Mineral Processing
Amirmohammad Nasrollahzadeh bafti; Laya Shakib Mehr; Esmaeel Darezereshki; Mohsen Akhoundi parizi; Hossein pour Shahnazari
Abstract
Copper smelting slag (CSS) represents a significant secondary resource containing valuable metals such as copper and molybdenum. However, its complex mineralogy and the glassy nature of the slag limit the efficiency of conventional flotation processes and require high reagent consumption. In this study, ...
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Copper smelting slag (CSS) represents a significant secondary resource containing valuable metals such as copper and molybdenum. However, its complex mineralogy and the glassy nature of the slag limit the efficiency of conventional flotation processes and require high reagent consumption. In this study, a native halophilic bacterium, Halomonas lutescens, was investigated as an eco-friendly bio-reagent to improve the flotation performance of CSS. Laboratory-scale experiments were conducted under controlled conditions to determine the optimal bacterial dosage, evaluate reusability, and analyze kinetic behavior. The results demonstrated that adding 40 mL of bacterial suspension (conditioned for 5 min) significantly enhanced copper and molybdenum recoveries compared to chemical flotation. Based on previous research on the adhesion of halophilic bacteria, supportive FTIR, SEM–EDS, and adhesion schematic analyses indicate that hydroxyl, carboxyl, and amine groups in bacterial EPS can coordinate with Cu²⁺/Fe³⁺ surface sites, thereby enhancing mineral hydrophobicity and improving Cu–Mo recoveries. Total copper recovery increased from 58.98% to 71.11%, and molybdenum recovery rose markedly from 4.50% to 28.51%, while maintaining similar concentrate grades. Kinetic modeling revealed higher rate constants and better fitting with bacterial presence, confirming enhanced flotation kinetics. Moreover, bacteria remained viable and reusable over multiple flotation cycles, indicating strong potential for process sustainability. Overall, H. lutescens acts as a bio-frother and collector aid, enabling more efficient and environmentally friendly flotation of copper smelting slag.
A. Hasanzadeh_Sablouei; Seyed M. Moosavirad
Abstract
The electrocoagulation/flotation process is a novel approach in mining industry that is implemented to return Cu metal to the production cycle, which improves copper recovery and reduces waste water. In this research work, the response surface methodology was applied to optimize the factors effective ...
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The electrocoagulation/flotation process is a novel approach in mining industry that is implemented to return Cu metal to the production cycle, which improves copper recovery and reduces waste water. In this research work, the response surface methodology was applied to optimize the factors effective in Cu metal recovery and sludge volume produced from thickener overflow. To this end, the D-optimal experimental design was utilized. The influences of four independent parameters including the electrolysis time, initial pH, current density, and electrodes type were studied to investigate the initial Cu grade percentage (28%) and sludge volume produced from thickener overflow. All these parameters were found to have important effects on the Cu metal recovery and the sludge volume produced. The linear and quadratic models were utilized for the Cu grade and sludge volume, respectively. The importance of the independent variables and the interaction between them was assessed by ANOVA. The optimum operating conditions with 27.22% Cu grade were taken to be: electrolysis time: 6.5 min, initial pH: 6.7, current density: 50.2 A/m2, and electrode type: Fe-Al. Similarly, for the produced sludge volume of 861 cm3, the following conditions were found: electrolysis time: 15 min, initial pH: 4.1, current density: 48.7, and electrode type: Fe-Al. The outcomes underscored a practical viewpoint of electrocoagulation, known as an acceptable method for Cu recovery from mine industrials, especially in mineral processing plants.
