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Mineral Processing Techniques

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Gravity Separation

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A method that separates minerals of different specific gravities by their relative movement in response to gravity and one or more other forces, such as fluid resistance or centrifugal force.

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Comminution

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The process of reducing the size of ore particles to liberate the valuable minerals from the waste rock. It typically involves stages of crushing and grinding.

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Amalgamation

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A process used to extract precious metals by combining them with mercury. The amalgam, containing the metal, is then heated, vaporizing the mercury and leaving behind the pure metal.

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Thickening

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A process of concentration by settling; the solid density particles settle to the bottom under gravity, and water is removed from the top, resulting in a higher concentration of solids in the slurry.

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Briquetting

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A process of compressing fine particulate material into larger, more solid blocks, called briquettes. These are used for easier handling, transportation, storage, or further processing.

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Panning

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The simplest method of placer mining, used to separate heavy, valuable minerals from lighter material. Material is placed in a pan and agitated with water; due to the higher density, the valuable material (like gold) settles to the bottom.

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Screening

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A mechanical process that separates particles on the basis of size by passing them over screens or grates. Different sizes of apertures allow particles of desired size to pass and separate from larger or smaller particles.

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Refining

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The process of purifying an impure metal. It is achieved through various methods, such as electrolysis, to attain high levels of purity for industrial applications.

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Pelletizing

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A process of agglomerating iron ore fines into larger pellets which then get hardened by heating. This improves blast furnace performance in steelmaking.

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Hydrometallurgy

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A technology that uses aqueous solutions to extract metals from ores. This involves leaching, solution concentration, and metal recovery. Often used in conjunction with solvent extraction and electrowinning.

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Filtration

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A solid-liquid separation process where a slurry is pressed or pulled through a filter medium that catches solids and allows liquid to pass through.

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Electrowinning

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A process that uses electric currents to precipitate metal from a chemical solution. After solvent extraction, the metal-rich electrolyte is subject to an electric current which causes the metal to deposit onto cathodes.

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Electrostatic Separation

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A process that separates minerals by their electrical conductivity. Particles pass through an electric field and are charged; differences in electrical conductivity cause them to be attracted to or repelled from electrodes.

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Pyrometallurgy

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A process that uses high temperatures to extract and purify metals by altering their physical and chemical properties. Commonly includes roasting, smelting, and refining operations.

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Tank Leaching

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Similar to heap leaching, ore is processed within tanks or reactors. Agitation and heating may be used to enhance the reaction between the ore and leaching solution.

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Jigging

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A gravity concentration technique where material is placed in a jig bed and pulsed with water, which causes the denser material to settle faster than the less dense material.

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Elutriation

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A process for separating lighter particles from heavier ones using an upward flow of fluid (usually air or water), the differential settling speeds of the particles allows for separation.

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Dewatering

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The process of removing water from solid material or soil, often through the use of a variety of techniques such as thickeners, filters, and drying beds, to improve the handling of the solid or to prepare it for further processing.

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Heap Leaching

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A technique where crushed ore is heaped onto a leach pad and irrigated with a leach solution to dissolve the valuable metals. The solution percolates through the heap and is collected for metal recovery.

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Bioleaching

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A method of extracting metals from their ores using living organisms. Microbes metabolize the ore and release the metal, making it easier to recover.

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Solvent Extraction

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A separation technique in hydrometallurgy where solvents are used to dissolve desired metals from the aqueous solution produced during the leaching phase. The metals are then recovered from the solvent by chemical or physical means.

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Magnetic Separation

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A technique that uses magnets to segregate mineral particles based on their magnetic properties. Strong magnets pull and separate magnetic minerals from the non-magnetic gangue material.

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Smelting

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A pyrometallurgical process used to extract metals from their ores by heating beyond the melting point, often in the presence of a chemical reducing agent, to chemically reduce metal compounds to metals.

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Froth Flotation

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A process where crushed ore is mixed with water and then chemicals and air are used to create froth. Minerals attach to the bubbles and are skimmed off, separating them from waste rock.

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Roasting

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A pyrometallurgical process that involves heating ores in the presence of oxygen. It is used to remove volatile impurities or to change the chemical composition of the ore in preparation for further processing.

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