Mineral processing is influenced by a variety of factors that control the efficiency, cost, and environmental impact of extracting valuable minerals from ores. These factors can be broadly categorized into ore characteristics, process parameters, equipment selection, and external influences. Below is a detailed breakdown:
1. Ore Characteristics (Feed Properties)
– Mineralogy: Composition, liberation size, and association of valuable minerals with gangue.
– Grade: Concentration of the valuable mineral in the ore (higher grade = easier processing).
– Particle Size Distribution: Affects crushing, grinding, and separation efficiency.
– Hardness & Abrasiveness: Influences energy consumption in comminution (crushing/grinding).
– Moisture Content: Affects handling, screening, and drying requirements.
– Chemical Reactivity: Determines suitability for chemical processes like leaching or flotation.
2. Process Parameters
– Comminution (Crushing & Grinding):
– Energy input (kW·h/tonne)
– Feed size vs. product size (P80)
– Grinding media type & mill speed
– Separation Techniques:
– Physical Methods (Density, Magnetic, Electrostatic separation)
– Froth Flotation (pH, reagent type, aeration rate)
– Gravity Separation (Jigs, spirals, shaking tables)
– Leaching (Cyanidation, heap leaching – depends on mineral solubility)
– Recovery & Grade T
e-off: Higher recovery may reduce concentrate grade and vice versa.
3. Equipment Selection
– Crushers (Jaw, Cone, Impact)
– Mills (Ball Mill, SAG Mill, Rod Mill)
– Separators (Flotation Cells, Magnetic Separators, Dense Media Cyclones)
– Dewatering Equipment (Thickeners, Filters, Centrifuges)
4. Economic & Environmental Factors
– Energy Costs (~50% of processing cost comes from comminution).
– Water Availability & Recycling (Closed-loop systems reduce consumption).
– Tailings Management (Disposal methods affect environmental compliance).
– Regulatory Constraints (Emissions, effluents, workplace safety).
5. Technological & Operational Factors
– Automation & AI-based process optimization.
– Maintenance &