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TABLEOFCONTENTS

Abstract.....................................................................................................................................3
Introduction..............................................................................................................................4
Classification.......................................................................................................................4
Formation..................................................................................................................................6
ViewsonFormation...........................................................................................................6
Occurrence.........................................................................................................................6
FeaturesofGraphiteDeposits...........................................................................................7
Specificationofgraphiteforvarioususes................................................................................8
USESOFGRAPHITE.............................................................................................................8
Specificationsforvariousapplications...............................................................................8
GraphiteResourcesanditsUtilization.....................................................................................9
WorldReview.....................................................................................................................9
GraphiteresourcesinIndia.....................................................................................................10
RESOURCES.......................................................................................................................10
EXPLORATION&DEVELOPMENT.....................................................................................10
PRODUCTIONinIndia.......................................................................................................10
State/GradeWisedistributionofGraphiteinIndia.........................................................11
GraphiteBeneficiationProcess...............................................................................................12
TypicalWetGrindingCircuitforhighgradeGraphite......................................................14
Graphitebeneficiationatotherlocations...........................................................................15
Panchmahal,Gujrat..........................................................................................................15
Minerologyandchemicalcharactersticsofthegivensample...............................................16
Experiments............................................................................................................................17
Test1:MoistureAnalysis.....................................................................................................17

Test2:VManalysis..............................................................................................................18
Test3:AshAnalysis.............................................................................................................19
Test4:SpecificGravity........................................................................................................20
Test5:HardgroveGrindabilityIndex...................................................................................20
Test6:SinkandFloatanalysis.............................................................................................21
Test7:FrothFlotation.........................................................................................................22
Results.....................................................................................................................................23
Conclusion...............................................................................................................................25
Bibliography............................................................................................................................27

ABSTRACT
Thepropertiesandoccurrenceofgraphitearoundtheworldhasbeenoutlined.Thevarious
types of graphite, its formation, and its major producers both locally and internationally
shave been reviewed. The major uses of graphite are pencils, lubricants, foundries,
electrodes,paintsetc.Theyrequiregradesofgraphiterangingfrom60%to99%.
Lowgradegraphitesamplescontaining1517%fixedcarbonfromPalamu,Jharkhand,India
have been investigated for characterization and amenability tobeneficiation.
Thegraphiteis of the crystallized flaky variety, and is associated with large proportion of
quartz and some feldspar and mica as dominant gangue minerals. The properties and
liberationofgraphiteandtheirimplicationsinbeneficiationaredescribedinthispaper.The
optimum liberation size of thegraphitewas determined to be below 200
m.Beneficiationstudiesindicatedthataconcentratewitharound50%fixedcarbon,ata
recovery of about 80% can be easily achieved by a single stage of froth flotation in a
conventionalflotationcell.
Building upon the data obtained as well established principles of mineral processing, a
methodofupgradingthegivensampletogradereaching8090%fixedcarbonormorehas
beenoutlined.
KEYWORDS

Industrialminerals;oremineralogy;liberation;frothflotation;

GRAPHITE
INTRODUCTION
Graphite,alsoknownasplumbagoorblacklead,isatypeofnaturallyoccurringcarbon.The
originofthewordgraphiteistheGreekwordgrapheinwhichmeanstowrite.Indeed,
graphitehasbeenusedtowrite(anddraw)sincethedawnofhistoryandthefirstpencils
were manufactured in England in the 15th century. In the 18th century, it was
demonstratedthatgraphiteactuallyisanallotropeofcarbon.
Itconsistsessentiallyofcarbonbutoftenimpurewithclays,ironoxides,andothergangue
minerals. It crystallises in a hexagonal system and has a lamellar form, a grey toblack
metallic lustre and feels greasy. In addition to natural graphite, synthetic or artificial
graphiteismanufacturedonalargescaleinelectricfurnaces,usinganthraciteorpetroleum
cokeasrawfeed.ThelatterisknownasCalcinedPetroleumCoke(CPC).
Graphiteisaverysoftmineralanditisaspecificgravityvariesfrom2.09to2.03.Itisan
excellentthermalandelectricalconductor.Thehighmeltingpointofgraphite,inabsenceof
oxygen, 3500C makes it suitable for a number of refractory applications. Excellent acid
resistanceandgeneralchemicalinertnessmakeitsuseidealinacidenvironmentsandother
chemical applications. Graphite fibres drawn from organic precursors, such as rayon,
polyacrylonitrileandtarpitchareusedasreinforcingcomponentsinpolymercomposites.
Graphiteisminedfromopenpitandundergroundmineoperations.Openpitoperationsare
moreeconomicaland,thus,arepreferredwheretheoverburdenisthinenoughtoremove.
Madagascar mines are mostly open pit type. In the Republic of Korea, Mexico, and Sri
Lanka, however, where the deposits are deep, underground mining is usually developed.
Higherpuritymaterialisobtainedbyfurthercrushing,grinding,andflotationsteps.
CLASSIFICATION
A useful classification of graphite depends on the mode of formation that leads to three
physically distinct common varieties: amorphous (microcrystalline) graphite, which has a
carbon content of 7085%; high crystalline graphite (lump, vein or crystalline vein), which
hasacarboncontentof9099%;andflakegraphite,whichhasacarbonrangeof8098%.
Flakegraphite(i.e.,flatplatelikegrainsfrom<1mmto2.5cminsize)issoldintwoparticle
size distributions: coarse flake (20 to +100 mesh) and fine flake (100 to +325 mesh).

