The Montevive celestine mineral deposit, set in the Granada Basin in a marine evaporitic uppermost Tortonian–lowermost Messinian sequence, is the largest reserve in Europe of this economically important strontium ore. Currently, the mine has a large amount of tailings resulting from the rejection of a manual dry screening of high-grade celestine mineral. This visual and density screening was carried out in the early days of mining (1954–1973). Concentrating the celestine mineral and increasing the ore recovery rate would reduce mine operation costs and the generation of new tailings, reducing the impact on the environment. In order to define more adequate concentration methods, we have used complementary analytical techniques such as optical (OM) and scanning and transmission electron microscopy (SEM and TEM), energy-dispersive X-rays (EDXs), X-ray fluorescence (XRF), and X-ray diffraction (XRD) to fully characterize the morphology, microstructure, chemistry, and mineralogy of the celestine mineral. The low-grade mineral is made of prismatic celestine crystals that are replacing a matrix of micro sparry calcite. Other minority minerals are strontianite, dolomite, quartz, and clays (kaolinite, paragonite, and illite). There is also a certain amount of iron oxides and hydroxides (mainly magnetite) associated with clays. We showed that the concentration of low-grade celestine mineral can be achieved through a low-cost and eco-friendly method based on grinding and size separation. The coarser fractions (>5 mm) have more celestine (up to 12 percent units higher than the starting unprocessed mineral) due to the selective loss of calcite and minority minerals (quartz, clays, and iron oxides) that are mainly found in the finer fraction (<1 mm). This process can make mine exploitation more sustainable, reducing the generation of residues that negatively impact the environment.

A semi-industrial scale hydrocyclone with a 250 mm internal diameter was used to concentrate medium-grade celestine ore (75%–85% celestine) from the Montevive deposit of Granada (Spain) using a dense ferrosilicon (FeSi) medium. For this purpose, a Box–Behnken factorial design (BBD) was carried out, with the response variable being the Sr concentration measured by X-ray fluorescence (XRF), as well as the concentration of celestine measured by X-ray diffraction (XRD) of the mineral collected from the under (sunk) stream of the hydrocyclone. The experimental factors to be optimised were the density of the medium in the mixing tank (water, FeSi, and feed mineral) varying from 2.7 to 2.9 kg/L, the hydrocyclone inlet pressure from 0.8 to 1.2 bar, and the hydrocyclone inclination (from 15° to 25° from the horizontal). The range of densities of the dense medium to be tested was determined from previous sink–float experiments using medium-grade ore, in which the distribution of mineral phases with different particle size fractions was determined. To evaluate the separation behaviour, the following parameters were considered: the enrichment ratio (E), the tailings discarding ratio (R), and the mineral processing recovery (ε). From the factorial design and the response surface, the optimum parameters maximising celestine concentration in the under stream (78%), were determined. These optimised parameters were: a density of 2.75 kg/L for the dense medium, an inlet pressure of 1.05 bar, and a hydrocyclone inclination varying from 18° to 20°. Under these conditions, a 94% recovery of celestine (68% Sr) can be achieved. These results show that medium-grade celestine ore, accumulated in mine tailings dumps, can be effectively concentrated using DMS hydrocyclones and that the operating parameters can be optimised using a factorial experiment design. This study can contribute to reducing overexploitation of strategic mineral resources, avoiding blasting and environmentally damaging clearing, by applying a simple and sustainable technique.

A pilot hydrocyclone plant was used to concentrate medium-grade celestine ore (67% celestine) from the Montevive deposit in Granada (Spain) by using a dense media concentration (DMS) process. To optimize the concentration process, several types of heavy minerals (coarse, fine C40 ferrosilicon and/or magnetite) were used to prepare a dense media with a constant density of 3.0 kg/L. Then, the dense media (loaded with run-of-mine celestine mineral) was fed into the hydrocyclone system. The mineral was then separated into two streams, the first containing the mineral fractions that float (over stream) and the second containing fractions that sink (under stream) in the dense media. Next, the heavy minerals (ferrosilicon and/or magnetite) were recovered from the dense media using magnetic separation. The celestine mineral recovered from each stream was divided into two fractions with particles size above or below 250 μm to study the effect of the mineral particle size on the separation process. Their mineral composition was quantified by X-ray diffraction (XRD) using the Rietveld method. The celestine is preferentially concentrated in the under stream in the mineral fraction with particles larger than 250 μm (up to 90% celestine). The optimum results (highest % of celestine) were obtained after desliming and using the ferrosilicon C40 medium, which has the smallest particle size (<40 μm) of all media used. The results of this study show that medium-grade celestine mineral accumulated in the mine tailings can be efficiently concentrated using a DMS process, which could help in making mine operations more sustainable and eco-friendlier.