When to choose gravity vs. flotation separation for scheelite processing?

2025-10-13

Choosing between gravity separation and flotation separation for scheelite (tungsten ore) processing depends on the characteristics of the ore, the mineral composition, the particle size distribution, operational costs, and specific user requirements. Here are some key criteria to help determine when to use gravity or flotation separation:

1. Utengenezaji wa Mvuto

Gravity separation is generally preferred when the ore is coarse-grained and has a significant difference in specific gravity between scheelite and gangue materials. This method is often used as a primary separation technique for simple scheelite ores.

Choose Gravity Separation When:

• Ore Grain Size: The scheelite mineral grains are relatively coarse (typically >0.037 mm) and liberation occurs at a coarse size.
• Density Contrast: There is a significant difference in specific gravity between scheelite (specific gravity ~6.1) and gangue materials (e.g., quartz with ~2.65).
• Low Impurities: The ore contains relatively pure scheelite and limited complex impurities or slimes.
• Economy and Simplicity: Gravity separation is cost-effective, energy-efficient, and does not require extensive chemical usage.
• Masuala ya Mazingira: There is a need to minimize chemical use in environmentally sensitive areas.
• Simple Ore Composition: The ore does not contain a significant amount of fine-grained, disseminated scheelite or reactive impurities (e.g., sulfides).

2. Flotation Separation

Flotation separation is typically employed for fine-grained or complex scheelite ores where gravity separation alone is insufficient to achieve a high recovery rate or concentrate grade. Fine and low-density particles often require flotation for efficient separation.

Choose Flotation Separation When:

• Fine Grain Size: Scheelite is finely disseminated, with particle sizes often <0.037 mm, making gravity separation impractical.
• Complex Ore Composition: The ore contains gangue minerals of similar density to scheelite (e.g., calcite, fluorite) or other impurities that require selective chemical separation.
• Higher Purity Requirement: A higher-grade concentrate is needed, and flotation can selectively collect scheelite while suppressing gangue minerals.
• Slime Issues: The ore has high amounts of slimes or clay that reduce the efficiency of gravity processes.
• Multiple Tungsten Minerals: The ore contains wolframite or other tungsten minerals that require different treatment processes.
• Economic Justification: Higher operational costs of flotation (due to reagents and more complex processes) are justified by better recovery rates and concentrate purity.

Combination of Both Methods

In some cases, a combination of gravity and flotation is the most effective approach:

• Gravity Pre-Concentration + Flotation: Employ gravity separation as a pre-concentration step to remove coarse gangue and increase the scheelite concentration, followed by flotation to enrich finer scheelite particles.
• Fine-Grained Tailings Recovery: Use flotation to recover fine scheelite from gravity separation tailings, minimizing losses.

Final Decision Considerations

A detailed laboratory-scale test and mineralogical study of the ore are crucial before deciding on the processing method. Key factors to assess include:

• Scheelite liberation size.
• The nature of the gangue minerals.
• Operating costs and sustainability objectives.
• Desired concentrate grade and recovery rate.

By considering these factors, you can determine whether gravity separation, flotation, or a hybrid approach is appropriate for your scheelite processing.

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