Varying Pyrite Feed Grade on Flotation Performance in Degrading Water Quality: Effects on Froth Stability and Gangue Management Mahlogonolo Nkadimeng, Malibongwe S. Manono, Kirsten C. Corin Minerals Engineering, 2026 • Varying pyrite feed grade and water quality studied simultaneously in flotation. • Higher feed grade and ionic strength of process water increased froth stability. • Depressant dosage improved pyrite grades by reducing non-floating gangue recovery. • No clear effect of feed grade or water quality on Fe recovery. • Developed relationships linking feed grade, water quality, and flotation performance. Flotation systems are complex, multifaceted and water intensive. Process operators are becoming increasingly aware that detrimental process water quality and variations in ore mineralogy can affect the overall process efficiency. The depletion of ore feed grades with respect to valuable minerals further complicates the concentration of ores through froth flotation. Although evidently critical, ore feed grade and water quality are in most cases not controlled, thereby rarely investigated together as varying parameters. This study seeks to develop an understanding into the effects of varying ore feed grade on gangue recoveries, froth stability and flotation performance under different water qualities. Batch flotation results showed solids and water recovered increased with feed grade all depressant dosages and ionic strength of plant water. Higher feed grades and ionic strengths generally resulted in the most stable froth as indicated by solids and water recoveries. The Fe recoveries were within a similar range of ∼80 to 94 % for all feed grades suggesting that there was not much influence on Fe recoveries either the feed grade, ionic strength of plant water or depressant dosage was varied. Increasing the feed grade led to an increase in Fe grades at all depressant dosages and synthetic plant water types. The highest Fe grade was about ∼27 % for 3 % pyrite feed < 34 % for 6 % pyrite feed grade < 35 % for 12 % pyrite feed. Furthermore, this increase was not directly proportional to the hydrophobic component. Finally, Fe grades increased in conjunction with depressant dosage at each pyrite feed grade for all synthetic plant water types, owing to the reduction in NFG reporting to the concentrate, which dilutes the grade. Overall, flotation performance was enhanced as measured by the solids and water recoveries, froth stability and grade.
Calcium and sulfate Ions on flotation performance of a Cu-Ni-PGM ore in the presence of anionic polyacrylamide and carboxymethyl cellulose Thabang O. Shamukuni, Malibongwe S. Manono, Lisa L. October, Kirsten C. Corin Minerals Engineering, 2025 • Higher solids recoveries were achieved in 100 g/t PAM compared to 100 g/t CMC. • Cu recoveries were unaffected by changes in [Ca 2+ ] or [SO 4 2− ], CMC or PAM. • Ni recoveries were higher in the presence of 100 g/t PAM. • Cu and Ni grades were the lowest in the presence of 100 g/t PAM compared to 100 g/t CMC. • The settling rate decreased with increasing [Ca 2+ ] and increased with increasing [SO 4 2− ]. The concentration of PGM ores through froth flotation is a water-intensive process, and with increasing global concerns about water scarcity, recycling process water in mineral processing plants has become essential. However, recycled water often contains deleterious ions and residual reagents that may alter mineral surfaces, pulp chemistry, and reagent action, impacting flotation performance and tailings dewatering. This study investigates the effects of calcium (Ca 2+ ) and sulfate (SO 4 2− ) ions on flotation performance and tailings dewatering in the presence of CMC and PAM, using a Cu-Ni-PGM ore from the Merensky reef. Batch flotation tests showed that solids and water recoveries increased and then decreased with higher Ca 2+ concentrations in the presence of CMC. PAM, however, resulted in steady water recoveries and slightly decreased solids recoveries with Ca 2+ spiking, suggesting PAM’s action overrides ionic effects. SO 4 2− spiking slightly increased water and solids recoveries with CMC, while with PAM, it showed minimal influence on water recovery but a slight decrease in solids recovery. Tailings settling rates decreased with higher Ca 2+ concentrations for PAM but increased initially for CMC before decreasing. SO 4 2− spiking improved settling rates for both polymers, this is attributed to induced coagulation of naturally floatable gangue. Overall, tailings settled faster with PAM than with CMC.
