Can preconcentration of cassiterite from its pegmatite ore reduce processing costs and improve operational sustainability?

Different concentration techniques were evaluated for preconcentration of a mineral ore at a coarser size to avoid energy and resource wastage. Specifically, the aim was to reduce milling costs and energy required in the beneficiation of tin. In this study, cassiterite (0.17% Sn) was the mineral of interest in a pegmatite ore body associated with quartz (SiO₂ > 60%) and alumina (Al₂O3 > 20%). Three concentration techniques, namely dense media, shaking table, and flotation, coupled with characterization analysis, were used to assess the concentration response. The results confirmed that particle size and mineral liberation impact the separation process. High recovery and grade were obtained with gravity concentration methods (dense media and shaking table) for coarser (+300 to +212 μm) and intermediate (+150 to +53 μm) particle sizes. Lower recovery and grade were identified for much finer sizes (−53 to −38 μm). Flotation produced a high-grade product at a relatively low recovery and appeared to be only applicable to finer grains. Separation efficiency based on Schulz’s equation measured a segregation performance of 74.8% for dense medium separation and 60.7% for the shaking table for the coarse and intermediate particle sizes. Flotation only achieved a separation of 30%–40%. The results suggest that use of dense media separation as a rough preconcentration method prior to further grinding, and the utilization of a more advanced concentration technique for mineral recovery and upgrade, constitute a successful approach to improve process economics.