Crystalline graphite ranges from chip or dust to fine or amorphous lump, to coarse or
crystallinelump.
Thetermflakeisselfexplanatory;flakeformsoccurdisseminatedinrock.Lumpgraphite
occurs in fissurefilled veins in pegmatite dykes, also associated with chips and the rarer
needle forms. Amorphous graphite occurs in beds that were once coal, but finegrained,
easilygroundveingraphiteisalsoclassifiedasamorphous.

FORMATION
VIEWSONFORMATION
Areviewofliteratureongraphitedepositsindicatesthattheyareformedbyoneormoreof
theprocessesmentionedbelow:
(a) METAMORPHISMThemetamorphismmighthavebroughtmineralizationofgraphite
byoneofthefollowingways:
(i)
metamorphismofcarbonaceouslayers,inwhichcasegraphiteoccursintheform
oflayers(Winchell1911;Clark1921a,andHarrington1947);
(ii)
recrystallizationoforganiccarbonasgraphiteduringmetamorphismgivingrise
tobeddeddeposits(Tilley1921;andAiling1921);
(iii)
metamorphism of sediments containing carbon impurities giving rise to
disseminatedoccurrences(Wadia1943;Mukherjee1965;andKrishnaRaoetal.
1971);
(iv)
Interaction of carbonaceous sediments with the gases derived from adjacent
intrusions for the graphite deposits at the contact of the intrusions (Brumell,
1908 quoted by Clark 1921a; Bastin 1912; Ailing 1918; Wilson 1920; Spence,
1920;Wadia1943;Bose1959;andKrishnaRaoetal.1971).
(b) DEOXIDATIONbydeoxidationofCO,fortheformationofveins(Winchell1911;Clark,
1921a;Tilley,1921;Clark,19216;Winchell,1921;Wadia1943;andMukherjee1965)or
by release of carbon as methane from carbonate (Salotti et al. 1971; 1972) and
formationofveins.
(c) PEGMATITEDEPOSITSthemineraloccursinacidintrusions(Clark1921,p.179;and
Wadia1943,p.16),orinmeteoritesandnephelinesyenites.
(d) PHYSICALMIGRATIONoffinegraphiteflakesalonggrainboundariesingraphitebearing
rocksalongapressuregradienttowardsfracturesduringtemporaryreleaseofpressure
underdeepseatedconditionsandforminggraphiteveins(Erdosh1970,1972).
OCCURRENCE
Graphiteoccurschieflyinthoserocksthathaveundergoneintensemetamorphismandthus
it is found in older gneiss and schists, crystalline limestone, carbonaceous material in
originalsandstone,shaleandlimestone,recrystallineintheformofgraphite.Itmayalsobe
productofcontactmetamorphismwhereigneousrocksintrudecarbonaceoussedimentary
rocks.
In Palamu district the main rocks associated in the graphite include various types of
metamorphosedsediments.Goodamountofgraphiteoccurshereasoriginalconstituentin

schistoserocks.Atsomeplacesitscloseassociationisfoundwithpegmatites,quartzveins
andgneissicrocks.

FEATURESOFGRAPHITEDEPOSITS

Some schistose rocks consist of essentially graphite, along with mica, quartz, and
feldspar.
Thegraphitebearinggneissicrocksaretraversedbyveinsandstockworksofgraphite.
Theveinsformanintricatenetworkinthehostrock.
The host rocks in which the veins of graphite are found to contain quartz, calcite,
dolomite,diopside,wollastonite,andtremolite.
Compressedandcontortedstructuresaredisplayedbythegraphitelodes.
The granitic intrusions are found at or near the graphite veins indicating their close
relationship.
Thegraphiteveinsoccurmostlyparalleltothecountryrocks,butthecrosscuttingjoints
inthelatterarealsooccupiedbygraphite.
Veins of calcite are frequently found traversing the host rocks (talcsilicate rocks) and
thegraphiteveins.
Graphite is not found in the acid intrusions, without the association of calciosilicate
rock.

