Chemical Engineering, Waste Management and Disposal, Renewable Energy, Sustainability and the Environment, General Chemical Engineering
38
Scopus Publications
Scopus Publications
Recovery and purification of graphite from spent lithium-ion batteries through flotation and subsequent leaching Wayne Chikwane, Tirivaviri Mamvura, Gwiranai Danha, Tumeletso Lekgoba, Babatunde Obadele, Nkosilamandla Moyo Next Energy, 2026 The purpose of this research is to recover and recycle graphite from spent lithium-ion batteries through the application of flotation and acid leaching. This is to promote the circular economy in the battery manufacturing industry and reduce environmental pollution by waste lithium-ion batteries. This study investigated the effects of collector dosage, pH, and roasting time on the separation of graphite and lithium metal oxides through flotation from black mass of spent lithium-ion batteries. The work also involved the purification of recovered graphite through leaching with HCl. The best flotation conditions were found to be a roasting time of 1 h, collector dosage of 200 g/ton, and pH of 7, resulting in a froth product containing 67.3% fixed carbon (FC). The product was leached with 3 M HCl at 80 °C for 4 h. The final product contained Co, Al, and Cl at concentrations of 6.1%, 0.9%, and 0.7%, while other elements were present at concentrations less than 0.5%. X-ray Diffraction (XRD) showed existence of carbon in multiple phases, with a dominant peak at 2θ = 26.65 ° for raw froth product and 26.48 ° for leached product. Scanning Electron Microscope- Dispersive X-ray Spectroscopy (SEM-EDS) revealed that leaching resulted in a smoother material surface. Raman spectroscopy indicated that crystallinity of the recovered graphite was reduced after leaching, with D-band intensity divided by G-band intensity (ID/IG) ratio increasing to 0.51 for the leached product from 0.24 for raw froth product. The leached product had FC, ash, volatile matter, and moisture contents of 92.5%, 3.6%, 3.9% and 0.2%, respectively. • Graphite can be recovered and purified from spent LIBs through flotation. • Leached froth product contains Co and Al as major impurities. • Leaching results in graphite losing its crystallinity. • The leached froth product has a fixed carbon content of 92.45%. • The recycled graphite has carbon as 5 crystalline phases.
The significance of coal ball milling model equations in manufacturing industries G. Gaesenngwe, G. Danha, P.V.S Raghupatruni, T.A. Mamvura International Journal of Coal Preparation and Utilization, 2026 The achievable area technique helps engineers optimize milling costs by precisely identifying optimal mill configurations, which results in lower expenses. Research advancements that utilize the achievable region strategic plan and mathematical model equations, have focused on the sustainability of mineral beneficiation by lowering milling power production costs, reducing inputs such as milling time and the number of grinding media employed, minimizing material wastage, and maximizing product yield, among other aspects. This research therefore seeks to optimize coal ball milling processes using an integrated Attainable Region (AR) and Response Surface Methodology (RSM) approach. The coal sample used in this study was obtained from a mine situated in the central region area in Botswana and the AR method was used to quantify the percentage coal mass retained across four optimal class intervals of M1 (−850 µm, +425 µm), M2 (−300 µm, +150 µm), M3 (−106 µm, +80 µm) and M4 (−63 µm). Our main objective was to investigate the application of the integrated approach in reducing the energy consumed during the comminution of this local coal that has been identified for application in the country’s upcoming coal-to-fuels industry. Practically, results obtained from this work shows that Botswana coal is also economically amenable for use in different types of industries including civil engineering, construction, cement manufacturing, pyrolysis, gasification and pharmaceuticals. Our characterization of the coal feed samples revealed that the ash components displayed phases of Quartz (ϱ), Dolomite (ς), Sphalerite (φ), and kaolinite (Δ) minerals mixed with organic maceral. These mineral components greatly influence the coal’s hardness, with strong minerals like sulfides (Sphalerite) and silicates (quartz) enhancing fracture toughness. The total percentage mass retained of all tested coal samples indicated a positive correlation indicating that factors like large mass recovery, material fragmentation, and grind-ability were significantly affected by the coal particle size. type. The response surface method charts displayed the graphical depiction of the quadratic model within 3-dimensional space and illustrate the optimal parameter interactions of a ball-mill operation for run-of-mine coal samples, with the Lack of Fit F-value of 2.99. indicating that the lack of Fit is not considerable when compared to the pure error, as the likelihood of obtaining such a significant Lack of Fit F-value due to random noise is 19.91%. A non-significant lack-of-fit is favorable since we desire the model to align well.
