FUCULTY OF ENGINEERING AND GEOSCIENCES
METALURGICAL ENGINEERING
NAME(s): : Munashe TheouphelousNyireR238179B
: Lovejoy MkuduR238977Q
MODULE :MINERALS BENEFICIATION 2
MODULE CODE : HMETE 226
ASSIGNMENT No_ :1
LEVEL :2.2
LECTURER :MR GUMBOCHUMA
DATE :30 MARCH 2025
Introduction
To assess the amenability of sulphidic nickel ore to flotation, a systematic approach involving
various experimentation methods, equipment, and facilities is essential. The goal is to evaluate
the ore's response to flotation and optimize the process parameters.
a. Sample Collection and Preparation
Before any flotation tests, thorough sample preparation and characterization are crucial to
understand the ore's fundamental properties.
Sample Collection: Obtain representative samples of the sulphidic nickel ore.
Sample Preparation: Crush and grind the ore to a specific particle size (typically 80%
passing 75 microns) to liberate nickel minerals from gangue.
b. Mineralogical Analysis
X-Ray Diffraction (XRD): Identify the mineral composition of the ore also mineral
identification and quantification of crystalline phases present in the ore. Helps confirm
mineral identifications from microscopy and provide relative proportions.
Scanning Electron Microscopy (SEM): Examine the morphology and liberation
characteristics of nickel-bearing minerals through Provides high-resolution imaging and
elemental mapping to identify fine-grained minerals, intergrowths, and associations
between valuable minerals and gangue. Crucial for understanding liberation and potential
mineral locking.
Chemical Analysis: Use techniques like Atomic Absorption Spectroscopy (AAS) to
quantify nickel [Link] how nickel is distributed among different minerals
(e.g., % Ni in pentlandite, % Ni in pyrrhotite, % Ni in silicates). This identifies the target
mineral for flotation.
c. Flotation Testing
. Bench-Scale Flotation Tests
Firstly Conduct a series of grinding tests (e.g., in a laboratory rod or ball mill) to determine the
relationship between grinding time/energy and particle size distribution (P80). Use a range of
grind sizes based on mineralogical data (e.g., P80s from 75 μm to 150 μm).
Then Identify the optimal grind size for achieving adequate liberation of nickel sulfides while
minimizing overgrinding, which can lead to slimes and reduced recovery.
Flotation Cell: Use a laboratory flotation cell (e.g., Denver D-12 or similar).
Reagents: Prepare various flotation reagents including:
o Collectors (e.g., xanthates)
o Frothers (e.g., Methyl Isobutyl Carbinol, MIBC)
o Modifiers (e.g., pH adjusters)
Procedure:
1. Pulp Preparation: Mix a specific weight of ground ore with water to create a
slurry (30-50% solids).
2. pH Adjustment: Adjust the pH to an optimal level for flotation (typically between
7 and 10).
3. Addition of Reagents: Sequentially add collectors, frothers, and modifiers.
4. Conditioning: Allow the mixture to condition for a set time (e.g., 10-15 minutes).
5. Flotation: Introduce air into the flotation cell and maintain specific operating
conditions (e.g., agitation speed, air flow).
6. Collection of Froth: Skim off the froth containing the nickel minerals after a
predetermined flotation time.
B. Sequential Flotation Tests
Conduct tests to separate nickel minerals from other sulphides, adjusting reagent types
and dosages accordingly it includes chemical dissolution techniques (e.g., ammonium
citrate for oxidized minerals, strong acids for sulfides) on flotation products to determine
the speciation of nickel (e.g., nickel oxides vs. nickel sulfides) and identify non-flotable
nickel forms.
Quantify nickel losses to oxidation or non-sulfide nickel forms, which are typically
unrecoverable by conventional flotation.
d. Performance Evaluation
Mass Balance Calculation: Determine the recovery of nickel in the concentrate.
Grade Analysis: Analyze the concentrate and tailings for nickel content using AAS.
