Technical Evaluation of Quartz and Feldspar Processing for Energy Efficiency and Environmental Management

Introducion: Ore beneficiation applied to industrial minerals, specifically high-purity quartz and feldspars, especially for use in the manufacture of porcelain tiles, poses challenges in terms of energy demand and efficiency. Due to the dry nature of the operations, it has the potential to disperse large volumes of particulate matter into the environment. Objective: This study aimed to analyze quartz and feldspar beneficiation operations at two mineral processing units located in Rio Grande do Norte, focusing on energy consumption and dust dispersion reduction. Method: For each processing unit visited, the crushing, screening, grinding, and classification variables were observed and evaluated, generating a process flowchart for comparison and identification of operational bottlenecks. Energy estimation (Bond's Law) was applied for each mineral substance (quartz and feldspar) to determine the correlation between WI and feed (F80) and product (P80) particle size distributions. Results and Discussion: For feldspar, the WI is 11.67 kWh/t at both units, but energy consumption at the first was 11.44 kWh/t, while at the second it rose to 12.34 kWh/t, representing an increase of approximately 7.9%. In the case of quartz, with a WI of 12.77 kWh/t, consumption was 12.52 kWh/t at Unit 1 and 13.49 kWh/t at the second, an increase of approximately 7.7%. From an environmental perspective, the need for equipment encapsulation, especially in the VSI crusher and screening, is highlighted, as a fundamental strategy for controlling particulate matter emissions in mining operations. Research Implications: The application of targeted research to assess energy efficiency in mineral processing plants proves essential to balance mining development with operating costs, and identifying potential impacts from the activity ensures the recommendation of environmental control measures. Originality/Value: The article presents a proposal for evaluating technical improvements in quartz and feldspar processing, highlighting trends such as the use of new crushers (HPGR) and changes in grinding parameters, ensuring reduced energy consumption and dust control measures.