The influence of grinding media and water chemistry on the closed-water flotation of single-mineral sulfide ores Sancho N. Nyoni, Cyril T. O’Connor, Zhiyong Gao, Shihong Xu, Kirsten C. Corin Minerals Engineering, 2025 • Residual SIBX and Eh tests could not independently indicate the expected flotation performance. • High-pH galena flotation achieved high Pb recoveries but low grades due to high water recoveries. • High-pH FS milling significantly reduced Fe recovery while achieving high Pb recoveries. • In a mixed-mineral case, high-pH FS milling most effectively achieves galena-pyrite separation. • High-ionic-strength water, which mimics recycling, had no major impact on process performance. The milling stage prior to flotation plays a significant role in determining the chemical characteristics of the pulp phase in mineral processing, in which the grinding media and nature of the process water play a key role. This study analysed the effects of using low or high-ionic-strength water and either forged steel or inert ceramic media. Pure sulfide minerals, viz., pyrite (FeS 2 ) and galena (PbS), were used, in which the former may also contribute, together with the forged steel media, to the presence of Fe ions in the mill pulp. Electrochemical effects were determined at controlled pHs 4 and 10 by measuring the mixed potential, Eh. Moreover, the dissolved Fe and Pb concentrations at the end of the milling process were measured. When pyrite was used, xanthate consumption during flotation showed some correlation with Eh and flotation results. In the case of galena, the xanthate collector rapidly complexes with Pb ions dissolved into the pulp phase. The findings showed that the optimal conditions for the effectiveness of the xanthate collector occurred when using inert ceramic media at low pH. However, using forged steel media at alkaline pHs proved advantageous in separating galena from pyrite in a mixed/complex ore. Using high ionic strength process water with forged steel media at high pH yielded the highest grades of pyrite and the lowest of galena. This correlated with the solids recovery results. In the case of galena, an alkaline pH improved Pb recovery but also resulted in significant froth overstabilisation − as indicated by the water recoveries −, hence the reduced grades. X-ray photoelectron spectroscopy (XPS) was used in order to attempt to elucidate the experimental findings. This research indicates that using recycled water under specific conditions did not negatively affect the flotation performance of either mineral. Different grinding media played a more significant role in that regard.
The impact of milling media and chemical conditions in the milling process for the flotation of a mixed-sulfide ore Sancho N. Nyoni, Cyril T. O’Connor, Kirsten C. Corin Minerals Engineering, 2025 • Gn and Py galvanic contact significantly affected Pb dissolution across all studied conditions. • Iron (Fe) from FS milling media is more susceptible to oxidative dissolution than pyritic Fe. • Milling media and water composition did not markedly affect Pb grades and recoveries at pH 10. • FS milling at all examined water compositions proved more effective in controlling Fe recovery. • High ionic strength water, mimicking water recycling, showed little effect on recoveries. Chemical reactions during milling and flotation are mostly driven by interactions between minerals, reagents, milling media, and water chemistry. Furthermore, due to these interactions, the valuable minerals may become more difficult to float, especially in the case of polymetallic ore processing in closed-water circuits. This study uses a mixed mineral − galena (Gn) and pyrite (Py) − synthetic ore sample to investigate how metallurgical performance is affected using different milling media, pHs in the mill, and process water ionic strengths. Mixed potential, DO, and pH were closely monitored in situ during milling. Using Gn and Py as the minerals of interest allows the effect of iron (Fe) in the mineral to be decoupled from that arising from the mill shell and Fe-bearing milling media.
