August 7, 2024

The Purpose of Mineral Processing and Modern Applications

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  • The Purpose of Mineral Processing and Modern Applications

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.

Why Are Minerals Processed?

  • Mineral processing isolates valuable minerals (calcium carbonate, limestone, barite, etc.) from waste rock to allow the extraction of precious metals or other valuable elements. This differentiates from mineral separation, which changes the physical properties of the ore to prepare it for further processing stages.
  • It improves the quality of raw materials for better suitability in industrial applications like manufacturing and construction.
  • By creating purer forms of ore, mineral processing substantially lowers the volume of waste, reducing mining’s environmental footprint.
  • Converting ores into concentrates increases the value of mined materials, making operations more economically sustainable.
  • This process also allows valuable elements to be recovered from recycled materials, supporting the circular economy.

Understanding the relationship between extraction and refinement is essential in mining and mineral processing, as both stages work together to improve resource recovery while reducing unnecessary waste.

From Ore to High-Purity Metals

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.

Advances in Process Control Systems

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.

Modern mineral processing technology uses improved automation, monitoring systems, and data-driven controls to help operators manage complex processing conditions. These advancements support better consistency, improved recovery rates, and more efficient use of resources across processing operations.

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.

Environmental Geochemistry and Sustainability

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 mineral processing industry have provided deeper insights into the environmental footprints of these activities, paving the way for more sustainable practices.

Leveraging Advanced Mineral Processing and Separation Technology

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.

Frequently Asked Questions

What technologies are used in modern mineral processing?

Modern mineral processing uses technologies such as automated process control, sensor-based sorting, flotation systems, magnetic separation, digital monitoring, and advanced data analytics. These tools help improve mineral recovery, reduce waste, optimize energy use, and maintain consistent processing performance.

What is the difference between mining and mineral processing?

Mining focuses on extracting raw materials from the earth, while mineral processing focuses on separating and refining valuable minerals from extracted ores. Processing improves mineral quality, removes unwanted materials, and prepares concentrates for further use or metal production.

What factors affect mineral processing efficiency?

Mineral processing efficiency depends on factors such as ore characteristics, mineral composition, particle size, equipment performance, energy consumption, water availability, and process control accuracy. Proper optimization of these factors helps improve recovery rates while reducing operational challenges and waste generation.

What equipment is used in a mineral processing plant?

A mineral processing plant may use equipment including crushers, grinding mills, screens, classifiers, flotation cells, magnetic separators, and material handling systems. The specific equipment depends on the type of ore, processing method, and desired final mineral product.

Fly Ash

Minerals

Animal Feed

Human Food

Jose Rivera Ortiz

Jose Rivera Ortiz

Production and Development Manager

Jose Rivera-Ortiz joined the company in 2004 as a Manufacturing Mechanical Technician. Over the years he took on many roles and responsibilities in the research and development and service and engineering departments. Jose is now the Manager of Production and Development as well as the Field Service Manager, and is responsible for manufacturing and production, field service, and product development. He holds many patents for STET belt development and equipment upgrades. Previous to joining STET Jose lived in Puerto Rico and worked as a chemical technician.
Lewis Baker

Lewis Baker

Service Manager

Lewis Baker provides engineering support to STET's fleet of processing plants throughout Europe and Asia and handles technical aspects of business development. He joined ST in 2004, initially as Plant Manager for STET's fly ash processing facility at Didcot Power Station in the UK, before moving to a broader role in technical support. After graduating from the University of Wales with a master’s degree in chemical engineering, Lewis held a number of roles in plant design and commissioning, process engineering, and plant management.
Kamal Ghazi

Kamal Ghazi

Senior Project Manager

Kamal Ghazi is a Project Manager with experience in mineral processing and industrial project implementation. He also collaborates closely with clients to ensure the successful integration of the STET Separator into their operations. Kamal joined STET in July 2015 as a Process Engineer and participated in designing and establishing the first-ever landfilled fly ash processing plant for Titan America in 2020. A mineral engineer by education, he earned a master’s degree from Tehran University and a bachelor’s degree from Kerman University.

Scott Mechler

Scott Mechler

Senior Mechanical Engineer

Scott Mechler is responsible for mechanical design work on STET’s electrostatic separator machines, focused primarily on research and development of new generations of separators. He joined the company in 2024 after a decade of experience in designing large high-tech industrial equipment in highly regulated design environments. Scott received a bachelor’s degree in mechanical engineering, with a minor in biomechanical engineering, from Northeastern University.

