Browsing by Author "Dzingai, Mathew"

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    Probing the Effect of Water Recycling on Flotation through Anion Spiking Using a Low-Grade Cu–Ni–PGM Ore: The Effect of NO3−, SO42− and S2O32−
    (2021-03-25) Dzingai, Mathew; Manono, Malibongwe S; Corin, Kirsten C
    Water scarcity necessitates the recycling of process water within mineral processing practices. This may however come with its disadvantages for unit operations such as froth flotation as this process is water intensive and sensitive to water chemistry. It is therefore important to monitor the water chemistry of the recycle stream of process water and any other water source to flotation. Monitoring the concentrations of the anions in recycled process water is therefore important to consider as these are speculated to impact flotation performance. Batch flotation tests were conducted using synthetically prepared plant water (3 SPW) with a TDS of 3069 mg/L as the baseline experiment. 3 SPW contained 528 mg/LNO3 − and 720 mg/L SO4 2−, other anions and cations, and no S2O3 2−. Upon spiking 3 SPW with selected anions, viz, NO3 −, SO4 2− and S2O3 2−, it was noted that NO3 − and SO4 2− exhibited threshold concentrations while S2O3 2− did not show a threshold concentration for both copper and nickel grade. Spiking 3 SPW with 352 mg/L more of NO3 − to a total 880 mg/L NO3 − concentration resulted in the highest copper and nickel grade compared to 3 SPW while increasing the S2O3 2− from 60 to 78 mg/L increased nickel and copper grade. 720 to 1200 mg/L SO4 2− and 528 to 880 mg/L NO3 − were deemed the concentration boundaries within which lies the threshold concentration above which flotation performance declines with respect to metal grades, while for S2O3 2− the threshold concentration lies outside the range considered for this study. Anion distribution between the pulp and the froth did not seem to impact the recovery of copper or nickel. Notably, the correlation between the concentrate grades and anion distribution between the froth and the pulp seemed to be ion dependent.
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    Simulating the Effect of Water Recirculation on Flotation through Ion-Spiking: Effect of Ca2+ and Mg2+
    (2020-11-19) Dzingai, Mathew; Manono, Malibongwe; Corin, Kirsten
    Froth flotation is a multifaceted complex process which is water intensive. The use of recycled water as an alternative source of water to meet water demands of the process may introduce deleterious inorganic ions that affect the mineral surface, pulp chemistry, and reagent action, hence the need to establish whether threshold ion concentrations exist beyond which flotation performance will be adversely affected. This is of paramount importance in informing appropriate recycle streams and allowing simple, cost-effective water treatment methods to be applied. Here we report that increasing ionic strengths of synthetic plant water (SPW); 3, 5, and 10 SPW respectively, resulted in an increase in water recovery in the order 0.073 mol·dm−3 (3 SPW) < 0.121 mol·dm−3 (5 SPW) < 0.242 mol·dm−3 (10 SPW), indicating an increase in froth stability as higher water recoveries are linked to increased froth stabilities. This behavior is linked to the action of inorganic electrolytes on bubble coalescence which is reported in literature. There was, however, no significant effect on the valuable mineral recovery. Spiking 3 SPW to 400 mg/L Ca2+ resulted in higher copper and nickel grades compared to 3 SPW, 5 SPW, and 10 SPW and was deemed to be the Ca2+ ion threshold concentration for this study since 3 SPW spiked with further Ca2+ to a concentration of 800 mg/L resulted in a decrease in the concentrate grade. The spiking of 3 SPW with Mg2+ resulted in higher copper and nickel grades compared to all other synthetic plant water conditions tested in this study.
