Ex-ante life cycle assessment of FineFuture flotation technology: case study of Grecian Magnesite

Purpose This study aims at evaluating the environmental performance of a novel froth flotation technology in mining industry from a life cycle perspective. The technology is being developed under EU Horizon 2020 project titled "FineFuture" (FF) with the aim of saving valuable materials in fine particles that are currently wasted due to lack of technology.Methods FF relies on chemically enhancing the physical characteristics of particles allowing it to float and concentrate. Prospective life cycle assessment (pLCA) was conducted for two possible industrial applications of FF flotation technology in the case study of Grecian Magnesite (GM) which is a main magnesium oxide producer in Europe. Each application can be perceived as a standalone comparative LCA study comparing current system with future system incorporating FF technology on industrial scale.Results and discussion The future scenarios did not decisively support FF technology in neither of the two applications from an environmental point of view. When applied to fines of < 4 mm granular size with the aim of material recovery, the future scenario performed better than the current situation only in 5 out of 16 impact categories. The main issue is the added burden of calcination phase. When the technology was tested to upgrade the existing magnesite concentrate before calcination, it introduced some gains in most of the impact categories, but the difference compared to the current situation is not very considerable. Testing improved scenarios showed a great benefit to the overall performance of the scenarios by introducing cleaner fuels and burners in calcination phase.Conclusion and recommendations Overall, the results tend to favour applying FF technology to upgrade low quality concentrates rather than beneficiating < 4 mm fines. However, and in any case, if FF technology is to be applied, combining it with cleaner fuels and burners in calcination should be prioritized. Furthermore, it was found that improving the purity (i.e. quality) in the flotation tank output is a key factor from an environmental view. The results also showed little impact of the added electric energy demand from the new units. As any pLCA, the study has limitations mainly originating from the low technology readiness level (TRL) when data collection activities were carried out. Further studies should start from pilot-scale data and adopting more accurate upscaling approaches to calculate the impacts of a full industrial deployment of the technology.