Flotation Recovery Calculation: Calculate the percentage recovery using the formula:
Recovery=Mass of Ni in ConcentrateMass of Ni in Feed×100\text{Recovery} = \frac{\
text{Mass of Ni in Concentrate}}{\text{Mass of Ni in Feed}} \times
100Recovery=Mass of Ni in FeedMass of Ni in Concentrate×100
Statistical Analysis: Apply statistical methods to evaluate the significance of different
variables and optimize parameters.
Cost Analysis: Preliminary assessment of reagent costs per tonne of ore.
Process Flowsheet Development: Based on the experimental results, propose a
preliminary flotation flowsheet (e.g., rougher-scavenger-cleaner stages, number of
cleaning stages).
e Optimization Studies
Parameter Variation: Vary parameters such as pH, collector type, and dosage to find
optimal conditions for flotation.
Response Surface Methodology: Use statistical approaches to model and optimize
flotation performance.
f. Equipment and Facilities Required
Laboratory Flotation Cell: For conducting flotation tests.
Crushing and Grinding Equipment: To prepare ore samples (jaw crusher, ball mill).
Analytical Equipment: For chemical and mineralogical analysis (AAS, XRD, SEM).
pH Meter: For pH adjustments during flotation.
Reagent Storage: Safe storage for flotation reagents
[Link]
As an Extractive Metallurgy consultant, selecting appropriate reagents and determining their
optimum dosages is crucial for the effective concentration of sulphidic nickel ores. This involves
systematic experimentation and analysis, including the evaluation of reagent types, sourcing
from suppliers, and conducting tests to establish optimal conditions.
Experimentation Methods
a. Reagent Selection
The main reason for this to select the most effective and cost-efficient reagents from commercial
suppliers and fine-tune their dosages.
Initial Research:
o Review literature on common reagents used in nickel sulphide flotation, such as
collectors (e.g., xanthates, thiophosphates), frothers (e.g., MIBC, pine oil), and
modifiers (e.g., pH regulators like lime or sodium hydroxide).
Supplier Assessment:
o Contact multiple suppliers to obtain technical data sheets, safety data sheets, and
pricing information for potential reagents.
Reagent Test Trials:
o Conduct small-scale flotation tests using different reagents to assess their
effectiveness.
b. Laboratory Setup
Required Facilities:
o Flotation cell (batch or continuous)
o Sample preparation area
o Weighing and mixing stations
o pH meter and titration setup
o Analytical balance
o Centrifuge for solid-liquid separation
Equipment:
o Flotation machine
o Beakers and flasks for reagent mixing
o Air supply system for flotation
o Magnetic stirrer for uniform mixing
c. Experimental Procedure
Sample Preparation:
o Crush and grind the sulphidic nickel ore to the desired particle size (typically 75
micrometers).
Reagent Addition:
o Prepare reagent solutions at varying concentrations (e.g., 0.1%, 0.5%, 1.0%,
1.5%).
Flotation Tests:
o Conduct flotation tests by adding reagents to the ore slurry in the flotation cell.
Adjust pH and aeration rates as necessary.
Sampling:
o Collect samples of the concentrate and tailings for analysis after a fixed flotation
time (e.g., 10-15 minutes).
d. Analysis of Results
Recovery and Grade Assessment:
o Analyze the concentrate and tailings for nickel content using techniques such as
X-ray fluorescence (XRF) or atomic absorption spectroscopy (AAS).
o Calculate recovery rates and concentrate grades to evaluate reagent performance.
Optimization of Dosage:
o Plot recovery versus reagent dosage to determine the optimum dosage for each
reagent. Use statistical analysis methods (e.g., response surface methodology) to
refine the dosage recommendations.
e. Data Interpretation
Assess the impact of each reagent on nickel recovery and grade.
Consider synergistic effects between different reagents and their interactions.
Evaluate the economic feasibility of selected reagents based on performance and cost.
f. Final Recommendations
Based on experimental results, recommend the most effective reagents and their optimal
dosages for large-scale operations.
Discuss potential environmental impacts and the need for additional testing.
[Link]
As an Extractive Metallurgy consultant, the objective is to determine expected recoveries and
concentrate grades for a sulphidic nickel ore concentrator. This involves several key
experimentation methods and analyses that will assess the ore's characteristics, optimize
processing parameters, and evaluate the efficiency of the beneficiation techniques.
