Recovery of Values from Low-Grade and Complex Minerals E-Book

• Herausgeber: John Wiley & Sons
• Kategorie: Wissenschaft und neue Technologien
• Sprache: Englisch

Seitenzahl: 445

Veröffentlichungsjahr: 2024

Beschreibung

Recovery of Values from Low-Grade and Complex Minerals The book elaborates on various physicochemical properties of minerals and technological developments to improve the recovery of metals while ensuring cost-effectiveness and minimal environmental impact. The mineral industry is undergoing significant cultural, organizational, and technological transformations to address some of the major limitations and challenges related to the environmental and productivity domains. As far as productivity is concerned, the decrease of high-grade ores has been one of the stumbling blocks toward the achievement of maximum recovery of metals while, on the other hand, the complexity of minerals therein makes it difficult to profitably extract metals using only conventional methods. This book presents eight specialized chapters that focus on the exploration of the complexity of minerals that are likely to negatively influence the recovery of values, as well as the development of adequate technologies capable of improving the process of mineral concentration and/or metal recovery from complex minerals in a sustainable manner. It reviews the various physicochemical properties of minerals that are likely to pose a challenge during the attempt to recover values using conventional methods. It also elaborates on the recent technological development that has been considered by researchers to improve the recovery of metals from gangue-dominated minerals while ensuring cost-effectiveness and minimal adverse environmental impact. Audience This book will be of interest to academic researchers from the fields of mineral processing, hydrometallurgy, geochemistry, environment, chemistry, engineering, and professionals including mining plant operators, environmental managers in the industries, government regulatory bodies officers, and environmentalists.

Leseprobe

Table of Contents

Cover

Table of Contents

Series Page

Title Page

Copyright Page

Preface

1 Optimization of the Mechanical Comminution – The Crushing Stage

1.1 Introduction

1.2 The Role of Crushers

1.3 Conclusion

References

2 Challenges Related to the Flotation Process of Complex Phosphate Ores

2.1 Introduction to the Geology of Complex Phosphate Ores

2.2 Phosphate Rock Beneficiation Processes

2.3 Froth Flotation of Sedimentary Phosphate Ore

2.4 Challenges Facing Flotation of Phosphate Rock

2.5 Future Research Directions

2.6 Conclusion

References

3 Increasing Ionic Strength and Oxyhydroxo Species in Process Water on the Floatability of Chalcopyrite and Pentlandite for a Selected Cu–Ni Bearing Ore Flotation

3.1 Introduction

3.2 Materials and Methods

3.3 Results and Discussion

3.2 Cu and Ni Recoveries and Grades from a Three-Phase Batch Cell

3.3 Water Recoveries from a Two-Phase Batch Float Cell

3.4 Froth Column Studies from a Two-Froth Column

Conclusions

Acknowledgments

References

4 Relating the Flotation Response of Pyrrhotite to the Adsorption of Sodium Carboxymethyl Cellulose and Sodium Isobutyl Xanthate on its Surface in Process Water of a Degrading Quality

4.1 Introduction

4.2 Experimental Methods

4.3 Results and Discussion

4.4 Conclusions

Acknowledgments

References

5 Simulated Short Cycle Water Recirculation on the Flotation Performance of a UG2 Cu–Ni–PGM Ore

5.1 Introduction

5.2 Materials and Methods

5.3 Results and Discussion

5.4 Conclusions

Acknowledgements

References

6 Complexity of Chalcopyrite Mineral Affecting Copper Recovery During Leaching

6.1 Introduction

6.2 CuFeS

2

Crystal Structure

6.3 Application of Dissolution/Leaching of Chalcopyrite

6.4 Challenges Associated with Copper Dissolution from the Chalcopyrite Mineral

6.5 H

2

SO

4

-Fe

2

(SO

4

)

