreased from 83.02% to 52.54%, showing the limited efficiency of depressants. These results provide a basis for the preliminary removal of CM prior to rough (bulk) flotation in the processing of different ore types, improving concentrate quality, reducing reagent consumption, and lowering metallurgical losses. Full article

Enargite (Cu₃AsS₄), a copper–arsenic sulfosalt, represents a critical challenge in copper mineral processing due to its high arsenic content, which poses significant environmental, metallurgical, and economic issues. Its flotation behavior closely resembles that of other copper sulfides such as chalcopyrite and chalcocite, complicating selective separation at early beneficiation stages. This review presents a comprehensive examination of enargite’s surface chemistry and electrochemical behavior, focusing on the influence of oxidation, pH, and pulp potential on surface reactivity, charge distribution (zeta potential), and hydrophobicity. Detailed insights into the formation of surface oxidation layers, passivation mechanisms, and contact angle variations are provided to elucidate collector-mineral interactions. Advances in selective flotation techniques are also discussed, including the use of depressant reagents, controlled redox environments, and reagent conditioning strategies. Special attention is given to flotation in seawater, where ionic strength and multivalent ions significantly influence mineral-reagent interactions and flotation outcomes. Galvanic interactions between enargite and other sulfide minerals are identified as critical factors affecting floatability and selectivity. The review consolidates findings from recent experimental and electrochemical studies, highlighting promising approaches to enhance enargite rejection and copper concentrate purity. It concludes with perspectives on future research aimed at optimizing flotation processes and developing sustainable solutions for processing arsenic-bearing copper ores. Full article

Titanium (Ti) and vanadium (V) are metals critical for the sustainable development of our society. Their growing demand and the depletion of ores rich in these metals along with technological development lead to a reconsideration of sources that were previously considered unpromising. The present work is devoted to the study of an iron (Fe) ore from southeastern Bulgaria, containing Ti and V in low but potentially recoverable concentrations. The aim was to check whether it is possible to obtain an iron concentrate containing Ti and V in concentrations comparable to those in similar market products. The material was examined by optical microscopy, XRD, SEM-EDS, and ICP MS. Magnetic separation was applied with and without predating gravity separation. By applying wet gravity beneficiation followed by a low-intensity magnetic field, an iron concentrate (40%–65% Fe) bearing 3%–5% Ti and 0.4%–0.59% V was obtained. Using only a low-intensity magnetic field, without gravity separation, an iron concentrate (59.4% Fe) containing 3.5% Ti and 0.44% V was obtained. Vanadium was extracted in the highly magnetic material, while a significant amount of Ti was left in the weak magnetic fraction. An additional 1.5% may be recovered by applying a high-intensity magnetic field. The main processing challenge appears to be the recovery, without flotation beneficiation, of magnetite that is oxidized to non-magnetic hematite and maghemite. Using magnetic separation (with or without preliminary wet gravity beneficiation) avoids pollution of the processing waste with reagents. Thus, the waste from the beneficiation of the studied type of ore can be used as a soil improver. As a result, the extraction of critical metals using a practically waste-free technology may be achieved. Full article

In the mining industry, key unit operations such as grinding, flotation, thickening, and tailings transport are negatively affected by the presence of clay minerals, which impart complex rheological behaviors to mineral suspensions by increasing their rheological properties. This deterioration arises from specific physicochemical characteristics of clay minerals such as fine particle size, anisotropic character, laminar morphology, and swelling capacity. This work reviews the effects of various rheology-modifying reagents on clay suspensions including kaolinite, illite, and montmorillonite. The reviewed reagents include inorganic salts, pH modifiers, polymers, surfactants, and nanoparticles. Their mechanisms of interaction with solid particles are analyzed, highlighting their influence on the degree of dispersion or aggregation. Furthermore, this review proposes research opportunities focused on the formulation of hybrid reagents, modified biopolymers, and the development of reagents effective under adverse conditions such as high salinity or elevated temperatures. This review provides a comprehensive basis for optimizing the use of rheological additives through more efficient and sustainable strategies for managing clay-rich suspensions in the mining industry. Full article

To achieve efficient desilication and improve the grade of magnesite, an environmentally friendly surfactant, cocamidopropyl dimethylamine (PKO-H), was employed as a collector for the flotation separation of magnesite and quartz. The flotation performance and adsorption mechanism of PKO-H was systematically investigated through flotation experiments, Fourier-transform infrared spectroscopy (FTIR), contact angle measurements, zeta potential analysis, and molecular simulations. The flotation results demonstrated that PKO-H exhibited excellent selectivity, achieving a MgO recovery rate of 98.8% and a concentrate grade of 45.7% in artificially mixed mineral samples. Contact angle measurements, FTIR spectra, zeta potential analysis, and molecular simulations revealed that the adsorption of PKO-H on quartz is primarily driven by electrostatic attraction. In contrast, due to electrostatic repulsion, the interaction between PKO-H and magnesite is weak, preventing stable adsorption. This study establishes PKO-H as a sustainable and efficient collector for magnesite beneficiation and provides new insights into interfacial mechanisms for the design of eco-friendly flotation reagents. Full article

