The present study focuses on the selective extraction of potassium from a hydrochloric acid-based feldspar leachate using solvent extraction with crown ethers, CE (dibenzo-18-crown-6 and 12-crown-4). The effects of hydrochloric acid concentration, extractant type, diluent, extractant concentration, and organic-to-aqueous phase ratio on potassium extraction efficiency have been examined. Dibenzo-18-crown-6 diluted in m-cresol was shown to preferentially extract potassium (≈85 %) from highly acidic hydrochloric acid solutions (2 to 6 M), with minimal co-extraction of impurities, such as aluminum and sodium, in a single extraction step. Aluminum, however, was shown to be extracted efficiently (≈99 %) at lower acidities (<0.1 M). The extraction mechanisms were explored using various analyses, such as slope analysis, nuclear magnetic resonance, and scanning electron microscopy showing that dibenzo-18-crown-6 forms a highly stable complex with potassium at 1:1 M ratio, (KCl)(CE), driven by the size compatibility between potassium ions and the crown ether cavity. For aluminum, the extraction mechanism likely involves the formation of a cooperative complex where aluminum ions are associated with the potassium-crown ether complex (AlKCl4)(CE). Increasing the concentration of hydrochloric acid increased potassium ion activity, chloride ion activity, and ionic strength in the solution. These changes would enhance selective potassium extraction over the formation and extraction of the aluminum‑potassium cooperative complex.

With the advancement of technology, many educators have started implementing technology enhanced tools like simulators and gamified learning applications to improve the training of industrial production staff. Currently, most operators in the mineral process industry are taught by traditional methods like slide presentations and hand-written exercises with a heavy focus on memorization. To facilitate the knowledge transfer from experienced to novice operators, a gamified educational tool was developed aiming to teach the core knowledge of the froth flotation process, with potential to teach the whole concentration process. Unity3D was used to develop the game based on a first-principles flotation model. This article presents a description of the application, as well as a questionnaire and the evaluation of the game by 25 experts in this field.

The increased use of lithium-ion batteries (LiBs) in electric vehicles (EVs) and other applications due to global efforts to reduce carbon emissions has led to an increase in end-of-life battery production. This has created a demand for efficient recycling methods to control waste and conserve resources. This study investigated the effect of thermal pre-treatment of spent LiBs materials on the liberation of anodic and cathodic materials from the aluminium and copper current collectors and the subsequent graphite recovery by flotation. The samples were pre-treated using a rotating kiln and microwave furnace at temperatures of 200 °C, 400 °C, and 600 °C, with an additional sample containing 10 wt% CaO treated at 400 °C. The results indicated that higher temperatures resulted in the breakdown of the binder, leading to graphite liberation. Specifically, at 600 °C, the anode and cathode materials exhibited significant separation from the Cu and Al current collectors with an almost similar liberation efficiency for both pre-treatment methods. Furthermore, adding 10 wt% CaO to the samples treated at 400 °C significantly lowered the flotation of the cathode materials and improved the flotation selectivity of graphite. The findings indicate that combined thermal pre-treatment with flotation can improve the recycling process, providing a more scalable and environmentally friendly approach to managing the increasing volume of spent LiBs.

A global transition from the current “brown economy” to a “green economy” has been perceived as an ineluctable carbon neutrality strategy to deal with climate change and its global devastating impacts. This global ambition of green economy necessitates large-scale electrification which imposes growing demand for lithium-ion batteries as state-of-the-art energy storage technologies. Thereupon, the developing market of batteries reinforces the concern over the resilient and consistent supply of battery raw materials. By the reason of the interdependencies of all the stages involved in a value chain of a battery, it is critical to identify the battery material supply-disruptive risks and uncertainties, and subsequently to analyze the impacts of the perpetuation of the supply issues on the future market of batteries. In this research study, to contribute to these processes necessary for overcoming the ongoing supply sustainability challenges, the focus is on lithium, nickel, graphite, and cobalt, which are among the battery raw materials with high supply risks. After analyzing and categorizing the driving forces behind the historical and current bottlenecks to their mining production, the regional and global mining production of those battery materials have been predicted for twenty years ahead using three time series forecasting techniques including Seasonal Autoregressive Integrated Moving Average, Holt's linear trend, and Holt-Winters’ methods. Forecasting possible future production trends of those battery raw materials is indisputably imperative to resolve planning strategies while dealing with uncertainties and supply risks. Reliable supply forecasting results provide more uncertainty and risk management achievements since the stakeholders and policymakers can use the outcomes as a source of information in the decision-making process at any stage of a lithium-ion battery value chain.

Understanding ore texture is essential for optimising comminution and mineral liberation, yet no standardised framework exists for defining and quantifying textural attributes. This review explores the complex relationship between ore texture, breakage mechanisms, and mineral liberation, emphasising the importance of textural parameters such as grain size, mineral intergrowths, and mechanical properties in determining comminution behaviour. The review is structured into key themes: (i) characterisation techniques for ore texture, spanning optical, electron beam, X-ray, and laser-based methods; (ii) conventional and proxy comminution tests for assessing ore hardness and breakage response; (iii) modelling approaches to relate ore texture to mineral liberation, including texture-based and kinetic-based liberation models; and (iv) innovative pre-treatment methods such as microwave heating, high-voltage pulse disintegration, and ultrasonication, which aim to promote non-random breakage and improve mineral liberation. The literature is analysed through a comparative assessment of these methods, evaluating their applicability, limitations, and integration potential in modern mineral processing.

