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Mineral processing, often called ore dressing, beneficiation, or mineral engineering, plays a critical role in the mining industry by extracting valuable minerals from ores while minimizing environmental impacts. This complex process involves several stages, from initial ore exploration to the final production of high-purity metals, engaging various physical and chemical methods tailored to the specific characteristics of the ore being processed.
The conversion of run-of-mine (ROM) ore into valuable concentrates and metals is a multifaceted process, starting with the liberation of minerals through crushing and grinding. Following liberation, separation techniques such as density media separation, froth flotation, and magnetic separation concentrate the valuable minerals. Learning why minerals are processed is crucial as it enables the derivation of valuable elements from their natural state in economically viable forms. Finally, hydrometallurgical or pyrometallurgical methods refine these concentrates into pure metals.
For example, the process flow diagrams in Figures 13.53 and 13.54 of the 2018 scientific study Mineral Exploration (Second Edition) highlight the progressive stages of mineral processing, from ore liberation to the production of 99.99% grade metals. Interestingly, a state-of-the-art zinc and lead smelting process is depicted in Figure 13.55, showcasing the integrated approach taken by modern smelters like Hindustan Zinc Limited’s facility in Rajasthan, India, to achieve annual outputs of 210,000 tons of zinc and 100,000 tons of lead, alongside generating significant power through captive plants.
The field of mineral processing has seen remarkable advancements in process control systems, which tackle challenges such as ore variability (defined by grindability, grade, mineralogy (textural and liberation characteristics) and surface characteristics), material transport delays, and nonlinear model predictive control (NMPC). “Why are minerals processed?” becomes relevant in light of these technological challenges and advancements because process efficiency and optimization are vital components to obtaining valuable minerals.
The development of adaptive model-based predictive controllers, such as the BrainWave system, demonstrates significant improvements in operational efficiency over traditional PID controllers or rule-based strategies, with better mineral crushing capacity. These advanced controllers are adept at managing long-time delays and complex multivariable interactions prevalent in mineral processing operations, reducing process variability and lowering operational costs.
The environmental aspects of mineral processing are increasingly coming under scrutiny. Mining and processing activities generate vast quantities of waste, according to the 2023 study Biodiversity Conservation Threatened by Global Mining Wastes, including tailings and refinery wastes that can lead to the release of acidic waters and heavy metals. However, contemporary research and technological advancements are geared toward understanding and mitigating these impacts. For example, the study and application of life cycle assessment (LCA) in the mining and mineral processing industry have provided deeper insights into the environmental footprints of these activities, paving the way for more sustainable practices.
In summary, the evolution of mineral processing techniques reflects an industry-wide shift towards efficiency, sustainability, and environmental responsibility. An example of this progress is the innovative separation technology developed by ST Equipment & Technology (STET).
Their Tribo-electrostatic Mineral Separator delivers high-rate, continuous, and completely dry mineral separation, covering various particle sizes. This technology offers advantages over traditional wet processing methods like flotation, including water-free separation, low energy consumption, high processing capacity, and minimal maintenance needs. By addressing economic and environmental concerns, STET’s mineral separator technology represents a leap forward in the mining industry’s drive toward sustainable practices.
For more information on why minerals are processed and how STET’s Tribo-electrostatic Mineral Separator can revolutionize your mineral separation processes, please contact us.