Anionic Polyacrylamide and Carboxymethyl Cellulose on Flotation Performance of a Cu-Ni-PGM Ore in Degrading Water Quality Thabang O. Shamukuni, Malibongwe S. Manono, Lisa L. October, Kirsten C. Corin Minerals Engineering, 2025 • Higher amount of solids reported to the concentrates in the presence of 100 g/t PAM. • Water recoveries were the lowest in the presence of 100 g/t PAM compared to 100 g/t CMC. • Ni recoveries were the highest in the presence of 100 g/t PAM compared to 100 g/t CMC. • Cu and Ni grades were the highest in the absence of PAM and CMC. • The settling rate of tailings was the poorest in PAM compared to CMC. Water scarcity is one of the leading environmental concerns, globally. South Africa as a mining rich economy is also faced with this threat. To respond to this global threat, most mining operations, recycle process water within mineral processing plants. This approach to onsite water management reduces the dependence on municipal or potable water. Within minerals processing plants, froth flotation, which is used to separate valuable minerals from gangue minerals contained within an ore, is water-intensive and may contain some substances which are harmful to the environment and/or the process performance. The recycling of the process water within operations may, therefore, benefit the environment as the discharge of effluent is minimised. Furthermore, since the process water is recirculated from the concentrates and tailings dewatering unit operations, there may be some residual reagents present in the recirculated water, this may be beneficial or detrimental to flotation depending on how residual reagents affect flotation chemistry. However, the recycling of water also leads to a build-up of ions which may have a negative impact on flotation performance. How the accumulated ions affect the flotation performance and tailings dewatering in the presence of flotation reagents such as PAM and CMC are topics of interest and fundamental to understanding the control and management of water quality together with its associated effects on the process. Hence, this study makes a comparative analysis between PAM and CMC on flotation performance and tailings dewatering in different water qualities of increasing ionic strength. Batch flotation results indicate that polymers and ionic strength of plant water significantly impact the flotation performance of Cu-Ni-PGM ore. PAM generally led to higher solid recovery in concentrates compared to CMC or no polymers. Increased ionic strength enhanced water recovery and froth stability, but slightly reduced solids recovery with PAM, while improving it in the absence of polymers or with CMC due to gangue activation. Ionic strength had no effect on copper and nickel recoveries but negatively impacted concentrate grades with CMC, while PAM showed no influence. Settling rates improved with CMC as ionic strength rose, but decreased with PAM, although PAM consistently had a faster settling rate overall.
The use of simple analytical techniques to assess surface oxidation of sulphide ores A.S. Sibiya, R.M. Manenzhe, M. Tadie, K.C. Corin Minerals Engineering, 2024 • Simple, low-cost techniques can be used to indicate surface oxidation for varied ore types. • The EDTA and OCF values differed between the different ores. • The OCF and EDTA values increased with finer grinding for both ores A and B. • High reactivity translated to poor flotation recovery. Surface oxidation is known to have a negative impact on the flotation performance of sulphide minerals. This is because severe oxidation makes it more difficult to process low-grade sulphide minerals, which reduces the recovery of valuable minerals during flotation. It may be possible to quantitatively correlate the rate/level of oxidation to oxidized sulphide ores using simple surface analytical techniques. This, if done well, could eliminate the need for numerous mineralogical tests, saving both time and money. This study investigated the EDTA Extraction Technique and Oxygen consumption factor (OCF) Technique as possible techniques to quantitatively describe oxidation levels in different ore types with different mineral compositions and grades. The aim was to determine if the changes in the surface character generated by oxidation are linked to a measurement obtained from the selected techniques. The techniques were validated on fresh ores of varying grades; high grade Cu (HG Cu) and Upper Group 2 (UG2). The two ores were then ground to generate varying particle size distributions and liberation profiles to study the link between oxidation, particle size and liberation. Based on ore type and sulphide liberation, the tests attempted to provide an indicator of feed grade and surface oxidation. Flotation is used as a diagnostic for the parameters mentioned. The results showed that (for Ore A/UG2) as particle size decreased (from grind size 40 %–75 μm), the recovery increased until it hit a maximum (grind size 60 %–75 μm) before monotonically declining (to grind size 80 %–75 μm). The OCF and EDTA values increased as the grind size became finer. The grind size 80 %–75 μm had suffered significantly more oxidation than the other grind sizes and this was indicated by the high OCF and the EDTA value. The liberated base metal sulphides (BMS) for Ore B (HG Cu) was generally consistent throughout the three grind sizes, however, the highest recovery was achieved by the grind size 80 %–75 μm (95.11 %), followed by grind sizes 60 %–75 μm and 40 %–75 μm respectively (92.25 % and 90.86 %). The recovery of this ore increases as the grind size becomes finer. Ore B demonstrated a direct correlation between the OCF and EDTA value for ore B increased as the grind size became finer, and the recovery. It is possible that the particles that were ground to achieve particle size 80 %–75 μm were at their most hydrophobic state, owing to the increased liberation of the BMS, particularly chalcopyrite.
