Recovery mineral separation

Foams, in the form of froths, are intimately involved and critical to the success of many mineral-separation processes (Chapter 10). Foams may also be applied or encountered at all stages in the petroleum recovery and processing industry (oil-well drilling, reservoir injection, oil-well production and process-plant foams). A class of enhanced oil recovery process involves injecting a gas in the form of a foam. Suitable foams can be formulated for injection with air/nitrogen, natural gas, carbon dioxide, or steam [3,5]. In a thermal process, when a steam foam contacts residual crude oil, there is a tendency to condense and create W/O emulsions. Or, in a non-thermal process, the foam may emulsify the oil itself (now as an O/W emulsion) which is then drawn up into the foam structure the oil droplets eventually penetrate the lamella surfaces, destroying the foam [3], See Chapter 11. 

Miranda and Berglund [79] used a food grade polymer, (hydroxypropyl)methyl cellulose (HPMC), and ammonium sulfate as additives for the recovery of recombinant a-amylase by flotation. The enzyme was removed from the liquid phase by partition to a salted-out HPMC phase and the enzyme-containing polymer floes were recovered by flotation. This system behaved in a manner similar to the flotation of mineral systems. The problem with this technique is the cost of the polymer and the separation of the enzyme from the polymer phase. Both of them complicate the process and increase the separation cost In general, for protein recovery and separation, especially in the pharmaceutical industry, it is not proper to add chemicals to the feed, because they have to be removed from the product completely and this separation causes problems and additive costs. 

Foams, in the form of froths, are intimately involved and critical to the success of many mineral separation processes (Chapter 10). Foams may also be applied or encountered at all stages in the petroleum recovery and processing industry (oil well drilling, reservoir injection, oil well production and process plant foams). 

On the above basis the energy required for the recovery of secondary lead is of the order of 3 5 per cent of the energy required for primary lead production from sulfide concentrates. If the energy required for mining, mineral separation and supply of lead concentrates to the primary smelters is considered, the total energy for secondary lead recovery is less than 25 per cent of the total for primary lead. 

Flotation or froth flotation is a physicochemical property-based separation process. It is widely utilised in the area of mineral processing also known as ore dressing and mineral beneftciation for mineral concentration. In addition to the mining and metallurgical industries, flotation also finds appHcations in sewage treatment, water purification, bitumen recovery from tar sands, and coal desulfurization. Nearly one biUion tons of ore are treated by this process aimuaHy in the world. Phosphate rock, precious metals, lead, zinc, copper, molybdenum, and tin-containing ores as well as coal are treated routinely by this process some flotation plants treat 200,000 tons of ore per day (see Mineral recovery and processing). Various aspects of flotation theory and practice have been treated in books and reviews (1 9). 

Minerals and Metals. HCl is consumed in many mining operations for ore treatment, extraction, separation, purification, and water treatment (see Mineral recovery and processing). Significant quantities are also used in the recovery ofmolybdenum (see Molybdenum and molybdenum alloys) and gold (see Gold and gold compounds). This market consumed about 36 thousand metric tons in 1993. 

Sulfide collectors ia geaeral show Htfle affinity for nonsulfide minerals, thus separation of one sulfide from another becomes the main issue. The nonsulfide collectors are in general less selective and this is accentuated by the large similarities in surface properties between the various nonsulfide minerals (42). Some examples of sulfide flotation are copper sulfides flotation from siUceous gangue sequential flotation of sulfides of copper, lead, and zinc from complex and massive sulfide ores and flotation recovery of extremely small (a few ppm) amounts of precious metals. Examples of nonsulfide flotation include separation of sylvite, KCl, from haUte, NaCl, which are two soluble minerals having similar properties selective flocculation—flotation separation of iron oxides from siUca separation of feldspar from siUca, siUcates, and oxides phosphate rock separation from siUca and carbonates and coal flotation. 

The aqueous sodium naphthenate phase is decanted from the hydrocarbon phase and treated with acid to regenerate the cmde naphthenic acids. Sulfuric acid is used almost exclusively, for economic reasons. The wet cmde naphthenic acid phase separates and is decanted from the sodium sulfate brine. The volume of sodium sulfate brine produced from dilute sodium naphthenate solutions is significant, on the order of 10 L per L of cmde naphthenic acid. The brine contains some phenolic compounds and must be treated or disposed of in an environmentally sound manner. Sodium phenolates can be selectively neutralized using carbon dioxide and recovered before the sodium naphthenate is finally acidified with mineral acid (29). Recovery of naphthenic acid from aqueous sodium naphthenate solutions using ion-exchange resins has also been reported (30). 

The treatments used to recover nickel from its sulfide and lateritic ores differ considerably because of the differing physical characteristics of the two ore types. The sulfide ores, in which the nickel, iron, and copper occur in a physical mixture as distinct minerals, are amenable to initial concentration by mechanical methods, eg, flotation (qv) and magnetic separation (see SEPARATION,MAGNETIC). The lateritic ores are not susceptible to these physical processes of beneficiation, and chemical means must be used to extract the nickel. The nickel concentration processes that have been developed are not as effective for the lateritic ores as for the sulfide ores (see also Metallurgy, extractive Minerals recovery and processing). 

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