Assessing the viability of magnetic separator tailings as a secondary source of nickel, cobalt and copper: a case study for Tati Nickel Mining Company
Abstract 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, pa...
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| Language: | English |
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SpringerOpen
2025-06-01
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| Series: | Journal of Engineering and Applied Science |
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| Online Access: | https://doi.org/10.1186/s44147-025-00663-3 |
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| author | Nkosilamandla Moyo Boitshepo Marakalala Tshepo Gaogane Gwiranai Danha Tirivaviri A. Mamvura |
| author_facet | Nkosilamandla Moyo Boitshepo Marakalala Tshepo Gaogane Gwiranai Danha Tirivaviri A. Mamvura |
| author_sort | Nkosilamandla Moyo |
| collection | DOAJ |
| description | Abstract 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. |
| format | Article |
| id | doaj-art-d7f73793af9040ea90ff05ce3bfd8e28 |
| institution | Kabale University |
| issn | 1110-1903 2536-9512 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | SpringerOpen |
| record_format | Article |
| series | Journal of Engineering and Applied Science |
| spelling | doaj-art-d7f73793af9040ea90ff05ce3bfd8e282025-08-20T03:45:10ZengSpringerOpenJournal of Engineering and Applied Science1110-19032536-95122025-06-0172111110.1186/s44147-025-00663-3Assessing the viability of magnetic separator tailings as a secondary source of nickel, cobalt and copper: a case study for Tati Nickel Mining CompanyNkosilamandla Moyo0Boitshepo Marakalala1Tshepo Gaogane2Gwiranai Danha3Tirivaviri A. Mamvura4Department of Chemical, Materials and Metallurgical Engineering, School of Earth Sciences and Engineering, Botswana International University of Science and Technology (BIUST)Department of Chemical, Materials and Metallurgical Engineering, School of Earth Sciences and Engineering, Botswana International University of Science and Technology (BIUST)Department of Chemical, Materials and Metallurgical Engineering, School of Earth Sciences and Engineering, Botswana International University of Science and Technology (BIUST)Department of Chemical, Materials and Metallurgical Engineering, School of Earth Sciences and Engineering, Botswana International University of Science and Technology (BIUST)Department of Chemical, Materials and Metallurgical Engineering, School of Earth Sciences and Engineering, Botswana International University of Science and Technology (BIUST)Abstract 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.https://doi.org/10.1186/s44147-025-00663-3Waste valorisationFroth flotationMagnetic separator tailingsActivox leaching |
| spellingShingle | Nkosilamandla Moyo Boitshepo Marakalala Tshepo Gaogane Gwiranai Danha Tirivaviri A. Mamvura Assessing the viability of magnetic separator tailings as a secondary source of nickel, cobalt and copper: a case study for Tati Nickel Mining Company Journal of Engineering and Applied Science Waste valorisation Froth flotation Magnetic separator tailings Activox leaching |
| title | Assessing the viability of magnetic separator tailings as a secondary source of nickel, cobalt and copper: a case study for Tati Nickel Mining Company |
| title_full | Assessing the viability of magnetic separator tailings as a secondary source of nickel, cobalt and copper: a case study for Tati Nickel Mining Company |
| title_fullStr | Assessing the viability of magnetic separator tailings as a secondary source of nickel, cobalt and copper: a case study for Tati Nickel Mining Company |
| title_full_unstemmed | Assessing the viability of magnetic separator tailings as a secondary source of nickel, cobalt and copper: a case study for Tati Nickel Mining Company |
| title_short | Assessing the viability of magnetic separator tailings as a secondary source of nickel, cobalt and copper: a case study for Tati Nickel Mining Company |
| title_sort | assessing the viability of magnetic separator tailings as a secondary source of nickel cobalt and copper a case study for tati nickel mining company |
| topic | Waste valorisation Froth flotation Magnetic separator tailings Activox leaching |
| url | https://doi.org/10.1186/s44147-025-00663-3 |
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