SPECIFICATIONOFGRAPHITEFORVARIOUSUSES
USESOFGRAPHITE
Graphite being versatile mineral and due to its diversified properties, it finds important
placeinmanycruciallyimportantindustries.Itisusedinthemanufactureofspecialtypeof
electrodes,speciallubricantsandalsointheatomicreactorsintheformofbricks ofhigh
purity graphite. It is also used for foundry when casting iron, copper, aluminum and also
steelandmagnesiumunderspecialcondition.
Graphite fibers composite absorbs rather than reflects radar waves and so the use of
graphitecontinuestogrowrapidlyintheuseofradarmaskingstealthtechnologyandalso
inmakingothernonaerospaceweapons.Inthedevelopmentofplasticengine90%ofthe
componentswouldbemadeofgraphitefibersreinforcedcompositestobeusedinFord's
small car to make them lighter and quieter. Although much of the graphite used in
industriesismanufactured,naturalgraphiteisindispensableforcertainpurpose.
SPECIFICATIONSFORVARIOUSAPPLICATIONS
Specifications for graphite for use in various industries differ considerably and sometimes
the consumers specify for the grade of graphite they use. The following table is however
indicativeofthespecifications,foritsuseinsomespecificindustries.
Application
Refractories
Aluminagraphite

Type Ccontent

F
Min.85%

Crucibles
Expandedgraphite

AF
F

8090%
Min.90%

Foundrycoreandmouldwashes
Brake/clutchlinings
Bearings
Lubricants

AF
AFV
FV
AFV

7090%
Min.98%
9093%
9899%

Flake

150 500
m
+150m
200 1700
m
75m
<75m
+150m
53106m

Drycellbatteries
Alkalinebatteries
RecarburizingsteMinn.
Carbonbrushes

A
AF
A
AFV

MM.88%
Min.98%
9899%
9599%

85%<75m
575m
5m
<53m

Electrical
Pencils
Packingpaints
Polishes
Drillingmud(lubricating)
Explosives(controlburningrate)

FV
AF
FV
AFV
F
AF

9395%
9597%
8590%
8590%
80%+
65%

+150m
+150m
<150m
<150m
N/A
<150m

Nuclearreactors(moderators)

9395%

N/A

Boilers(scaleprevention)

50%+

N/A

Size

Bulkdensity4854gper100cm3

Free from sulphides, abrasive material and


metalliccontaminants.
NometallicimpuritiesandSlessthan0.5%
NoimpuritiessuchasCu,Co,SbandAs.

< 1% ash / silica. No abrasive or metallic


contaminants.

Freeofgrittyimpurities

About41bperbarrelofmud
Free from sulphides and acids. Low moisture
content
Free from high neutron absorbing elements.
e.g.boron

GRAPHITERESOURCESANDITSUTILIZATION
WORLDREVIEW
World production of graphite in 2008 was estimated to be 1100000 tons, showing a
significantincreasefromthe1995valueof741,000tons.Thefigureis,however,about20%
lessthanthatofpreviousyears.ThemostsignificantdecreaseinproductionwasinChina.
China continued to be the leading producer followed by India, Brazil, North Korea and
Canada.Thesecountriesaccountedforalmost90%oftotalworldproductionofgraphite.
Country
2005
2006
World
2000
2039
Brazil
76
76
Canada
17
15
China
1650
1730
India
126
124
Korea, Dem.E People's 30
30
Rep.of
Mexico
12
12
Russia
14
14
Ukraine
10
6
Zimbabwe
4
7
Othercountries
61
25
Source:WorldMineralProduction.20032007.

2007
2100
77
15
1800
116
30
10
14
NA
7
31

China leads the pack with over 800,000 ton per annum production alone. It is the largest
produceraswellastheconsumerofcommercialgraphite.Thecountryhasmorethanhalf
of the worlds top 12 producing companies. Its resources are located in Inner Mongolia,
Shandong,ShanxiandHeilongjong.
Indiaistheworld'ssecondlargestgraphiteproducerwithaproductionof140,000tonnes
perannum.ItsmajorsourcesarelocatedinOrissa.Brazilisthethirdlargestproducerwith
aboutathirdofthetotalworldreserves.Thegraphitemarkethasrecentlysufferedslowing
ofthepaceduetotherecenteconomicdownturn.
Europehasdeceleratedgraphiteproductionprimarilyduetoexhaustionofresourcesand
availability of cheap graphite from China. Africa has some serious reserves of graphite in
SouthAfrica,Uganda,Angola,Tanzania,EthiopiaandNamibia.