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 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

Colloidal silica acts as a multifunctional reagent in the froth flotation process of semi-soluble salt-type minerals, enabling the selective depression of calcite. This study investigates its effect on four key minerals—calcite, scheelite, apatite, and fluorite—using a comprehensive suite of techniques to identify the flotation subprocesses modulated by colloidal silica. This work also aims to determine the specific flotation zones affected by colloidal silica, assessing the influence of its dosage, surface modification, and specific surface area on metallurgical outcomes. Atomic force microscopy revealed mineral-specific surface responses to colloidal silica conditioning: calcite exhibited localized nanoparticle adsorption, whereas apatite underwent a dissolution–reprecipitation mechanism. Scheelite and fluorite, in contrast, showed minimal surface modifications. These differences are attributed to variations in surface reactivity, hydration behavior, and crystallographic structure, with calcite offering a uniquely favorable environment for colloidal silica attachment. Mechanistic insights show that colloidal silica—especially the aluminate-modified type with high specific surface area—influences both the pulp and froth zones by producing small, stable bubbles, enhancing fine scheelite recovery, stabilizing froth, and effectively depressing calcite. In contrast, non-functionalized colloidal silica resulted in poor bubble control and unstable froth. These findings elucidate the subprocess-specific mechanisms by which colloidal silica operates and highlight its potential as a tunable, multifunctional reagent for improving selectivity in the flotation of semi-soluble salt-type minerals. Full article

The transition to sustainable energy systems demands efficient recycling methods for critical raw materials like lithium. In this study, we present a new class of pH- and light-switchable flotation collectors based on isomeric derivatives of the natural product Punicine, termed inverse Punicines. These amphoteric molecules were synthesized via a straightforward four-step route and structurally tuned for hydrophobization by alkylation. Their performance as collectors was evaluated in microflotation experiments of lithium aluminate (LiAlO₂) and silicate matrix minerals such as melilite and calcium silicate. Characterization techniques including ultraviolet-visible (UV-Vis), nuclear magnetic resonance (NMR) and electron spin resonance (ESR) spectroscopy as well as contact angle, zeta potential (ζ potential) and microflotation experiments revealed strong pH- and structure-dependent interactions with mineral surfaces. Notably, N-alkylated inverse Punicine derivatives showed high flotation yields for LiAlO₂ at pH of 11, with a derivative possessing a dodecyl group attached to the nitrogen as collector achieving up to 86% recovery (collector conc. 0.06 mmol/L). Preliminary separation tests showed Li upgrading from 5.27% to 6.95%. Radical formation and light-response behavior were confirmed by ESR and flotation tests under different illumination conditions. These results demonstrate the potential of inverse Punicines as tunable, sustainable flotation reagents for advanced lithium recycling from complex slag systems. Full article

Using hydrogen peroxide (H₂O₂), a simple and easily accessible reagent, as a selective depressant, flotation separation experiments of chalcopyrite and copper-activated sphalerite were conducted. The micro-flotation tests of single minerals indicated that H₂O₂ selectively depresses copper-activated sphalerite and exerted almost no depressant effect on chalcopyrite. In the flotation tests of artificially mixed minerals, a copper concentrate with a grade of 29.95% and a recovery of 87.30% was obtained, while the zinc content was only 5.76%, demonstrating a significant separation effect. The results of contact angle measurement, Zeta potential measurement, surface adsorption analysis, and XPS analysis suggested that H₂O₂ had a stronger oxidation capacity on the surface of copper-activated sphalerite than chalcopyrite, generating hydrophilic hydroxyl groups on the surface of sphalerite and preventing further adsorption of the collector Z-200 on the surface of sphalerite. Full article

In this study, Bacillus tropicus (BT), a non-toxic and eco-friendly microorganism, was employed to substitute traditional inorganic depressants in the flotation separation of copper-molybdenum sulfides. Single mineral flotation tests were performed to examine BT’s impact on the flotation behavior of molybdenite and chalcopyrite. The results indicated that excessive BT inhibited the flotation of both minerals, reducing their recoveries below 40%. At a BT dosage of 2.5 kg/t and pH 9.0, chalcopyrite recovery was 74.10%, while molybdenite recovery was 20.47%, achieving an effective separation of the two minerals. BT’s adsorption mechanism on molybdenite and chalcopyrite was analyzed through contact angle tests, thermogravimetric analysis, and Fourier transform infrared spectroscopy. These analyses revealed that increased BT absorption on molybdenite enhanced its surface hydrophilicity. This research offers a novel perspective on utilizing microorganisms as efficient flotation reagents. Full article