Traci Geer

Traci Geer

Office Manager

Traci Geer is responsible for the daily operations of the STET office, facility management, marketing, special events, and safety. She also provides support to the leadership team, staff, and human resources. She joined the company in 2017 after having worked as an executive assistant to the Superintendent of a virtual public school. Earlier, she spent a decade as an IT system analyst. Traci earned a bachelor’s degree in computer information systems and an associate’s degree in management from Bentley University.
Tim Choi

Tim Choi

Electrical and Controls Engineering Manager

Tim Choi is the Electrical and Controls Engineering Manager at STET. He joined the company in 2017 as a Senior Electrical and Controls Engineer. Since then, he has contributed to developing control systems for separators, commissioning various balance of plant systems, and working on equipment development at the Needham facility. Tim has been in a managerial role since 2021. He holds a bachelor’s degree in electrical engineering from Hanyang University in Korea and a master’s degree in electrical engineering from the University of Texas at Arlington.

Richard Lane

Richard Lane

Pilot Plant and Laboratory Technician

Richard Lane, who has been with STET for more than 13 years, is responsible for analyzing daily pilot plant run samples in the lab. He also helps prepare, mill, condition, and organize samples to be run in the pilot plant. After so many years working with STET technology in the pilot plant, Rich has gained an intimate knowledge of the machines along with vast experience with the separation processes. He received an associate’s degree in applied science from Massasoit.
Kristin Cappello

Kristin Cappello

Operations Manager

Kristin Cappello joined the company in 2014 as a Purchasing and Accounting manager, added Materials Manager to her role, and became the Operations Manager in 2022. She is responsible for supply chain management, inventory and purchasing, customer relations, and operation planning. Previous to 2014, Kristin worked as an Office Manager and Executive Assistant in a corporate/family law firm and as a part-time Real Estate Agent. She received her bachelor’s degree in political science/pre-law from Northeastern University.

Kelsie Garretson

Kelsie Garretson

Lead Chemist

Kelsie Garretson is responsible for the daily operations of the STET lab, including testing, instrument maintenance and upkeep, and data collection. Some of the instruments she manages include protein analyzers, near-infrared (NIR) spectrometers, and X-ray fluorescent (XFR) analyzers.

She joined STET in 2021 after graduating from Boston University with a bachelor’s degree in earth and environmental science, with a minor in marine science. She is currently pursuing a master’s degree in natural resources and environmental science from the University of Illinois at Urbana-Champaign.

Tom Newman

Tom Newman

Process Engineer

Tom Newman joined STET in 2022, handling the day-to-day operation of minerals testing. He designs experiments, analyzes data, optimizes results, and writes reports to provide insights to customers. Tom often travels with STET’s containerized unit to provide on-site support for mineral enrichment projects. He also works on research and development projects to find new ways to improve and understand the triboelectrostatic process. He received a bachelor’s degree in chemical engineering from the University of Pittsburgh. As part of his role at STET, he attends conferences to share his research findings with peers in the mineral processing industry.
Natsuki

Natsuki Barber

Senior Food Technologist

Natsuki Barber is responsible for human food and animal feed customer projects as well as R&D in those areas, especially managing research collaboration. Before joining STET in 2019, Natsuki worked as a food scientist with the Northern Crop Institute, where she developed deep understanding of crop physiology, functionality, application, processing, and nutrition. She worked especially closely with the development and application of plant protein ingredients.. She holds a bachelor’s degree in food science and a master’s degree in cereal science, both from North Dakota State University.
Abhishek Gupta

Abhishek Gupta

Director of Process Engineering

Abhishek Gupta leads bench and pilot-scale test programs to develop novel applications of STET electrostatic separation technology. He also manages auxiliary equipment selection, process design, separator installation, and optimization for commercialized applications. Abhishek joined STET in 2014 as a process engineer. Before that, he worked at QD Vision, a nanotechnology company working with semiconductor crystals called Quantum Dots, to develop display and lighting products. He is a chemical engineer by education with a bachelor’s degree in chemical engineering from the Indian Institute of Technology (IIT) and a master’s degree in chemical engineering from Penn State University.

Tomasz Wolak

Tomasz Wolak

Director, Business Development

 Tomasz Wolak is working to introduce STET technology for animal feed and human food industries outside the United States and for fly ash and minerals industries in Europe. Tomasz originally joined STET in 2019 as a Business Development Manager for Europe, focusing on human food and animal feed applications. He has worked in the food and feed industries in both engineering and operational roles, gaining insight on design, engineering, and manufacturing as well as operating and optimizing processing plants. Tomasz earned a master’s degree in mechanical engineering from the University of Science and Technology in Cracov and an executive MBA from Apsley Business School in London, and he participated in an advanced management and leadership program at Rotterdam School of Management.