Metallurgical Effects of Milling Media and Water Composition in the Flotation of a Mixed-Mineral Ore Impc 2024 31st Impc International Mineral Processing Congress, 2024
The Emergence of Techniques and Methodologies for Measuring Bubble–Particle Attachment Impc 2024 31st Impc International Mineral Processing Congress, 2024
Flotation Reagents on the Coagulation and Dewatering of Flotation Concentrates from a Cu-Ni-PGM Ore Impc 2024 31st Impc International Mineral Processing Congress, 2024
Process Mineralogical Investigation into the Distribution of Silver at Gamsberg Zinc Impc 2024 31st Impc International Mineral Processing Congress, 2024
A Determination of the Effect of Changing Collector Chain Length Under Varying Water Quality Impc 2024 31st Impc International Mineral Processing Congress, 2024
Process water effects on mineral-depressant adsorption in sulphide flotation Impc 2018 29th International Mineral Processing Congress, 2019
On the management of gangue minerals in the flotation of platinum group minerals 2019 SME Annual Conference and Expo and Cma 121st National Western Mining Conference, 2019
The effect of hydrogen peroxide addition in the flotation of sulphide ores Impc 2018 29th International Mineral Processing Congress, 2019
The effect of water quality on the adsorption of a xanthate collector in the flotation of a sulphide ore Impc 2018 29th International Mineral Processing Congress, 2019
The effect of water quality on the adsorption of a xanthate collector in the flotation of a sulphide ore Impc 2018 29th International Mineral Processing Congress, 2019
The effect of water quality on the adsorption of a xanthate collector in the flotation of a sulphide ore Impc 2018 29th International Mineral Processing Congress, 2019
Investigating froth stability and entrainment: A comparative study of ionic strength and depressant dosage Impc 2016 28th International Mineral Processing Congress, 2016
Application of potential control to the flotation of galena by varying dissolved oxygen, PH and ionic strength levels Impc 2016 28th International Mineral Processing Congress, 2016
Effect of using different grinding media on the flotation of a base metal sulphide and UG2 ore containing platinum group minerals Impc 2016 28th International Mineral Processing Congress, 2016
Investigating the role of pulp chemistry on the floatability of A Cu-Ni sulfide ore 26th International Mineral Processing Congress Impc 2012 Innovative Processing for Sustainable Growth Conference Proceedings, 2012
The use of automated mineralogy to interpret the batch flotation performance of merensky reefore Xxv International Mineral Processing Congress 2010 Impc 2010, 2010
The effect of ionic strength of plant water on valuable mineral and gangue recovery in a platinum bearing ore from the Merensky reef Xxv International Mineral Processing Congress 2010 Impc 2010, 2010
Zeta potential as a tool for investigating surface chemistry: implications for mineral flotation LL October, TJ Mashamba, MS Manono, KC Corin Minerals Engineering 245, 110345 , 2026 2026
Varying Pyrite Feed Grade on Flotation Performance in Degrading Water Quality: Effects on Froth Stability and Gangue Management M Nkadimeng, MS Manono, KC Corin Minerals Engineering 237, 109992 , 2026 2026
Calcium and sulfate Ions on flotation performance of a Cu-Ni-PGM ore in the presence of anionic polyacrylamide and carboxymethyl cellulose TO Shamukuni, MS Manono, LL October, KC Corin Minerals Engineering 234, 109708 , 2025 2025 Citations: 1
The influence of grinding media and water chemistry on the closed-water flotation of single-mineral sulfide ores SN Nyoni, CT O’Connor, Z Gao, S Xu, KC Corin Minerals Engineering 232, 109509 , 2025 2025 Citations: 5