Assessing the viability of magnetic separator tailings as a secondary source of nickel, cobalt and copper: a case study for Tati Nickel Mining Company Nkosilamandla Moyo, Boitshepo Marakalala, Tshepo Gaogane, Gwiranai Danha, Tirivaviri A. Mamvura Journal of Engineering and Applied Science, 2025 To date, the recovery of nickel and cobalt sulphide minerals from low-grade ores poses significant challenges in mineral processing due to their complex nature. With the decline of rich ore bodies, a paradigm shift to low-grade ores and secondary sources exists for these critical metals, particularly in the renewable energy sector, i.e. storage batteries. This study explores the potential consideration of the magnetic separator tailings obtained from Tati Nickel Mining Company in Botswana as a lucrative base metal secondary resource for the recovery of nickel, cobalt and copper. It becomes a dual approach to obtain valuable base metals while economically handling the waste material to ease the environmental challenges it was posing to the mine and the community. Characterisation of the samples obtained through crystallographic analysis, mineralogy and mapping, and elemental analysis showed the presence of nickel and copper minerals to a degree by which they can be economically extracted through hydrometallurgical means. Cobalt concentration in the sample was in trace amounts as it could only be detectable through the destructive technique. Concentration through froth flotation was conducted post characterisation, with emphasis on flotation time. The optimum flotation time was determined to be 3 minutes, giving metal recoveries of 15.56%, 27.40% and 52% for cobalt, nickel and copper respectively, with an enrichment ratio of 7.39 for copper. However, the yield obtained was 7.04% highlighting the ineffectiveness of the traditional concentration route previously practised in the mine. It was recommended therefore to re-design the flotation process and tailor it for the magnetic separator tailings, concentrating on the effects of pH and particle size distribution primarily, before the other factors, e.g. collectors, modifiers, etc. In conclusion, it was noted that the recovery of nickel, copper and the by-product iron was feasible; therefore, a recommendation was made to apply the Activox technology.
Pressurized torrefaction of waste biomass to improve bio coal quality: Synergistic effect between animal waste and wood chips N.M. Tshuma, L.B. Moyo, G. Danha, T.A. Mamvura, G.S. Simate, C.D. Artur, G. Charis Cleaner Chemical Engineering, 2025 This study aims to investigate the effect blending waste material to improve its fuel properties using pressurized torrefaction. This research explored the benefits of blending animal waste with wood chips to produce a bio-coal with improved fuel properties. The process conditions investigated were temperature and pressure intervals of 200°C to 280°C and atmospheric pressure (AP) to 4MPa, respectively. The results showed that an increase in temperature and pressure improved the fixed carbon content of the blend almost threefold from 19.87 % to 66.93 % and the higher heating value (HHV) to 27.32MJ/kg from 13.90MJ/kg at mild torrefaction temperature of 280°C and gas pressure of 4MPa compared to atmospheric pressure conditions and the lowest temperature investigated. The HHV increased primarily due to a release of bound and unbound moisture and volatile matter. Wood chips had an HHV of 27.00MJ/kg at a torrefaction temperature of 280°C due to the decomposition of hemicellulose and cellulose which enhanced the thermal stability, fixed carbon content and calorific value. However, animal waste had the least incremental increase in HHV (16.45MJ/kg) due to a high initial content of volatile matter and moisture. The improved properties of the blend of materials indicated that pressurized torrefaction was effective in increasing fixed carbon content through secondary polymerization reactions. Moreover, it facilitated the decomposition of cellulose at a lower temperature than the typical range of 315-400°C if conducted at atmospheric pressure. This study elucidates the notable role of the synergistic effects of blending feed materials prior to torrefaction towards improving the properties and pyrolysis performance of biomass components.
