
Mineral processing
Mineral processing encompasses a range of physical and physico-chemical techniques used to separate, concentrate, and upgrade valuable minerals from ores and raw materials. The primary objective is to enhance mineral liberation and produce marketable concentrates while minimizing waste and improving downstream metallurgical performance. Mineral processing forms a critical link between geological characterization and extractive metallurgy.
Particle size analysis (Sieving)
Sieving is a fundamental particle size separation technique used in mineral processing, geotechnical investigations, and environmental studies to classify materials based on particle size distribution.
Density separation processes
Spiral gravity separation
Spiral Gravity separation is a mineral processing technique that exploits differences in particle density to separate valuable minerals from gangue material. The technique relies on the combined effects of gravity, fluid resistance, and particle motion to achieve separation. When particles are subjected to a flowing fluid or a pulsating medium, denser particles tend to settle or move differently from lighter ones.
Shaking table separation
Shaking table separation is a gravity concentration technique used to separate minerals based on differences in specific gravity, particle size, and shape. It is widely applied in laboratory and small- to medium-scale mineral processing for the beneficiation of ores containing free-liberated, high-density minerals such as gold, cassiterite, scheelite, chromite, and heavy mineral sands.
Floatation process
Flotation is a widely used mineral processing technique that separates minerals based on differences in density, surface chemistry and hydrophobicity. The method enables selective concentration of valuable minerals from finely ground ores and is particularly effective for the beneficiation of sulphide minerals, as well as certain oxide, phosphate, and industrial mineral systems.
In the flotation process, the ore is ground to an appropriate particle size to achieve mineral liberation and mixed with water to form a slurry. Specific chemical reagents are added to modify the surface properties of minerals. Collectors render target minerals hydrophobic, frothers generate stable air bubbles, and modifiers such as depressants and activators enhance selectivity. When air is introduced into the slurry, hydrophobic mineral particles attach to rising bubbles and form a froth layer that is removed as a concentrate, while hydrophilic gangue minerals remain in the pulp.
Heavy-Density Liquid (HDL) Separation
It is the separation of two or more minerals of different specific gravities by their relative motion in response to gravity and buoyancy forces. Examples of such liquids include sodium metatungstate or sodium polytungstate (SPT) and lithium metatungstate (LMT). The tungsten anion of SPT and LMT is [H₂W₂O₄]₆. They belong to a class of structures known as the "Keggin" type. Organic heavy liquids constitute the "older" generation of heavy liquids. The two most commonly used heavy organic liquids for mineral separation processes today are bromoform (CHBr3) and TBE (1,1,2,2-tetrabromoethane; C2H2Br4). Bromoform has a density of 2.87 g/mL and TBE has a density of 2.95 g/mL.
Particle size analysis (Sieving)
Clay separation is a mineral processing and sample preparation technique used to isolate fine clay-sized particles from coarser mineral fractions based on differences in particle size, settling velocity, and surface behavior. The process is commonly applied in geological, geochemical, and mineral processing studies where the presence of clay minerals can influence analytical results.
Magnetic Separation
There are three magnetic properties of minerals (Paramagnetic, Ferromagnetic and Diamagnetic). Magnetic separation of minerals depends on a three-way competition between:
Magnetic forces; Gravitational or inertial forces; and the attractive and repulsive forces between particles. The combination of these forces determines the outcome of any given magnetic separation and is greatly influenced by the nature of the feed, such as size distribution, magnetic susceptibility, and other physical and chemical properties. The strength of the magnetic field is determined by the equation f = m/kH/dh/dx. Where k = magnetic susceptibility, H = magnetic field strength, and dh/dx is the magnetic field gradient. The laboratory has a three-disc magnetic separator operating with an induced magnetic field and an electric current of up to 20,000 gauss.
Electrostatic Separation
Electrostatic separation is a dry mineral processing technique that separates particles based on differences in their electrical conductivity and surface charge behavior. The method is particularly effective for materials where minerals exhibit contrasting electrical properties and where moisture-sensitive processing conditions are required.
In electrostatic separation, particles are charged by contact, induction, or ionization and then exposed to a high voltage (20-60 kV) electric field. Conductive minerals lose their charge rapidly and are deflected differently from non-conductive minerals, which retain their charge and follow an alternate trajectory.