The impact of milling media and chemical conditions in the milling process for the flotation of a mixed-sulfide ore SN Nyoni, CT O’Connor, KC Corin Minerals Engineering 229, 109369 , 2025 2025 Citations: 5
Anionic polyacrylamide and carboxymethyl cellulose on flotation performance of a Cu-Ni-PGM ore in degrading water quality TO Shamukuni, MS Manono, LL October, KC Corin Minerals Engineering 228, 109307 , 2025 2025 Citations: 5
The role of grinding media and water composition on the chemical characteristics in a laboratory ball mill SN Nyoni, CT O’Connor, KC Corin Minerals Engineering 224, 109214 , 2025 2025 Citations: 4
Influence of surface oxidation rate on the flotation of sphalerite and galena inhibited by gum arabic L Jiang, B Feng, J Liu, Y Guo, KC Corin, J Mabounda Process Safety and Environmental Protection 192, 998-1007 , 2024 2024 Citations: 16
The effect of residual coagulants and flocculants in process water on the flotation performance of a selected Cu-Ni-PGM ore MS Manono, SF Khan, LL October, KC Corin Minerals Engineering 216, 108850 , 2024 2024 Citations: 4
The use of simple analytical techniques to assess surface oxidation of sulphide ores AS Sibiya, RM Manenzhe, M Tadie, KC Corin Minerals Engineering 213, 108753 , 2024 2024 Citations: 2
Water of Increased Ionic Strength on Surface Interactions with Labradorite MS Manono, LL October, RM Manenzhe, KC Corin Proceedings 105 (1), 142 , 2024 2024
Residual Dewatering Aids in Process Water on the Depressant Adsorption and Zeta Potential of Labradorite MS Manono, LL October, RM Manenzhe, KC Corin Proceedings 105 (1), 136 , 2024 2024
Residual Dewatering Aids in Process Water on the Depressant Adsorption and Zeta Potential of Plagioclase M Manono, L October, R Manenzhe, K Corin MDPI , 2024 2024
Carboxymethyl Cellulose and Sodium Isobutyl Xanthate on its Surface in Process Water of a Degrading Quality MS Manono, LL October, KC Corin Recovery of Values from Low-Grade and Complex Minerals: Development of … , 2024 2024
Increasing Ionic Strength and Oxyhydroxo Species in Process Water on the Floatability of Chalcopyrite and Pentlandite for a Selected Cu–Ni Bearing Ore Flotation MS Manono, KM Matibidi, LL October, CK Thubakgale, KC Corin Recovery of Values from Low‐Grade and Complex Minerals: Development of … , 2024 2024 Citations: 1
Relating the Flotation Response of Pyrrhotite to the Adsorption of Sodium Carboxymethyl Cellulose and Sodium Isobutyl Xanthate on its Surface in Process Water of a Degrading … MS Manono, LL October, KC Corin Recovery of Values from Low‐Grade and Complex Minerals: Development of … , 2024 2024
Simulated Short Cycle Water Recirculation on the Flotation Performance of a UG2 Cu–Ni–PGM Ore MS Manono, MS Ngau, KC Corin Recovery of Values from Low‐Grade and Complex Minerals: Development of … , 2024 2024
Malibongwe S. Manono1*, Katlego M. Matibidi2, Lisa L. October1 CK Thubakgale, KC Corin Recovery of Values from Low-Grade and Complex Minerals: Development of … , 2024 2024
Residual dewatering aids in process water on flotation performance of a selected Cu-Ni-PGM ore from a siliceous reef MS Manono, SF Khan, LL October, KC Corin Minerals Engineering 209, 108637 , 2024 2024 Citations: 6
Water quality impact on flotation Response: A focus on specific ions and temperature KC Corin, A Charamba, MS Manono Minerals Engineering 207, 108549 , 2024 2024 Citations: 17
MOST CITED SCHOLAR PUBLICATIONS
The effect of ionic strength of plant water on valuable mineral and gangue recovery in a platinum bearing ore from the Merensky reef KC Corin, A Reddy, L Miyen, JG Wiese, PJ Harris Minerals Engineering 24 (2), 131-137 , 2011 2011 Citations: 115
The effect of ionic strength of plant water on foam stability: A 2-phase flotation study MS Manono, KC Corin, JG Wiese Minerals Engineering 40, 42-47 , 2013 2013 Citations: 101