Kyle Flynn

Kyle Flynn

Director, Business Development
Kyle Flynn is responsible for STET business activities in North America, as well as providing technical support to business development activities worldwide. He joined STET in 2008 as a member of the process engineering group. He has worked closely with customers and the pilot plant to develop projects worldwide for the processing of food and feed materials, industrial minerals, and fly ash using the patented dry STET technology. Kyle has assisted in commissioning multiple industrial mineral and fly ash separators, as well as research and development, process design and process optimization. Beginning in 2018, Kyle joined the business development team. Kyle received a bachelor’s degree in chemical engineering from Worcester Polytechnic Institute (WPI) and a master’s degree in chemical engineering from North Carolina State University.
Herve Guicherd

Hervé Guicherd

Vice President, Business Development

Since 2018, Hervé Guicherd has served as Vice President of Business Development for STET, responsible for building, animating, and supporting the business development team. He has assumed many roles during his more than quarter century with the company, including International Business Development Director in charge of introducing STET products in new applications (e.g., mining) and new territories outside the Americas (e.g., India, East Asia); European Business Development Manager (based in Greece); and positions in supply chain and marketing. After an early career as a Navy Officer, Hervé held several positions in marketing and sales during his long involvement with technology-related companies. He received a business degree from the University of Bordeaux; a master’s degree in electrical engineering from the Institute Polytechnique of Bordeaux; and an MBA from the Darden Graduate School of Business at the University of Virginia.

Lou Comis

Lou Comis

Controller
Lou Comis has been responsible for all aspects of financial analysis for STET since joining the company in 2017. Previously, Lou held controller positions at Siemens Medical, for the PLM R&D division, and at Draeger Medical. Immediately before joining STET he was a consultant working with companies migrating from Oracle’s Enterprise to Hyperion Financial Management. He began his career as a financial analyst and finance manager for companies including WR Grace, Polaroid, and Siemens Healthcare. Lou earned an MBA with a concentration in finance from Bentley University’s Elkin B. McCallum Graduate School of Business.
David Schaefer

David Schaefer

Vice President of Engineering and Manufacturing
David Schaefer is responsible for the manufacturing division and the design and build of STET’s patented electrostatic separation equipment. He works closely with the company’s commercial and processing teams to enhance STET’s customer experience and help drive innovation. David has more than 30 years of engineering and manufacturing leadership experience in technology and product development in everything from multifunction printers to self-driving vehicle technology. Additionally, he has consulted for several startup operations and founded an energy technology development company, eWindSolutions. Earlier in his career, he was director of mechanical engineering and chief new product architect at Xerox and a staff engineer in product development at IBM. His deep experience with innovation-driven technology and leading end-to-end engineering programs helps drive the entrepreneurial spirit of STET. David earned a bachelor’s degree in mechanical engineering from Rochester Institute of Technology. He holds multiple patents in the areas of product performance improvement, cost reductions, and usability improvements
Frank Hrach

Frank Hrach

Chief Technology Officer
As Chief Technology Officer for STET, Frank Hrach is responsible for STET process technology development for fly ash and industrial minerals, and design, construction, and commissioning of new processing facilities. He joined STET in 1995, bringing over 25 years of experience in research & development, design & construction, and operation of specialty chemical, material handling, and high temperature combustion processes. Before becoming CTO, he served as Director of Process Engineering. Frank received a bachelor’s degree in chemical engineering and a master’s degree in chemical engineering practice from the Massachusetts Institute of Technology.
Tom Cerullo

Tom Cerullo

President
“Leading a unique mix of technology and business development individuals, my job is to help customers gain more value from their processes and products. Notably, our niche is to create value from waste and by-product streams. Sustainability is in our DNA, viewing near-zero waste as a reality within our reach. “While our separation technology is recognized for delivering products of high value in cement, minerals, and protein for humans and animals, entering new markets requires addressing the needs of many stakeholders and achieving buy-in from private and public organizations. This demands a comfort level with the big picture and opening minds to new endeavors. Projects take vision and commitment to bring to fruition, and that’s why our staying power, backed by Titan Cement, an international cement and technology leader, is necessary for continuous success.” Tom Cerullo’s leadership roles at STET began in operations, sales, and business development. At the start of his career, he managed STET’s early commercial installations, the first of which was commissioned in 1995. He has helped drive the growth and evolution of the business from startup to the viable commercial business it is today. Tom is a graduate of the Massachusetts Maritime Academy, which provides a unique education for professionals entering the merchant marine, the military services, and the global marketplace. Before joining STET, he spent more than 4 ½ years as a marine engineer with Military Sealift Command. Adds Tom, “A rigorous academic program, combined with a regimented lifestyle at a young age, gave me a foundation for taking responsibility, having the discipline to endure long-term challenges, and persevering  through complex challenges.”