It is done to predict the commercial-scale metallurgical performance of the concentrator.
Experimentation Methods
a. Sample Collection and Preparation
Objective: Collect representative samples of the sulphidic nickel ore.
Method:
o Use a core drilling method for large-scale sampling.
o Ensure samples are homogenized and split for various tests.
Equipment:
o Core drill
o Sample splitter
[Link] Analysis
Objective: Determine the mineral composition and textural characteristics of the ore.
Method:
o Perform X-Ray Diffraction (XRD) and Scanning Electron Microscopy (SEM) to
identify minerals.
o Employ Optical Microscopy for detailed textural studies.
Equipment:
o XRD machine
o SEM
o Optical microscope
c. Physical Properties Testing
Objective: Assess the physical properties such as density and particle size distribution.
Method:
o Use a sieve analysis to determine particle size distribution.
o Conduct a specific gravity test to find bulk density.
Equipment:
o Sieve shaker
o Balance for specific gravity
d. Flotation Tests
Objective: Optimize the flotation conditions to achieve maximum recovery and
concentrate grade.
Method:
o Conduct batch flotation tests varying parameters such as pH, collector type, and
dosage.
o Measure the recovery of nickel and the grade of the concentrate produced.
Procedure:
[Link] a flotation pulp with a known weight of ore.
[Link] the pH and add collectors.
[Link] flotation in a laboratory flotation cell.
[Link] and analyze the froth (concentrate) and tailings.
Equipment:
o Laboratory flotation cell
o pH meter
o Agitator
e. Chemical Analysis of Concentrate and Tailings
Objective: Quantify the nickel content in both concentrate and tailings.
Method:
o Use Atomic Absorption Spectroscopy (AAS) or Inductively Coupled Plasma
Mass Spectrometry (ICP-MS) for detailed chemical analysis.
Equipment:
o AAS or ICP-MS
f. Mass Balance Calculations
Objective: Calculate the overall recovery and concentrate grade.
Method:
o Perform a mass balance based on the weights and grades of the feed, concentrate,
and tailings.
Procedure:
1. Calculate the mass of the concentrate and tailings.
2. Apply the formula:
Recovery (%)=(Nickel in ConcentrateNickel in Feed)×100\text{Recovery (\%)} = \left( \
frac{\text{Nickel in Concentrate}}{\text{Nickel in Feed}} \right) \times
100Recovery (%)=(Nickel in FeedNickel in Concentrate)×100
Concentrate Grade (%)=(Nickel in ConcentrateMass of Concentrate)×100\
text{Concentrate Grade (\%)} = \left( \frac{\text{Nickel in Concentrate}}{\text{Mass of
Concentrate}} \right) \times
100Concentrate Grade (%)=(Mass of ConcentrateNickel in Concentrate)×100
Required Facilities and Equipment
[Link] Facilities:
o Flotation laboratory with necessary safety equipment.
o Sample preparation area with appropriate tools for crushing and grinding.
o Analytical lab equipped with AAS/ICP-MS and XRD/SEM.
[Link] Plant Setup:
o A pilot flotation circuit for scaling up the laboratory results.
o Facilities for handling and processing larger quantities of ore.
[Link] Equipment:
o Balances for precise measurement.
o pH control systems.
o Data acquisition system for monitoring flotation parameters.
List of References
M Gharabaghi, M Irannajad, AR Azadmehr.(2012),"Industrial & Engineering Chemistry
Research" 51 (2), 954-963.
FS Hoseinian, M Irannajad, AJ Nooshabadi.(2015),"International Journal of Mineral
Processing"143, 131-137.
."Introduction to Mineralogy" by William D. Nesse: 2000 (2nd edition, 2012)
. "Principles of Mineralogy" by William L. RobertsYear: 1996
. "Scanning Electron Microscopy: Physics of Image Formation and Microanalysis" by David B.
Williams and Colin Barry Carter: 1996 (2nd edition, 2009)
. "Mineral Processing Technology" by B. A. Wills and J. A. Finch: 2006 (7th edition)