A methodology for detecting systematic errors in sets of equally accurate, uncorrelated, aggregate measurements is proposed and applied within the automatic real-time dispatch control system of a copper concentrator plant (CCP) to refine the technical and economic performance indicators (EPIs) computed by the system. This work addresses and solves the problem of selecting and obtaining reliable measurement data by exploiting the redundant measurements of process streams together with the balance equations linking those streams. This study formulates an approach for integrating cloud technologies, machine learning methods, and forecasting into information control systems (ICSs) via predictive analytics to optimize CCP production processes. A method for combining the hybrid cloud infrastructure with an LSTM-DNN neural network model has been developed, yielding a marked improvement in TEP for copper concentration operations. The forecasting accuracy for the key process parameters rose from 75% to 95%. Predictive control reduced energy consumption by 10% through more efficient resource use, while the copper losses to tailings fell by 15–20% thanks to optimized reagent dosing and the stabilization of the flotation process. Equipment failure prediction cut the amount of unplanned downtime by 30%. As a result, the control system became adaptive, automatically correcting the parameters in real time and lessening the reliance on operator decisions. The architectural model of an ICS for metallurgical production based on the hybrid cloud and the LSTM-DNN model was devised to enhance forecasting accuracy and optimize the EPIs of the CCP. The proposed model was experimentally evaluated against alternative neural network architectures (DNN, GRU, Transformer, and Hybrid_NN_TD_AIST). The results demonstrated the superiority of the LSTM-DNN in forecasting accuracy (92.4%), noise robustness (0.89), and a minimal root-mean-square error (RMSE = 0.079). The model shows a strong capability to handle multidimensional, non-stationary time series and to perform adaptive measurement correction in real time. Full article

The reprocessing of metallurgical wastes to recover much-needed metals such as copper not only ensures an adequate supply of metals but also contributes to the cleaning of the environment. A copper smelter in Namibia accumulated significant amounts of spent refractory bricks that are enriched with metal values including copper. This supposedly waste material can potentially serve as a supplement to the ore concentrate, as a smelter feedstock for this toll smelter. Representative samples of crushed bricks, designated as Sample 1 and Sample 2, were used for mineralogical characterisation and flotation test work. The assays for Sample 1 and Sample 2 were 14% Cu and 18% Cu, respectively. Microscopy results identified various copper phases including metallic Cu, bornite, malachite and chalcopyrite. Batch flotation tests were conducted to investigate the effect of grind size (P₈₀ of 53, 75 and 106 μm), pulp pH (natural pulp pH, 10, 10.5 and 11) and collector (potassium amyl xanthate, PAX) dosage (70, 100 and 130 g/t) on the recovery of copper, concentrate grade and weight recovery. In some tests, a co-collector (dithiophosphate, DTP) and sulphidiser (Na₂S) were also added in the quest to maximise the recovery of copper. Based on the test conditions investigated in this study, the grind size is the key variable affecting the recovery of copper. The best copper recovery of 86% (with a weight recovery in the range of 42 to 45% (w/w) and concentrate grade of 37% Cu) was achieved for the finest grind size of 53 μm. The reagent suite that yielded the best recovery was 70 g/t PAX with no addition of the sulphidiser while the pH was 10. There is scope for developing the process routes to recover other valuable metals such as iron, lead and zinc that are also in the spent bricks, as well as potential reuse of the spent bricks (after recovering valuable metals) to make new refractory bricks. Full article

In this study, flotation tests were conducted on a laboratory scale using a sample of microcrystalline graphite ore from the Canindé region, Ceará, Brazil. The objective was to investigate the grinding time, reagent dosage, and purification process for obtaining graphene-based nanomaterials. Natural graphite has a stacked planar structure and exhibits polymorphism with rhombohedral, hexagonal, and turbostratic geometries, characteristics that directly influence its properties and technological applications. The results demonstrated that it was possible to obtain rougher concentrate with a graphite carbon content of 23.4% and a recovery of 86.4%, using a grinding time of 7.5 min and reagent dosages of 150 g/t of kerosene and 100 g/t of Flotanol D-25. This flotation process resulted in a graphite concentrate with 76.6% graphite carbon content. To increase the purity of the concentrate and expand its industrial applications, the graphite was purified in an alkaline autoclave using the hydrothermal method. In the next stage, acid leaching was performed, and this chemical treatment destabilized the regular stacking of the graphite layers, promoting the formation of graphene-like nanoplates, including monolayer graphene. Thus, the nanomaterials obtained through the process developed in this study have potential for various innovative applications, such as lithium-ion batteries, electric vehicles, and two-dimensional graphene-based materials. Full article