GRAPHITERESOURCESININDIA
RESOURCES
Graphite occurrences are reported from various states but the deposits of economic
importancearelocatedinAndhraPradesh,Jharkhand,Karnataka,Kerala,Orissa,Rajasthan
andTamilNadu.
AspertheUNFCsystem,thetotalresourcesofgraphiteason1.4.2005areplacedatabout
168.77milliontonnes,comprising10.75milliontonnesinthereservescategoryand158.02
million tonnes under remaining resources category. Resources containing +40% fixed
carbon constitute about 1.11 million tonnes and resources analyzing 1040% fixed carbon
21.23 million tonnes. Balance resources of 146.43 million tonnes fall under 'others',
'unclassified' and 'not known' grades. Out of total resources, Arunachal Pradesh accounts
for43%followedbyJammu&Kashmir(37%),Jharkhand(6%),TamilNadu(5%)andOrissa
(3%).However,intermsofreserves,TamilNaduhasleadingshareofabout37%followedby
Jharkhand(30%)andOrissa(29%)
EXPLORATION&DEVELOPMENT
GSI continued exploration for graphite in PuvandiArasanur and Usilampatti area in
Sivaganga district,Tamil Nadu. In Arasanur block, presence of graphite mineralization has
beenprovedforastrikelengthof1km.Theaveragewidthofthezoneisabout12m.and
overall average grade is 14% F.C. A resource of 0.76million tonnes of graphite (average
gradeof13%FC)hasbeenestimatedin200607.
In the westernextension of Arasanur block, a new block named Kiranurblock, was
investigated and the results were found tobe not encouraging. The west of the Kiranur
block,135meastofamineofM/s.V.Thiruvanavukasasu,atrench(KT1)acrossgraphite
gneissexposedthreebandsofgraphitehaving1.90m,2.5mand1.6mwidths.In200708,
Directorate of Geology, Jharkhand,carried out exploration to determine one million
tonnesgraphiteresourcesofpossiblecategorywereestimatedwithfixedcarboncontentof
5.95to23.47%.
PRODUCTIONININDIA
Orissawastheleadingpositioncontributingamajorshareofabout44%ofthetotaloutput
during200708,followedbyTamilNadu43%andJharkhandby13%(Tables2to5).Mine
headstockattheendoftheyear200708was45thousandtonnesasagainst72thousand
tonnesinthebeginningoftheyear.Theaveragedailyemploymentoflaborduring200708
was331asagainst490intheprecedingyear.


STATE/GRADEWISEDISTRIBUTIONOFGRAPHITEININDIA

Grade/State

Reserves
Proved

Probable

Total(A)

Feasibility

AllIndia:Total
ByGrade
+40%FC
10%40%FC
Others
Unclassified
Notknown
ByStates
AndhraPradesh
ArunachalPradesh
Gujarat
Jammu&Kashmir
Jharkhand
Karnataka
Kerala
MadhyaPradesh
Maharashtra
Orissa
Rajasthan
TamilNadu
Uttarakhand

5163505

413639
4733667
15574

625

442537
1308

1553293
47600
3118767

1021869

77132
937943
6794

670448
6794
8300

336327

4564534

10749908

Remainingresources
Pre
Measur
feasibilit ed
12000
78386
930118

342807
3943249
210952
67526

833578
9614859
233320
67526
625

12000

37000
41386

80
930038

1135

2163106
188812
17762

1217349
165920
810450

1135

3276091
196914
26062

3106969
213520
3929217

12000

38900

39486

720000
35600

172032

2486

Total
Inferred

Indicated
51326

8740

2750
39836

2750

8740

29136
10700

5956595

16506673

Recon
Total
134489932

951
1596449
3283001
5882
1070312

238500
8952091
2330151
3127538
1858393

73897

61497720
72918315

276531
11614601
5613152
64633890
75886856

1110109
21229460
5846472
64701416
75887481

124758

2520805

1143701
18200
1148350

103281
250000
647500

301306

835000
1059520
5180124
52500
240418
1006660
1160000
1954721
1450034
3266390

72758257

61681035
24350

426064
72758257
3355805
62740555
7070925
70700
1424368
1006660
1160000
2315964
1700034
3984998
10700

427199
72758257
3355805
62740555
10347016
267614
1450430
1006660
1160000
5422933
1913554
7914215
10700