The recovery of oxide copper minerals from a complex copper ore by sulphidisation KC Corin, M Kalichini, CT O‘Connor, S Simukanga Minerals engineering 102, 15-17 , 2017 2017 Citations: 87
An investigation into the effect of various ions and their ionic strength on the flotation performance of a platinum bearing ore from the Merensky reef MS Manono, KC Corin, JG Wiese Minerals Engineering 36, 231-236 , 2012 2012 Citations: 86
Investigating froth stability: A comparative study of ionic strength and frother dosage KC Corin, JG Wiese Minerals Engineering 66, 130-134 , 2014 2014 Citations: 75
The generation of toxic reactive oxygen species (ROS) from mechanically activated sulphide concentrates and its effect on thermophilic bioleaching GC Jones, KC Corin, RP van Hille, STL Harrison Minerals Engineering 24 (11), 1198-1208 , 2011 2011 Citations: 65
A study of the effect of grinding environment on the flotation of two copper sulphide ores J Liu, H Long, KC Corin, CT O'Connor Minerals Engineering 122, 339-345 , 2018 2018 Citations: 61
Redox potential control during flotation of a sulphide mineral ore W Chimonyo, KC Corin, JG Wiese, CT O'Connor Minerals Engineering 110, 57-64 , 2017 2017 Citations: 58
The role of dithiophosphate as a co-collector in the flotation of a platinum group mineral ore KC Corin, JC Bezuidenhout, CT O’connor Minerals engineering 36, 100-104 , 2012 2012 Citations: 56
Effect of using different grinding media on the flotation of a base metal sulphide ore KC Corin, ZG Song, JG Wiese, CT O'Connor Minerals Engineering 126, 24-27 , 2018 2018 Citations: 51
Challenges related to the processing of fines in the recovery of platinum group minerals (PGMs) KC Corin, BJ McFadzean, NJ Shackleton, CT O’Connor Minerals 11 (5), 533 , 2021 2021 Citations: 45
A fundamental study considering specific ion effects on the attachment of sulfide minerals to air bubbles LL October, KC Corin, MS Manono, N Schreithofer, JG Wiese Minerals Engineering 151, 106313 , 2020 2020 Citations: 42
The role of pulp potential and the sulphidization technique in the recovery of sulphide and oxide copper minerals from a complex ore M Kalichini, KC Corin, CT O'Connor, S Simukanga Journal of the Southern African Institute of Mining and Metallurgy 117 (8 … , 2017 2017 Citations: 40
Water quality effects on bubble-particle attachment of pyrrhotite L October, K Corin, N Schreithofer, M Manono, J Wiese Minerals Engineering 131, 230-236 , 2019 2019 Citations: 38
Simulating the Effect of Water Recirculation on Flotation through Ion-Spiking: Effect of Ca 2+ and Mg 2+ M Dzingai, M Manono, K Corin Minerals 10 (11), 1033 , 2020 2020 Citations: 36
Water quality effects on a sulfidic PGM ore: Implications for froth stability and gangue management MS Manono, K Corin, J Wiese Physicochemical Problems of Mineral Processing 54 (4), 1253-1265 , 2018 2018 Citations: 36
The effect of sodium isobutyl xanthate on galena and chalcopyrite flotation in the presence of dithionite ions N Mhonde, LS Johansson, K Corin, N Schreithofer Minerals Engineering 169, 106985 , 2021 2021 Citations: 33
The effect of the ionic strength of process water on the interaction of talc and CMC: Implications of recirculated water on floatable gangue depression M Manono, K Corin, J Wiese Minerals 9 (4), 231 , 2019 2019 Citations: 33
Considering the effect of pulp chemistry during flotation on froth stability N Sheni, K Corin, J Wiese Minerals Engineering 116, 15-23 , 2018 2018 Citations: 33
Perspectives from literature on the influence of inorganic electrolytes present in plant water on flotation performance MS Manono, K Corin, J Wiese Physicochemical Problems of Mineral Processing 54 , 2018 2018 Citations: 33