Coal-based reduction roasting and magnetic separation of low-grade Botswana iron ore for sustainable beneficiation Mompati Mpho Bulayani, Prasad Raghupatruni, Tirivaviri Mamvura, Gwiranai Danha Minerals Engineering, 2025 This study demonstrates a novel pathway to beneficiate low-grade hematite-rich iron ore (56.1 % Fe) from Botswana’s Ikongwe deposit through coal-based magnetizing roasting and low-intensity magnetic separation (LIMS). Leveraging Botswana’s underutilized resources, Morupule non-coking coal (50.01 % fixed carbon, 21.13 % ash) was utilized as a sustainable reductant. A Taguchi L9 orthogonal array systematically optimized critical parameters: roasting temperature (700–900 °C), residence time (30–90 min), and coal dosage (25–50 %). Optimal conditions (800 °C, 60 min, 50 % coal dosage) yielded a magnetic concentrate grading 68.2 % Fe at 85.7 % recovery, representing a 21.6 % relative iron upgrade. Advanced characterization (XRD, SEM-EDS) confirmed efficient phase transformation from hematite to magnetite with concurrent gangue reduction. Kinetic modelling indicated a chemically controlled reaction mechanism, with activation energies ranging from 159.1 to 160.6 kJ/mol. Thermodynamic evaluation revealed negative Gibbs free energy values (ΔG), supporting the spontaneity of the reduction reactions across the tested temperatures. This integrated approach validates the technical and economic feasibility of utilizing Botswana’s local resources to valorise low-grade iron ore, offering a viable route for Botswana to enhance its mineral-based industrialization and to reduce reliance on imported ferrous materials.
Prediction of coal ball-mil product stream cost(s) using particle size distribution data G. Gaesenngwe, G. Danha, P. V. S. Raghupatruni, T. A. Mamvura International Journal of Coal Preparation and Utilization, 2025 Particle size distribution analysis of a coal ball-mill product stream remains a major challenge for engineers who are manufacturing coal products in several coal firms, due of improper identification of optimum-retained mass yield regions. In our study, experimental data generated from ball-milling of five (5) different coal samples (the run-of-mine coal, cobble coals, nuts coals, peas coals and fine coal type) were reviewed. A new approach was employed that uses a combination of the population balance model (PBM) approach and the volumetric retained mass yield against particle size, obtained from twenty (20) laboratory trials of dry batch grinding. Moreover, the gross power required to generate adequate mass yield at desired size classes was successfully measured using the Stephen Morrell Power Law Model. The resultant estimations were then used to scale up the cost(s) of milling from laboratory to industrial scale. Based on the conclusions, the monetary inputs required for milling different coal types changed proportionally with the coal grindability and hardness of the coal material observed under each coal grade. Coal macerals are formed from fossil fuel deposits and its usage in Africa and the rest of the world is increasingly gaining traction and more than 25% of the world’s electrical power is generated from coal. Additionally, coal size reduction through milling is extremely energy intensive when targeting to process large concentrates of the product stream, hence a proper and more reliable technique that can precisely calibrate a desired particle size and particle size distribution (PSD) is a vital aspect in coal beneficiation.
Exploring Low-Grade Iron Ore Beneficiation Techniques: A Comprehensive Review Mompati Mpho Bulayani, Prasad Raghupatruni, T. Mamvura, G. Danha Minerals, 2024 The beneficiation of low-grade iron ores is a key research and development topic in the mineral processing industry. The gradual exhaustion of high-grade iron ore reserves, and rising consumer iron and steel demand globally necessitate efficient low-quality iron ore beneficiation to meet steelmaking quality requirements. This comprehensive review explores various beneficiation techniques for low-quality iron ore, focusing on conventional methods including comminution, froth flotation and gravity separation. This article discusses the principles, processes, and equipment used in these techniques and highlights recent advancements and research efforts in the field. This review also emphasizes the importance of effective beneficiation processes in enhancing economic viability, sustainable resource management, and environmental conservation. Furthermore, it presents a case study of iron ore deposits in Botswana, highlighting the potential economic growth and sustainable development that can be achieved by maximizing resource utilization through reductive roasting, followed by magnetic separation of iron ore using semi-bituminous coal as a reductant. Overall, this review provides valuable insights into low-grade iron ore beneficiation techniques and their significance in meeting the growing demand for high-quality iron and steel products.