Key takeaways include the need for a standardised classification of ore texture, at least for mineral processing purposes, improved methods for quantifying breakage modes, and the development of more accurate liberation models that incorporate textural heterogeneity. While advanced pre-treatment techniques show promise in promoting non-random comminution, their widespread adoption remains constrained by energy consumption and economic feasibility. By synthesising recent advancements and identifying research gaps, this review contributes to the field by advocating for a geometallurgical approach that integrates ore texture characterization into comminution models. 

Potassium-containing feldspars provide a high potential for producing potash, a product with widespread use in agriculture. The present work assesses applying the anti-solvent crystallization method for the purification and recovery of high-purity muriate of potash (KCl) from feldspar leaching solutions. Initially, screening experiments were carried out on a synthetic leaching solution with the aim of analyzing the crystallization behavior of key components. Screening experiments were performed using five anti-solvents, namely methanol, ethanol, acetone, 2-propanol, and ethylene glycol. Acetone and 2-propanol were viable options for crystallization of potassium chloride. Then, the effects of anti-solvent ratio (O/A), time, and anti-solvent addition rate on potassium-chloride crystallization were further investigated using acetone and 2-propanol. A recovery of 83% of potassium was achieved when using acetone at the O/A of 5 with the addition rate of 10 mL/min, at room temperature with a hold time of 180 min. The optimum conditions for 2-propanol were determined to be similar, except for using a 5 mL/min addition rate for 79% recovery. The final muriate of potash products had a purity of over 99.9% using either of the anti-solvent. However, differences in morphology and crystal size of products were observed. Acetone-formed potash crystals were aggregates of cubic crystals with an average size of 3 microns, while 2-propanol-formed potash crystals were 20 microns in size as cubic particles with a hollow core. Despite having almost the same performance in potassium recovery, acetone was found to be a more feasible anti-solvent for potash recovery due to simpler downstream solvent recovery.

The global commitment to decarbonizing the transport sector has resulted in an unabated growth in the markets for electric vehicles and their batteries. Consequently, the demand for battery raw materials is continuously growing. As an illustration, to meet the net-zero emissions targets, the electric vehicle market demand for lithium, cobalt, nickel, and graphite will increase 26-times, 6-times, 12-times, and 9-times respectively between 2021 and 2050. There are diverse challenges in meeting this demand, requiring the world to embrace technological and knowledge advancements and new investments without provoking conflicts between competing goals. The uncertainties in a sustainable supply of battery minerals, environmental, social and governance complexities, and geopolitical tensions throughout the whole battery value chain have shaped the global and regional concerns over the success of transport decarbonization. Here, focusing on the entire value chain of electric vehicle batteries, the approaches adopted by regulatory agencies, governments, mining companies, vehicle and battery manufacturers, and all the other stakeholders are evaluated. Bringing together all these aspects, this literature review broadens the scope for providing multifaceted solutions necessary to optimize the goal of transport decarbonization while upholding sustainability criteria. Consolidating the previously fragmented information, a solid foundation for more in-depth research on existing difficulties encountered by governmental and industrial actors is created. The outcomes of this study may serve as a baseline to develop a framework for a climate smart and resource efficient supply of batteries considering the unique impacts of individual players.

It is well documented that the use of grinding aids (GAs) can reduce milling energy consumption. However, the impact of GAs on downstream processes must be addressed in view of complex processes such as froth flotation separation. This study investigates the effects of polyacrylic-based grinding aids (Zalta™ GR20-587: AAG) on the grinding performance and quartz flotation from magnetite. Various AAG dosages and conditions were examined. The grinding results showed lower energy consumption and a finer, more uniform product size with roughened surfaces for AAG compared to grinding without the grinding aid. Flotation tests of single pure minerals showed that AAG enhanced quartz collection with minimal effect on magnetite. Mixed mineral flotation showed that by using AAG, Fe recovery of 92.1 % and 64.5 % Fe grade could be achieved with a lower collector dosage of 100 g/t compared to 200 g/t in the absence of AAG. Zeta potentials and stability measurements showed that AAG shifts the potential, thus improving the stability and dispersion of the suspension. Adsorption tests illustrated that AAG adsorbed on both quartz and magnetite, the former having a higher capacity. FTIR indicated the physisorption interaction between AAG and the minerals. Therefore, the presence of AAG not only improved grinding efficiency but could potentially decrease the amount of collector required to achieve comparable metallurgical performance.

Grinding is the most energy-intensive step in mineral beneficiation processes. The use of grinding aids (GAs) could be an innovative solution to reduce the high energy consumption associated with size reduction. Surprisingly, little is known about the effects of GAs on downstream mineral beneficiation processes, such as flotation separation. The use of ecofriendly GAs such as polysaccharide-based materials would help multiply the reduction of environmental issues in mineral processing plants. As a practical approach, this work explored the effects of a novel polysaccharide-based grinding aid (PGA) on magnetite's grinding and its reverse flotation. Batch grinding tests indicated that PGA improved grinding performance by reducing energy consumption, narrowing particle size distribution of products, and increasing their surface area compared to grinding without PGA. Flotation tests on pure samples illustrated that PGA has beneficial effects on magnetite depression (with negligible effect on quartz floatability) through reverse flotation separation. Flotation of the artificial mixture ground sample in the presence of PGA confirmed the benefits, giving a maximum Fe recovery and grade of 84.4 and 62.5%, respectively. In the absence of starch (depressant), PGA resulted in a separation efficiency of 56.1% compared to 43.7% without PGA. The PGA adsorption mechanism was mainly via physical interaction based on UV–vis spectra, zeta potential tests, Fourier transform infrared spectroscopy (FT-IR), and stability analyses. In general, the feasibility of using PGA, a natural green polymer, was beneficial for both grinding and reverse flotation separation performance.