26290

Total
158025030

168774938

GRAPHITEBENEFICIATIONPROCESS
Asageneralrulethegraphiteoresarenotinsucharichstate,whentheycomefromthe
mine,astoadmitoftheirbeingatoncesentdirecttothemarket;theycontainmoreorless
impuritiessuchasoxideofiron,silica,aluminaandlimeoraresohardthattheycannotbe
employedatallintheirnaturalstate.Theymustbeenrichedbysomemeansoranotherso
thattheworthlessgangueorcountryrockmaybegotridof,thusincreasingthequantityof
carbonintheore.Themethodsofenrichingorrefininggraphitemaybedividedintothree
general systems. 1. Hand sorting. 2. Mechanical separation. 3. Chemical refining. The
mechanicalseparationisagainsubdividedintothedryorwetmethod.
Astohandsorting,thisispractisedinaveryefficientmannerintheAustrianandBavarian
mines, while no or scant attention is paid to this particular branch ofore dressing on the
North American continent. The choice of one or the other systems in the mechanical
separationorchemicalrefiningdependsentirelyuponthenatureoftheoretobetreated
and the purposes to which the finished product is to be applied, though too often the
selectionisbasedonchance,prejudiceandlimitedexperience.
The selection of the most profitable process and machinery for the treatment of a given
graphiteoreisofgreatimportanceinaminingenterprise;butassomeoresaresusceptible
ofsuccessfulworkingbymorethanoneprocessandinsuchcaseslocalconditionsmust
determinewhichmethodswillyieldthebestresultsitisnotpossibletolaydownexactrules
coveringallcases.
Flake graphite is usually too finely disseminated for hand sorting and cobbing methods,
whichareusedinfewcountriestorecovermassiveflakegraphite.Productionofgraphiteis
usuallyonlypossiblebyacombinationofcarefulgrindingandscreeningtorecovercoarse
flakes and by flotation to recover fine graphite. Flotation concentrates are sometimes
furtherbeneficiatedbytablingtoremoveassociatedganguemineralssuchasquartz,mica,
hornblende,feldspar,calcite,andsulphides.
Impurities tend to float with graphite since, being soft, graphite tends to smear and coat
impuritymineralsduringgrindingsothattheybehavelikegraphite.Thisisespeciallytrue
whenprocessingfinelydividedoresthatrequireextensivegrinding.Sizereductionisusually
accomplished by jaw, cone, or hammer milltype crushers; screening to recover coarse
flakesortorejectcoarsehardimpuritiesisaccomplishedbytrommelorvibratoryscreens.
The recovery of intermediate and fine flake graphite is possible by roll crushing, ball, rod
milling, or jet milling, followed by additional screening, air classification, wet tabling, or
flotation.Graphiteisnaturallyfloatableandparticlesascoarseas1mmmaybefloatedina
slightlyalkalinepHmedium.Pineoilandkerosenearethestandardreagentsandareusually
employed together. Pine oil acts as a frother. The function of kerosene or fuel oil is as a

promoter to recover unliberated graphite middlings. Flotation is fairly fast and multiple
cleaningsarenecessaryforrecoveriesof8085%;recoverycanbeimprovedbyregrinding
and reflotation, but careful regrinding is necessary to avoid the smearing of gangue
minerals and the production of slime graphite. Modifiers and depressants to improve
selectivityincludesodiumsilicate,whichactsasaquartzdepressantandslimedispersant,
andlacticacid,C3H6O3,whichisusedtodepressmica.Graphitemaybefurtherpurifiedto
99%carbonbychemicaltreatment,chloridization,orfluoridization.
Synthetic graphite, mainly produced in the United States, is made from a mixture of
petroleum coke or anthracite filler, coal tar, or petroleum pitch binder, and various
impregnating or additive materials. The coke or anthracite, which should contain 95%
carbonandhavealowsulphurcontent,iscalcinedtoremovevolatiles,ground,mixedwith
binderandothermaterials,andmoldedtotherequiredshape.Theproduct,knowninthe
trade as green bar or green stock, is then baked at 8001000C to convert the pitch
binder to coke and to solidify the shape. The resulting product is then graphitized by
heatinginanelectricfurnaceat26003000Coveranextendedperiod.Itisthencooledand
machinedtofinalsizespecifications(e.g.,theproductionofelectrodesturnedonlathesto
thedesireddiameterforuseinsteelminimills).

TYPI CALWETG
G RINDINGC
C IRCUITFO
ORHIGHGR
R ADEGRAP
P HITE

GRAPHITEBENEFICIATIONATOTHERLOCATIONS
PANCHMAHAL,GUJRAT
The ore is won by cutting trenches by manual labour and transporting it by trucks to the
beneficiatingplant.Themethodsareveryprimitiveandtheexcavationstartsfromsurface
outcropsofgraphiteoreandcontinuesalongthestrikeanddownwards.Rateofproduction
isslowandintermittent.Mostminesselltheirproductswithoutanybeneficiation.
ThesampleshadbeensenttoBhabhaAtomicResearchCentreforbeneficiationtests.They
were able to upgrade the materials from 6090 percent depending on the samples which
contained 1030% Fixed carbon. The tests carried out at Regional research Laboratory at
Bhubneshwarindicatedthatupgradationoforeupto95%waseconomicallyfeasible.
Sahu and Mungee (1972) have shown feasibility of upgrading ore from 25% to 55% with
around 50% recovery. Mild acid treatment before flotation reduces impurities and
repetition of flotation in identical cells further improve the grade. Multistage flotation
improvesrecoverybyover30%.
Mostofthemineralresourcesinourcountry(exceptingironoresetc.)arelowtomedium
ingradewhichneedbeneficiationinsomeformorothertomakethemsuitableforusein
mineral based industries. As such, these have to be upgraded to the desired specification
(within specified tolerance limits). Beneficiation of graphite includes gravity concentration
methods and also flotation. Sometimes chemical treatment like acid leaching and
chloridisationarealsoappliedforproductionofhighpuritygraphiteover99%F.C.

