Image analysis data obtained from scanning electron microscopy provided data for a detailed evaluation of the separation efficiency for various processes involving the beneficiation of particulate materials. A dry magnetic separation by a drum type magnetic separator served as a case study to visualize effects of processing of a skarn ore with a high content of cassiterite as ore mineral (~4 wt%). For this material, iron oxides and silicates are the main gangue mineral groups. Based on the obtained data, partition curves were generated with the help of local regression. From the partition curves, the separation efficiency was evaluated and the relevant particle properties deduced. A detailed analysis of the bias of the quantitative mineralogical data is presented. This bias was monitored and further analyzed in detail. Thorough analysis of feed and products of magnetic separation enabled identification of the most important factors that control losses of cassiterite to the magnetic product, namely the association with iron oxides and particle sizes below ~40 µm. The introduced methodology is a general approach applicable for the optimization of different separation processes and is not limited to the presented case study.

The reprocessing of tailings can have economic and environmental benefits compared to the processing of primary ore deposits. In this paper we present the characterization of a tailings dam in southern Chile by means of mineralogical and geochemical investigations, focusing on sphalerite and trace elements with the aim to investigate a potential reprocessing. The assessment is followed by a flotation study, focusing on the recovery of sphalerite with a high selectivity towards sulfidic and non-sulfidic gangue minerals. An in-depth analysis of a selected test based on mineral liberation analysis data is used to refine the liberation, concentration and flotation weighting function for future investigations.