Reclamation of iron and copper from BCL slag in Botswana T.S Gabasiane, G. Danha, T. Mashifana, T. Mamvura Heliyon, 2024 <h2>Abstract</h2> High-grade copper ores have been depleted over the years, making it a challenge in the mining industry. This investigation focused on a methodology to recover iron (Fe) and copper (Cu) from a copper/nickel slag obtained from the Bamangwato Concession Limited (BCL) mine in Botswana. In this modified flotation approach, the Response Surface Methodology (RSM) was used in conjunction with the Central Composite Design (CCD) and Analysis of Variance (ANOVA) to obtain the best optimal flotation conditions for the recovery of iron and copper. Using the RSM – CCD methodology, the optimal predicted responses were illustrated by a coefficient of determination R<sup>2</sup> = 0. 9839 for recovery for Fe and 0.9655 for recovery for Cu. The recovery of copper increased with the increasing dosage of Na<sub>2</sub>S and collector dosage, while the increase of pH, had a decrease in recovery of copper due to the decline in the stability of the froth, which led to the resistance to form stable bubbles for efficient recovery of copper. Selective flotation of copper and iron was achieved by varying the Na<sub>2</sub>S dosage to achieve maximum recovery. Under these flotation conditions of PAX (800 g/t), pH (8), −75 μm, sulfurizing agent (Na<sub>2</sub>S, 1000 g/t), flotation time of 8 min, pH regulator of NaOH and <mml:math><mml:mrow><mml:mi>H</mml:mi><mml:mn>2</mml:mn><mml:mrow><mml:mi>S</mml:mi><mml:mi>O</mml:mi></mml:mrow><mml:mn>4</mml:mn></mml:mrow></mml:math> and Methyl Isobutyl Carbinol (MIBC) from the experimental runs merited a grade upgrade of Cu in froth concentrate from 0.581 mass% to 0.884 mass%. An enrichment ratio of 2 was realised, with the recovery of Cu being 62%, whereas Fe in the froth concentrate increased from 69.8 mass% to 71.8 mass%. The main aim was to upgrade the grade and recovery of copper and iron to enhance the recovery for copper and iron in the next experimental stage of leaching.
A review of the combined torrefaction and densification technology as a source of renewable energy Thandiwe Sithole, Godwell Pahla, Tebogo Mashifana, Tirivaviri Mamvura, Elena-Niculina Dragoi, Anbalagan Saravanan, Hasan Sadeghifar Alexandria Engineering Journal, 2023 Densification techniques allow biomass to be used in the energy mix with coal or as a direct replacement for coal as it is a renewable resource. Typically, biomass is bulky, so thermochemical methods, like torrefaction, reduce volatiles and moisture, leaving a higher composition of fixed carbon. After the torrefaction process, the torrefied biomass poses problems during handling, transportation, and storage because it consists of small (<100 μm) disintegrated particles. Densification minimizes these problems through thermal compaction which produces integrated and larger (4 mm – 200 mm diameter) solid particles. This process can be done naturally (without any additives) or by adding binders which improve the torrefied biomass’s physical, chemical, mechanical, and heating properties. This in turn reduces any costs associated with handling/transportation and storage of the biomass before it is used for energy generation. Densification increases the biomass’s energy content per unit volume thereby enabling coal substitution. Recent reviews on densification have mainly focused on the binding of coal fines, raw biomass, and some torrefied biomass. Reviews on the binding theories are also available. This current review focuses solely on the aspect of torrefied biomass densification and the factors associated with the process. Insights and recommendations for the possible application of an integrated biomass torrefaction and densification process were provided herein. In addition, the gaps in literature were identified to enable future research on the application of the process to realize innovative renewable energy production in industry.