MINEROLOGY AND CHEMICAL CHARACTERSTICS OF THE


GIVENSAMPLE
The sample under study was procured from near Daltonganj in Palamu District of
Jharkhand.TheregionhasalargereserveoflowgradegraphitewithFixedCarboncontent
rangingfrom5%to30%dependinguponthesource.
Thegivensampleseemedtobeofflakytype.Thesewerepresentaslenticularpocketsof
quartz graphite schist embedded in granite gneiss. The chief gangue minerals associated
withthesampleweremostlyquartz,withsmalleramountsoffeldspar,andshinymicas.
Uponcrushing,thegraphiteseemedtobeprettywellliberatedatsizesaround400microns.
Fromthedataofthemineralogy,grainsize,theirliberationandfixedcarboncontentofthe
samplesafewimportantconclusionscouldbedrawn.
1. Chemical superiority of the sample alone does not signify the real worth of the
samplebutexternalcharacteristicshaveanimportantroleindeterminingthevalue
of any workable deposits. Sometimes the textural characteristics play a dominant
roleinthisregard.
2. Flakynatureofgraphitehavingflakesabove80meshfindsmanyimportantusesin
industriesaswellasinmanufactureofcrucibles.Itfetcheshigherpricealso.
3. Interlockingofthegangueswithgraphite(atveryfinesize)needsveryfinegrinding
which consumes 4060% of the total processing cost rendering it uneconomical.
Moreovergrindingofgraphitetoveryfinesizeisalsoextremelydifficultowingtoits
greasynature.
Keeping the above points in view two ways of beneficiation of graphite may be
suggested.
(a) if the liberation of graphite is at a coarse size, gravity methods of
concentrationmaybeeffective.
(b) If the graphite grains are liberated at a finer size, perhaps flotation
techniquesmightwork.
(c) Ifthegraphitemineralsareassociatedwithgangueatexceptionallyveryfine
stage, the processing may not be economical for obvious reasons (grinding
costwillbeveryhigh).

EXPERIMENTS
Experiments on graphite bearing ore are aimed to characterize the ore, to establish the
optimummethodtobeneficiatethegivengraphiteorewithmaximumpossiblegradeand
recovery. Due to unavailability of Indian standards for graphite characterization and
beneficiation procedures ASTM standards are adapted for the standardization of the
procedures.

TEST1:MOISTUREANALYSIS
ThegivensamplewastestedinaccordancewithASTMStandardsforflakegraphite.
The sample was pulverized to a size of 75 # in a pulveriser. The testing that followed
included heating the sample in a suitable container at a temperature of about 110 C for
durationof16hours.Thesamplewasleftovernightinanopenairoven.
Thesamplewasweighedinthelabusinghighprecisionelectronicbalancesbeforeandafter
thetestingtoobtainthefollowingdata:
Sample

InitialWeight FinalWeight Difference %Moisture

Sample1 9.9497

9.859

0.0907

0.911585274

Sample2 9.9085

9.8033

0.1052

1.061714689

Sample3 10.2377

10.132

0.1057

1.032458462

Total

1.001919475

Theaboveanalysisindicatesthatthesampleisfairlydry.Thetracesofmoisturearemostly
harmlessandshouldposenoconcernineitherwetordryprocesses.

TEST2:VMANALYSIS
The standards for measuring Volatile Matter content of graphite were not available. It
forced us to modify existing standards to suit the purpose. Since graphite can easily
withstand high temperatures, an assumption was made to heat the sample to a
temperatureof900Cfordurationof10minutes.
Onegramofthesamplewegotinthelaststep(75#,dried)wasthentransferredtoaVM
crucible.TheVMcruciblewasthenputinsideafurnacepreheatedto900Cfordurationof
10minutes.Afterthestipulatedtime,thesamplewascooledandweighedinanelectronic
balance.Thedataobtainedwasthefollowing:

Sample

InitialWeight FinalWeight Difference %Moisture

Sample1 1.09

1.0833

0.0067

0.614679

Sample2 1.0023

0.994

0.0083

0.828095

Sample3 0.9997

0.9926

0.0071

0.710213

0.7176%

TheresultofVolatilematteranalysisindicatesthatthereisnodiscernableVolatilematterin
the sample. The presence of low VM indicates that graphite can be processed and used
withoutmuchproblem.

