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Abstract

The interaction and synergic effect of particle size on flotation efficiency were investigated by a comparison study between laboratories (size-by-size flotation modes) and industrial scale operational data (whole mixed size fraction). For this purpose, sampling was done from the feed, concentrate, and tailing of the flotation rougher cells of the Sungun copper processing complex (located in the northwest of Iran). In the size-by-size flotation mode (lab scale), the sample was first subjected to different size fractions, and then flotation tests were performed for each fraction. On an industrial scale, the particle size distribution of feed, concentrate, and tailing of flotation of the rougher stage have been analyzed. According to the results, in the case of industrial flotation mode (whole mixed size fraction), the particles with d 80 =84 μm were more likely to reach the tailing of flotation, and the particles within the size range of +63-180 μm constituted the highest amount of concentrate particles. In lab flotation mode (size-by-size), the maximum recovery was in the size fraction of +40-60 μm. By comparing the two flotation modes of industrial (whole mixed size fraction) and lab (size-by-size), for fractions <45 μm, the industrial flotation recovery was approximately 40% greater than the lab flotation recovery. However, for fractions >125 μm, the recovery trend was reversed and the lab flotation recovery was greater than the industrial flotation recovery. Coarse particle flotation has significant economic and technological benefits. By improving the recovery of coarse particles during the flotation process, the amount of grinding requirements will be reduced and consequently, it will considerably decrease the amount of energy consumption.