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    The effect of ion accumulation owing to water recycling on flotation performance
    (2019) Dzingai, Mathew; Corin, Kirsten; Manono, Malibongwe
    With the drive to reduce water usage globally, the mining sector must reassess its water usage as it has in the past contributed greatly to environmental degradation due to effluent discharge, tailing disposal and process water seepage into the water-table. Mineral beneficiation entails different unit operations; amongst them is froth flotation. Froth flotation is a multifaceted complex process which is water intensive and to manage water usage, the global mining industries are now recycling water. The recycled water may contain deleterious ions that affect the mineral surface, pulp chemistry and reagent action, hence the need to establish whether threshold concentrations exist beyond which the flotation performance will be adversely affected. This is of paramount importance in informing appropriate recycle streams and allowing simple, cost-effective water treatment methods to be applied. To better understand the influence of water recycling in flotation, a low-grade Cu-Ni-PGM sulphide ore was used. This study investigated the effects of increasing ionic strength as well as increases in specific ion concentrations to determine whether these selected ions had beneficial or deleterious effects on the flotation process. Copper and nickel were the target metals, floated as chalcopyrite and pentlandite, respectively. Their recovery and grade under different conditions was used as a measure to quantify whether a threshold ion concentration existed. The key performance indicators used were: (a) water recovery, (b) solids recovery, (c) valuable metal recovery, (d) grade of the recovered concentrates and (e) electrical conductivity. While a complex background water chemistry of 3 SPW was maintained for the spiking tests, ion spiking was intended to mimic the recycling of water and the most prevalent ions which would likely be recycled and therefore accumulated, such ions as: Ca2+, Mg2+, NO3 - , SO4 2- and S2O3 2-. These ions were chosen based on speculation from relevant literature that they might impact the flotation performance due to their influence on pulp chemistry and reagent interaction. This was achieved by conducting sequential batch flotation and electrical conductivity (EC) tests. Batch flotation tests were performed to investigate the effect of different ionic strength conditions on the overall flotation performance. The same ionic strengths and spiking concentrations were used for froth (or foam) column studies with a focus on tracking the ion concentration distribution between the froth and the slurry (or solution) by means of measuring the EC of each of the froth and the pulp (solution) phases. The differences implied whether the ions were selectively concentrated at the air-water or solids-water interphases in a 3-phase system or likewise at the v bubble surface or within the solution for a 2-phase system. This distribution of ions was linked to the other key performance indicators. Increasing ionic strength; 3, 5 and 10 SPW respectively, resulted in an increase in water recovery in the order 3 SPW < 5 SPW < 10 SPW, indicating an increase in froth stability due to inhibition of bubble coalescence at high ionic strength. There was, however, no significant effect on the valuable metal recovery. Most of the nickel was recovered in the copper circuit which was expected as on-site conditions were not maintained at the laboratory scale, no lime was added to adjust the pH in the copper circuit and an EDTA chelating agent was not included in the nickel circuit. Spiking 3 SPW with 800 ppm Ca2+ results in considerably higher water recovery per unit solids recovered compared to 3 SPW, 5 SPW, 400 ppm Ca2+, 350 ppm Mg2+, 700 ppm Mg2+. 400 ppm Ca2+ resulted in the highest copper and nickel grade and was deemed the threshold for this study while for Mg2+ threshold lies outside of the range considered for this study. 10 SPW shows a decrease in the copper and nickel grade while the copper and nickel recoveries were not significantly impacted. The presence of the Ca2+ and Mg2+ at high concentrations leads to gangue activation which as a consequence will result in decreased grade. 880 ppm NO3 - gave the highest copper and nickel grade compared to 3 SPW while increasing the S2O3 2- from 60 to 78 ppm resulted in an increase in nickel grade. 1200 ppm SO4 2- and 880 ppm NO3 - were deemed the threshold concentration for these anions, above which the flotation performance declines, while for S2O3 2- the threshold lay outside the range considered for this study. This study has shown that the accumulation of ions within plant water, owing to recycling, is, in general, beneficial to flotation. This study has also shown that there is a concentration for each ion beyond which it is no longer beneficial to flotation. While this finding is clearly ore and ion dependent, it gives an indication as to the need for water treatment and considering the threshold concentrations found, may direct operations to suitable treatment methods for their systems.