TEST3:ASHANALYSIS
ThegivensamplewastestedinaccordancewithASTMStandardsforflakegraphite.
Thesamplewaspulverizedtoasizeof75#inapulveriser.Theprocedureoutlinedinthe
standardsstatesthatthesampleshouldbeintroducedinasilicadish.Thesamplewasput
in the silica dish so that a thin layer of sample covered the bottom of the dish (about 2
grams).Themufflefurnacetobeusedfortheprocesswaspreheatedtoatemperatureof
500C.Thetemperaturewasraisedto750Cslowlywithinonehour.Thiswasfollowedby
another200Cincreaseintemperatureinthefollowinghour.
Thesamplewaskeptatthisfinaltemperatureof950Cfor24hoursandwasperiodically
disturbed by a clean iron wire to expose surfaces to air. The sample was weighed twice
duringtheprocessanditwasdeterminedthattheentirecarbonhasbeenoxidized.Theend
productfailedtoshowanyblackparticles.Thesamplewasthenplacedinadesiccatorfor
coolingandweighedinanelectronicbalance.Theresultobtainedindicatedthefollowing:
Sample

InitialWeight FinalWeight Difference %Ash

Sample1 2.073

1.722

0.351

83.06802

Sample2 2.113

1.735

0.378

82.11074

Sample3 1.982

1.62

0.362

81.73562

82.30479

The ash percent of 82% is very high. The ash mostly contains quartz and sand particles.
Correcting for moisture and VM, the final Fixed Carbon percentage can be calculated to
around16%.Thisisadifficulttowashsampleandneedsmuchprocessingbeforeanyviable
productcanbeachieved.

TEST4:SPECIFICGRAVITY
Thegivensamplewastestedforitsspecificgravitywiththehelpofaspecificgravitybottle.
ThespgravityofKerosenewasfoundtobe0.82.
Usingthisvalue,andthespecificgravitybottle,thedensityofaconedandquartered75#
samplewasdeterminedtobe2.56.
ThespecificgravityofBromoformwasdeterminedtobe2.86

TEST5:HARDGROVEGRINDABILITYINDEX
Hardgrove grindability index is basically defined for coal, but in the particular case it has
alsobeendoneforgraphitetoevaluatebreakingcharacteristicsofthegraphite.Hardgrove
indexhasbeencalculatedas
HGI=13+6.93W
WhereWistheamountof200#materialobtainedaftertest

Weightof200# HGI

Sample1

4.80gm

46.264

Sample2

5.43gm

50.6229

AverageGardgroveIndex=48.45
The sample is thus very difficult to grind and the minimum amount of grinding must be
done.Otherwise,thegrindingcostcanmaketheprocesstooexpensive.

TEST6:SINKANDFLOATANALYSIS
Thegivensamplewaspulverizedtoasizebelow400micronsandthensubjectedtoasink
andfloatanalysis.
PREPARATIONOFDENSEMEDIA
Dense media was prepared by using Bromoform and Kerosene. The proportion of dense
media to be used was determined using mathematical equations. The exact volume of
ingredientsrequiredwasthusdetermined.Densemediawaspreparedatdifferentdensities
rangingfrom2.7to2.4g/ccat.1intervals.
SINKANDFLOATTESTS
Thesamplewasfloatedinthedensemediapreparedandtheamountofsinkandfloatin
eachdensityclasswasdetermined.
Sp
Gravity
2.4
2.42.5
2.52.6
2.62.7
2.7

wt%

cumwt%

3.116348406
13.52310641
47.31312558
26.12337616
9.924043444

3.116348406
16.63945482
63.95258039
90.07595656
100

Theflotationtestclearlystatesthatmostofthemassisconcentratedinthedensityrange
of2.52.6g/cc.Thisisprimarilyduetopresenceofdensequartz.
ASHANALYSISOFFRACTIONS
An ash analysis of each of these fractions was performed to better understand their
characterstics.TheprocedureisalreadyoutlinedinTest3.
Sp
Gravity
2.4
2.42.5
2.52.6
2.62.7
+2.7

wt%

Ash%

3.116348406
13.52310641
47.31312558
26.12337616
9.924043444

60.6
70.35
77.36
84.86
89.77

Theashanalysisconfirmstheearlierinferencethatmostoftheparticlesofasharefinely
disseminatedanddifficulttoliberateatasizeof400microns.Asizereductionbelow200
micronswillbenecessarytoliberatethegraphiteproperlyfromquartz.