3

-FeSO

4

-H

2

O Speciation

6.6 Parameters Affecting Dissolution

6.7 Thermodynamic Considerations

6.8 CuFeS

2

Phases Conversion/Copper Sulfide (Cu-S) Intermediate Phases

6.9 Conclusion

References

7 Fe

3+

-Fe

2+

Redox Cycle Peculiarity in the Acid Dissolution of Copper–Cobalt Complex Ores

7.1 Introduction

7.2 Conventional Leaching of Copper–Cobalt Minerals

7.3 Fe

3+

-Fe

2+

Redox Cycle in the Dissolution of Mixed Oxidized and Sulfide Minerals

7.4 Application of Mineral–Mineral Leaching Process to the Dissolution of Complex Ores

7.5 Conclusion

References

8 Rare Earth Elements (REEs) in Complex Ores and Spent Materials: Processing Technologies and Relevance in the Global Energy Transition

8.1 Introduction

8.2 The Chemistry of REEs

8.3 REE Minerals and Deposit Types

8.4 REE Ore Mining and Processing Technologies

8.5 Relevance of REEs in Energy Transition

8.6 Conclusion

References

Index

Also of Interest

End User License Agreement

List of Tables

Chapter 1

Table 1.1 Comparison of different types of crushers.

Chapter 2

Table 2.1 Global phosphate rock mine production in 2019 [14].

Table 2.2 Quartz occurrence and possible beneficiation approach [31].

Table 2.3 Mineralogical composition of sedimentary phosphate ore [27].

Table 2.4 Collectors used in phosphate ore flotation [48].

Table 2.5 Depressants used in phosphate ore flotation [48].

Table 2.6 Some of the frothers and dispersants used in phosphate ores.

Table 2.7 Some of the phosphate elements and their impact on processing [87]...

Chapter 3

Table 3.1 Reagent addition and sequence.

Table 3.2 Water quality of synthetic plant water (SPW).

Table 3.3 Paired t-test for solids recoveries: pH 9 and pH 11.

Table 3.4 Paired t-test for water recoveries: pH 9 and pH 11.

Chapter 4

Table 4.1 Ion concentration, total dissolved solids (TDS), and ionic strengt...

Chapter 5

Table 5.1 Mean calculated feed values for the UG2 ore received in 2019.

Table 5.2 The concentration of ions (in mg/L) present in synthetic plant wat...

Table 5.3 Summary of the properties of flotation reagents utilized in the ex...

Table 5.4 Characteristics for the 10-L stainless steel laboratory scale mill...

Table 5.5 Summary of the batch flotation procedure.

Table 5.6 Analytes, reagents, and reference standards [59].

Table 5.7 Entrained gangue (Ent. gangue) and solids to water ratio for all t...

Table 5.8 Concentration of dissolved Ca

2+

, Mg

2+

, SO

4

2-

, and Cl

-

present in t...

Chapter 6

Table 6.1 Mineral characteristics.

Table 6.2 Summary of some of the commercial processes.

Chapter 8

Table 8.1 Rare earth elements’ global production and estimated reserves (in ...

Table 8.2 Selected rare earth minerals with their rare earth oxide (REO) % [...

Table 8.3 General application of REEs in clean energy technologies [102].

List of Illustrations

Chapter 1

Figure 1.1 Illustration of a double jaw crusher [37].

Figure 1.2 Gyratory crusher [37].

Figure 1.3 Horizontal shaft impactor [52].

Figure 1.4 VSI [55].

Figure 1.5 Schematic diagram of a cone crusher [82].

Chapter 2

Figure 2.1 Distribution of the world’s phosphate resources [11].

Figure 2.2 Apatite (phosphate mineral).

Figure 2.3 Simple flow diagram of phosphate mining and beneficiation process [...

Chapter 3

Figure 3.1 Final solids and water recoveries in increasing ionic strength of s...

Figure 3.2 Final Cu recovery and grade in increasing ionic strength of synthet...

Figure 3.3 Final Ni recovery and grade in increasing ionic strength of synthet...

Figure 3.4 The effects of ionic strength of synthetic plant water and pH on th...

Figure 3.5 The effect of the ionic strength of synthetic plant water and pH on...

Chapter 4

Figure 4.1 Total pyrrhotite recoveries and grades in increasing ionic strength...

Figure 4.2 Total solids (in split fractions of gangue and sulfides) and water ...

Figure 4.3 Pyrrhotite recoveries in increasing ionic strength of SPW in (a) th...

Figure 4.4 Attachment probability of pyrrhotite under increasing ionic strengt...

Figure 4.5 Residual sodium isobutyl xanthate under increasing ionic strength o...

