mineralsprocessing

Minerals processing, also known as ore dressing or mineral processing, is the practice of separating valuable minerals from gangue to produce concentrates or refined metals. The aim is to liberate target minerals from the surrounding rock and to separate them from unwanted material using physical and, where appropriate, chemical methods. The workflow typically spans from mine to market and may include crushing, grinding, size classification, concentration, dewatering, and drying.

The initial stage, liberation, relies on size reduction through crushing and grinding to expose mineral grains. This is followed by classification, which sorts particles by size using screens, hydrocyclones, or other classifiers. Efficient liberation and appropriate particle size are critical for downstream separation.

Separation and concentration rely on differences in physical properties. Common methods include gravity concentration (jigs, spirals, shaking tables), magnetic and electrostatic separation, and flotation, the dominant technique for many sulfide and some oxide ores. Hydrometallurgical processes, such as leaching, are used for certain oxide or highly disseminated ores. The choice of method depends on ore mineralogy, grade, and economic considerations.

Dewatering and drying prepare concentrates for smelters or refineries and generate tailings and process water streams. Equipment used includes thickeners, filters, centrifuges, and dryers. Environmental and safety considerations are integral, with attention to water management, energy use, tailings storage, and handling of reagents.

Advances in minerals processing focus on higher recovery, energy efficiency, automation, and sustainable practices, while maintaining product quality and economic viability.