TEST7:FROTHFLOTATION
The given sample was pulverized and screened to obtain a size passing a screen of 400
microns.
CONDITIONING
Thefeedwaspreparedwithapulpdensityof1.5g/ccusing496gramsofsample.Graphiteis
anaturallyfloatablemineralandisthuseasytofloat.
Conditioningisperformedtoachievethefollowing:
AlkalinepH:additionofabout.5gofNaOHpelletstotheconditioningtank.AlkalinepHis
showntoimproveflotability.
Quartzdepressant:Sodiumsilicateselectivelydepressesquartz.Itproveshugelybeneficial
inflotation.Italsoactsasslimedispersant.
Conditioner: Kerosene itself is used as a conditioner. It is highly effective in graphite
flotation.
Frother:Pineoilwasaddedtostabilizethefrothlongenoughtoremovetheconcentrate.
FLOTATION
The froth was collected at fixed intervals of 30seconds upto 3 times for each sample.
FloatationcellusedisaDenverlaboratoryfloatationcellhavecapacityof3l,thismachine
hasbeenchosenasgraphiteneedsmoreforceforlifting,thusmoreagitation.Thesamples
weredriedinanairovenandweighed:

Weightrecovered Wtofsample wtofcarbon Carbon% Yield Recovery

Tailing

323.2

1.87

0.089

2.359

0.660 0.086026162

030sec

70.03

0.67

0.3835

57.23

0.143 0.452209878

3060sec 64.08

0.908

0.479

47.75

0.131 0.345216262

6090sec 32.6

1.365

0.434

31.79

0.067 0.116933791

489.91

TheFlotationtestsindicatethataproductwith60%FCcaneasilybepreparedbyasingle
stageflotation.

RESULTS
By the above experiments and data collection most appropriate method for recovery of
bestpossiblegradeofgraphitecanbeselected.
Bytakenintoconsiderationsofthesizeoftheore,andtheneedofthesizeliberationfor
the process size reduction is usually accomplished by jaw, cone, or hammer milltype
crushers;
screening
to
recover
coarse
flakesortorejectcoarsehardimpuritiesisaccomplishedbytrommelorvibratoryscreens.
Therecoveryofintermediateandfineflakegraphiteispossiblebyrollcrushing,ball,rod
milling,followedbyadditionalscreening,airclassification.
Thedatacollectedformfloatandsinktestandfloatationtestcanbeanalyzedtocheckthe
amenabilityoforebeneficiationbyeveryprocess.

35
30
25
20
Carbon%
15
10
5
0
0

10

20

30

40

50

60

70

80

90

100

CummWt%

SinkandFloattest:FloatCurve

Fromtheabovefloatcurveithasbeenestimatethatgradegreaterthan31%carboncant
be achieved by the gravity separation method. This practical result can be theoretically
justified as the density of graphite and other gangue matter as quartz, etc are too close.
Since 31 % carbon graphite is not used in any application, thus there is no mean is
upgradingcarboncontentofgraphitefrom16%to31%.
Floatationisalsoanalyzedinthesamewaytocheckitsamenability.Thedataoffloatation
timeandgraderecoveredisplotinafollowinggraph.

58
57
56
55
54
CummCarbon% 53
52
51
50
49
48

20

30

40

50

60

70

80

90

100

Floatationtime

Sinceitcanbeseenthatthegradeofalmost58%canbeachievedatgoodrecoveryof15%
and grade of 51% can be achieved at recovery of 80%. Thus the process is effective in
upgradationoflowgradegraphiteore.Thiscanbetheoreticallyjustifiedasthegraphiteis
naturallyfloatablematerial.

CONCLUSION
Graphiteisnaturallyfloatableandparticlesascoarseas1mmmaybefloatedinaslightly
alkaline pH medium. Pine oil and kerosene are the standard reagents and are usually
employed together. Pine oil acts as a frother. The function of kerosene or fuel oil is as a
promoter to recover unliberated graphite middling. Flotation is fairly fast and multiple
cleaningsarenecessaryforrecoveriesof8085%;recoverycanbeimprovedbyregrinding
andrefloating,butcarefulregrindingisnecessarytoavoidthesmearingofgangueminerals
and the production of slime graphite. Modifiers and depressants to improve selectivity
includesodiumsilicate,whichactsasaquartzdepressantandslimedispersant,andlactic
acid,C3H6O3,whichisusedtodepressmica.
Graphite may be further purified to 99% carbon by chemical treatment, chloridization, or
fluoridization.
Floatation as a process can be improved by using cleaner circuits in series for better
recoveryofhighgradegraphite.
Thusthegraphiteobtainedhavecarboncontent58%,itcanbeusedinvariousapplications
likefoundries,conductivecoatings,boilers.Etc.However,afterupgradingthisgraphiteby
various methods of multicleaning flotation process and chemical methods, it can be used
foranyapplication.

FLOWSHEETOFATYPICALGRAPHITEUPGRADATIONCIRCUIT

BIBLIOGRAPHY
1. GraphitedepositsofDevgadBaria,Panchmahal,GujratScopefordevelopmentBL
Narayana
2. IndustrialMineralsLaboratoryManualFlakeGraphiteCJMitchell
3. ThebrightsideofgraphiteAlexandraFeytis,July2010industrialminerals
4. GraphiteMichelDumont
5. GRAPHITERustuS.Kalyoncu
6. AreviewonbeneficiationprospectofsomeofthegraphitedepositsofBiharP.N.
Pathak,M.V.RanganathanandD.M.Chakraborti

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