Figure 4.6 Residual sodium carboxy methyl cellulose under increasing ionic str...

Figure 4.7 Zeta potential of pyrrhotite under increasing ionic strength of SPW...

Chapter 5

Figure 5.1 One factor at a time design for the experimental conditions tested ...

Figure 5.2 Individual elemental composition of the UG2 ore feed analyzed using...

Figure 5.3 A summary of the experimental sequence adopted for the flotation of...

Figure 5.4 Simulation of short water recirculation to the mill.

Figure 5.5 Simulation of short water recirculation float cell.

Figure 5.6 The quantity of solids and water reporting to the concentrate for a...

Figure 5.7 Cumulative solids recovery across all the floats from the second ph...

Figure 5.8 The recovery and grade of copper in the solids reporting to the con...

Figure 5.9 The recovery and grade of nickel in the solids reporting to the con...

Chapter 6

Figure 6.1 CuFeS

2

crystal structure.

Figure 6.2 Effect of pH on the Fe speciation at 25°C.

Figure 6.3 Potential-pH diagram of the Cu-Fe-S-H

2

O system at 25°C: all solutes...

Figure 6.4 Schematic diagram of typical electrochemical leaching [74].

Chapter 7

Figure 7.1 Copper and cobalt extraction process route from oxidized ore.

Figure 7.2 Location of Cu

–

Co deposits along the Lufilian arc [13].

Figure 7.3 Eh–pH diagram of copper

–

water system at 25°C (HSC Chemistry 6...

Figure 7.4 Eh

–

pH diagram of cobalt–water system at 25°C (HSC Chemistry 6...

Figure 7.5 Eh

–

pH diagram of cobalt

–

water system in its simplified ...

Figure 7.6 Leaching test results with and without the addition of a reducing a...

Figure 7.7 Influence of Fe

2+

on Co(III) leaching (Co vs. Fe

2+

) [7].

Figure 7.8 Influence of Na

2

S

2

O

5

on Co (III) leaching (Co vs. Na

2

S

2

O

5

) [7].

Figure 7.9 Influence of Fe on Co(III) leaching (Co vs. Fe

0

) [7].

Figure 7.10 Influence of Cu on Co (III) leaching (Co vs. Cu

0

) [7].

Figure 7.11 List of critical metal suppliers as defined by the European Union ...

Figure 7.12 Intergranular cracks and intragranular flaws as generated by micro...

Figure 7.13 Attritioned and original high-grade oxidized cobalt material parti...

Figure 7.14 The pre-processing of cobalt

–

copper ore by microwave prior t...

Figure 7.15 (a) Metal distribution in non-microwaved and (b) multimode cavity ...

Figure 7.16 Leaching kinetics of cobalt in the high cobalt bearing ore [24], (...

Figure 7.17 Leaching of a mixed complex Co

–

Cu ore low in Co:Cu ratio [24...

Figure 7.18 Schematic of different reactions involved in pyrite oxidation [25]...

Figure 7.19 Schema showing two oxidation ways of pyrite (P) dissolved oxygen (...

Figure 7.20 Schema of reaction involving the arseno-pyrite (P) [4].

Figure 7.21 Fundamental schematic of the process of mineral–mineral oxydo-redu...

Figure 7.22 Copper, cobalt, and iron recoveries in terms of the mass of iron o...

Guide

Cover Page

Table of Contents

Series Page

Title Page

Copyright Page

Begin Reading

Index

Also of Interest

WILEY END USER LICENSE AGREEMENT

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Scrivener Publishing100 Cummings Center, Suite 541JBeverly, MA 01915-6106

Publishers at ScrivenerMartin Scrivener ([email protected])Phillip Carmical ([email protected])

Recovery of Values from Low-Grade and Complex Minerals

Development of Sustainable Processes

Edited by

Elvis Fosso-Kankeu

Department of Metallurgy, University of Johannesburg, South Africa

Bhekie B. Mamba

College of Science, Engineering and Technology, University of South Africa, Pretoria, South Africa

and

Antoine F. Mulaba-Bafubiandi

Emeritus Professor at the University of Johannesburg, South Africa

This edition first published 2024 by John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, USA and Scrivener Publishing LLC, 100 Cummings Center, Suite 541J, Beverly, MA 01915, USA© 2024 Scrivener Publishing LLCFor more information about Scrivener publications please visit www.scrivenerpublishing.com.

