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As the global demand for tellurium (Te) increases, it is crucial to develop efficient recovery methods that consider existing supply streams. This research combines gravity separation and froth flotation processes to enhance the recovery of Te minerals from tailings produced during the beneficiation of copper porphyry ores. Prior to processing, a systematic and comprehensive characterization study of copper tailing (CT) samples was conducted to examine the deportment of Te minerals in different mineral phases and to understand their locking and liberation behavior. Characterization techniques included inductively coupled plasma mass spectrometry (ICP-MS) and TESCAN’s integrated mineral analysis (TIMA). Copper tailing characterization showed that minerals with gold (Au), silver (Ag), bismuth (Bi), and Te were present in various forms, including native Au, electrum, tellurides, and sulfosalts. TIMA revealed that >90% of these minerals were primarily hosted in pyrite as less than 10 µm inclusions in the CT. TIMA also revealed that Te minerals exhibited fine-grained liberation of less than 20 μm. Moreover, TIMA results showed that >80% of mica and other silicate minerals were concentrated in size fractions < 38 μm, suggesting that desliming processes would positively impact Te enrichment. The results from the processing tests showed a Te recovery rate of ~77% and a Te enrichment ratio of 13 when using the combination of gravity separation and froth flotation at 90 g/t xanthate collector and 50 g/t glycol frother. The findings from this study show a significant potential for Te recovery from unconventional sources if appropriate physical beneficiation approaches are adopted.

This study aimed to investigate the potential of enrichment of rare-earth-bearing minerals in historic mine tailing using the froth flotation process. Characterization studies indicated that tailings contained 11,000 ppm of rare earth elements (REEs). The major mineral in the tailings was apatite at ~84%, which was associated with iron oxides (~16%). TESCAN’s integrated mineral analysis (TIMA) showed that monazite was the main REE mineral, and 69% of monazite was locked in apatite grains. Characterization studies suggested that the separation of REEs-bearing apatite from iron oxides is possible using froth flotation, wherein apatite was floated and iron oxides were depressed. Zeta potential experiments were conducted to understand the behavior of the main minerals in the feed when selected depressants of iron oxides were added. Depressants included corn starch, sodium metasilicates, polyacrylamide (PAM), hybrid polyacrylamide (HyPAM), and chitosan. Zeta potential results suggested that chitosan and polyacrylamide-based polymers had the strongest adsorption on magnetite at pH 7 and pH 9, respectively, as indicated by the large shift in the zeta potential of magnetite suspensions. Flotation results were consistent with zeta potential findings and showed that Hy-PAM and chitosan had the best depression efficiency of iron oxides at pH 9 and pH 7, respectively.