Sustainable Lithium Recovery from Biotite Waste of Nepheline Syenite via Magnetic Separation and Flotation with MLA-Based Mineralogical Characterization

This study investigated lithium beneficiation from nepheline syenite ore containing 242.57 ppm Li, identifying biotite as the primary lithium-bearing mineral. A high-intensity dry magnetic separation produced a pre-concentrate assaying at approximately 850–1000 ppm Li, and flotation tests were conducted on both the run-of-mine ore and this magnetic product. Flotation performance was systematically evaluated using two top sizes (−500 and −300 µm), six size fractions (−500 + 75, −500 + 53, −500 + 38, −300 + 75, −300 + 53, −300 + 38 µm), four pH values (2.5, 4.0, 6.5, 9.5), and three collectors (DAHC, Derna 7, and Der A4). Among the reagents, Der A4 yielded the most promising results. Optimization using sodium silicate as a depressant demonstrated that, at 20 g/t Der A4, 500 g/t Na2SiO3, and pH 4.0, the −300 + 75 µm fraction of the run-of-mine ore reached approximately 5300 ppm Li. Applying the same parameters to the magnetic pre-concentrate resulted in a 6326.46 ppm Li concentrate with roughly 80% of flotation recovery. Mineralogical characterization using MLA, XRD, modal mineralogy, and SEM-EDS confirmed that the optimized product consisted predominantly of biotite, accompanied by K-feldspar, nepheline, and albite. Liberation results showed high liberation levels and the free surface, supporting the efficiency of combining magnetic separation with flotation for upgrading nepheline syenite as a potential lithium resource.