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Library of Congress Cataloging-in-Publication Data

ISBN 978-1-119-89641-8

Cover image: Pixabay.ComCover design by Russell Richardson

Preface

The mineral industry is undergoing significant cultural, organizational, and technological transformations to address some of the major limitations and challenges related to the environmental and productivity domains. As far as productivity is concerned, the decrease of high-grade ores has been one of the stumbling blocks toward the achievement of maximum recovery of metals while, on the other hand, the complexity of minerals therein makes it difficult to profitably extract metals using only conventional methods. Recent developments in comminution, froth flotation, and leaching processes have focused mainly on the improvement of technologies to minimize the impact of gangue materials on the recovery of values and therefore increase the grade of minerals or the recovery rate of metals, as well as minimizing the environmental impact of extractive metallurgy activities. In fact, a sustainable recovery of values from minerals implies a cost-effective process, but also a cleaner and responsible production that suggests an ethical and preventative strategy that reduces the risk of environmental pollution.

The refractoriness of metal sources including ore, flotation concentrates, mill tailings and others that could affect mineral/metal processing could be due either to the fine dissemination of the metal in minerals or gangue matrixes that can react with metal host minerals, increasing the consumption of lixiviant and decreasing the rate of leaching reactions. On the other hand, the formation of intermediate phases or species may occur during the leaching process and form passivation layers, or consume important lixiviation reagents, and both will negatively affect the extraction of metal. There are also challenges associated with the greater mineralogical complexity of low-grade minerals from which metals can be extracted.

After the comminution, froth flotation constitutes an important segment of the separation process in the mineral processing industry and was introduced several decades ago to effectively separate gangue materials from valuable minerals. Despite being a matured process, the complexity of minerals can make froth flotation suffer from a relative inefficiency that could be attributed to poor insight regarding the physical and chemical phenomena that underpin the relationship between surface wettability and floatability. For instance, with the decrease of high-grade minerals coupled with the increased complexity of mineral composition and dissemination, the mineral industry has devoted its attention to low-grade and complex ores with high clay contents. However, to liberate values from such ores requires that they are ground to very fine sizes, which also contributes to the liberation of large quantities of fine gangue that are likely to cause problems related to slime coating, rheology, and entrainment during the flotation process. These issues mainly result in overconsumption of reagents, reduction of direct contact between the targeted mineral and collectors, and the reduction of the grade of flotation concentrations that contribute to minimizing the efficiency of the flotation process.

For all these cases, a pre-treatment of the mineral is needed to reduce the amount of the gangue upfront or adapt an adequate technique that will effectively control the formation of unwanted transition phases that can negatively affect the recovery of values.

The technological imperative will be therefore to improve the efficiency and reliability of the processes considered for metal extraction from the source. This technology should additionally be cost-effective and ensure the minimal negative impact on the environment. The various challenges encountered in the industry regarding the processing of complex minerals, research questions raised from unsolved technological mysteries, as well as the research illustrations presented are the various research benefits the readers will find in this book.

This book presents eight specialized chapters that focus on the exploration of the complexity of minerals that are likely to negatively influence the recovery of values, as well as the development of adequate technologies capable of improving the process of mineral concentration and/or metal recovery from complex minerals in a sustainable manner.

This book reviews the various physicochemical properties of minerals that are likely to pose a challenge during the attempt to recover values using conventional methods. It also elaborates on the recent technological development that has been considered by researchers to improve the recovery of metals from gangue-dominated minerals while ensuring cost-effectiveness and minimal adverse environmental impact.

The editors and the publisher are grateful to the reviewers who have contributed to improving the quality of the book through their constructive comments. The editors also thank the publisher for including this book in their series.

This book will be of interest to academic researchers in the fields of mineral processing, hydrometallurgy, geochemistry, environment, chemistry, engineering, and professionals, including mining plant operators, environmental managers in the industries, government regulatory officers, and environmentalists.

Elvis Fosso-KankeuBhekie B. MambaAntoine F. Mulaba-BafubiandiJanuary 2024