Mineralogical Factors Affecting the Dense Medium Separation of Nickel Sulfide Ores

Dense medium separation (DMS) is often used to reject a large portion of gangue material upfront to create cost and energy savings during processing. As lower-grade ores with complex mineralogy are being increasingly exploited, the properties of the gangue minerals begin to play a more important role in the upgrading of the ore. It is therefore important to understand these mineralogical factors to be able to select suitable processing routes for specific ore types. Two nickel sulfide deposits in southern Africa were chosen as case studies to understand differences in DMS efficiency when applied to different ores: Ore A and Ore B. Both ores showed nickel upgrades using DMS and the products were then characterized using QEMSCAN, with the aid of X-ray diffraction and electron probe microanalysis. Overall, particle density remains the main control on the separation, followed by sulfide texture, with massive and net-textured sulfides having larger grain sizes and therefore better liberation than disseminated sulfides. In addition to the concentration of sulfides, primary and secondary silicate minerals are separated by their density differences, which can affect the recovery of finely disseminated sulfides associated with them. Particle size is also important in DMS, with material near the cut-point density separating on size rather than density. The understanding of the mineralogical properties affecting DMS can aid in the prediction of the suitability of DMS for different ore types.