Development and calibration of a dynamic flotation circuit model

Seppälä, Pirjo; Sorsa, Aki; Paavola, Marko; Ruuska, Jari; Remes, Antti; Kumar, Haresh; Lamberg, Pertti; Leiviskä, Kauko

doi:10.1016/j.mineng.2016.07.004

Cited by 12 publications

(10 citation statements)

References 20 publications

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“…The maximum recovery (R ∞ ) and flotation kinetic rate constant (k) of the minerals were obtained by performing a nonlinear regression analysis of the experimental results using Equation (1). Because the coefficient of determination (R 2 ) of all minerals was calculated to be 0.96 or more, the experimental results can be assumed to have correlated significantly with the first flotation kinetic model (Equation (1)) [27,41]. In general, the R∞ and k values of gold and pyrite were higher than those of quartz and muscovite.…”

Section: Flotation Kineticsmentioning

confidence: 99%

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Diagnosis and Optimization of Gold Ore Flotation Circuit via Linear Circuit Analysis and Mass Balance Simulation

et al. 2021

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The aim of this study is to diagnose and optimize a closed multistage gold ore flotation circuit in an operational industrial plant. Linear circuit analysis (LCA), a partition-based model, and a mass balance model using flotation first-order kinetics are employed to diagnose the current process. The result shows that the current circuit operates with high recovery but the gold grade of the final concentrate is low owing to the low buoyancy ratio. Hence, several alternative circuits with different streamlines and cell arrangements are proposed and simulated using LCA and a mass balance model. The result suggests that if the current process is changed to an alternative circuit in which the floated product stream of the rougher bank is changed, then the gold grade of the concentrate can be improved by 128%. Finally, the current circuit is optimized by changing it to an alternative circuit. This study provides a methodology for adapting the simulation of optimization for the flotation circuit of an industrial plant via LCA and mass balance simulation.

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Section: Flotation Kineticsmentioning

confidence: 99%

“…However, this method is prone to errors when scaled up to accommodate the plant. Furthermore, it is expensive to configure and test multiple plant-scale flotation circuits [14,19,26,27].…”

Section: Introductionmentioning

confidence: 99%

Diagnosis and Optimization of Gold Ore Flotation Circuit via Linear Circuit Analysis and Mass Balance Simulation

et al. 2021

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“…Depending on the availability and cost of a measurement either direct, indirect or even novel measurements can be experimented. As an example, a dynamic model of a copper flotation circuit has been developed in Seppälä et al work [3]. The model can be applied e.g.…”

Section: Extended Abstractmentioning

confidence: 99%

Considerations in Mineral Processing of Scale-up from Bench to Pilot Plant to Full Production

Sinche-Gonzalez¹,

Luukkanen²,

Paavola³

2017

World Congress on Mechanical, Chemical, and Material Engineering

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Extended AbstractPilot plants are used to reduce the risk of scaling laboratory results to full scale production. Material handling, solidliquid separations, recycling streams (mediums), waste handling, recycled water as well as process control can be addressed in the pilot plant before the demonstration and commercial plants are built. These issues are difficult to investigate during bench scale tests.For example, in flotation, laboratory scale tests have to be performed as completely and carefully as possible not only to optimize the metallurgical performance but also to tackle hydrodynamic issues and changes in the surface of mineral particles with the interaction of reagents, water constituents and air bubbles that would affect collection efficiency. Those are important considerations as chemistry and process will vary from plant to plant [1].Additionally, pilot plant testing enables evaluating the performance of the process based on the preceding laboratory scale testing and against mechanical and operating difficulties that may arise; aiming at optimized continuous mode process operations before a full scale plant development. Additionally, a full automatized pilot plant will allow adjusting operational conditions due to changes in mineral composition, liberation (PSD, association, texture, others), oversee any variation on the process [2] and predict with more accuracy the final product at full scale.A continuous pilot plant also enables to study the most suitable measurements and process control systems. Depending on the availability and cost of a measurement either direct, indirect or even novel measurements can be experimented. As an example, a dynamic model of a copper flotation circuit has been developed in Seppälä et al. work [3]. The model can be applied e.g. for studying the complex flow arrangements and back-circulations that need to be taken into account in control design. An additional advantage of the pilot plant is that it might reduce cost and time of developing advanced process control (APC) system for a plant. As reported in [4] the development of an optimal-setting control for grinding circuit, although providing significant savings and fast payback time, took over 20 months and 2 million dollars.The objectives of this paper are first to show the importance of mineralogical and R&D data from laboratory batch flotation testing, demonstration at pilot plant scale and the interpretation and conversion of the data into practical design requirements and consideration of scalability factors. Secondly, to emphasize the need of reliable information in scaling up from bench to pilot and further to full scale by modelling and, finally, to present the key considerations of scale-up and results obtained in the work done with Cu-Zn ore from First Quantum Mineral´s Pyhäsalmi mine in a continuous and completely automatized pilot plant at Oulu Mining School at University of Oulu, Finland. A series of batch flotation test were used to evaluate the behaviour of main ore minerals (copper, zinc). Obtained da...

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“…Some alternative calibration approaches include trial and error, statistical inference, and a suitable optimization strategy [21]. Among these alternatives, optimization stands out in that it yields near-optimal solutions within a feasible amount of time for practical applications and offers a structured and replicable framework [22,23].…”

Section: Introductionmentioning

confidence: 99%

“…The advantages of model calibration based on optimization techniques have been established in the literature [22,23]. In 1984, Klimpel and Austin stated their preference for a condensed breakage function model, arguing that solving the calibration problem with an uncondensed model demands too much computational power [24].…”

Section: Introductionmentioning

confidence: 99%

Calibration and Validation of a Cone Crusher Model with Industrial Data

et al. 2021

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This paper reports the calibration and validation of a cone crusher model using industrial data. Usually, there are three calibration parameters in the condensed breakage function; by contrast, in this work, every entry of the lower triangular breakage function matrix is considered a calibration parameter. The calibration problem is cast as an optimization problem based on the least squares method. The results show that the calibrated model is able to fit the validation datasets closely, as seen from the low values of the objective function. Another significant advantage of the proposed approach is that the model can be calibrated on data that are usually available from industrial operation; no additional laboratory tests are required. Calibration and validation tests on datasets collected from two different mines show that the calibrated model is a strong candidate for use in various dynamic simulation applications, such as control system design, equipment sizing, operator training, and optimization of crushing circuits.

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Development and calibration of a dynamic flotation circuit model

Cited by 12 publications

References 20 publications

Diagnosis and Optimization of Gold Ore Flotation Circuit via Linear Circuit Analysis and Mass Balance Simulation

Diagnosis and Optimization of Gold Ore Flotation Circuit via Linear Circuit Analysis and Mass Balance Simulation

Considerations in Mineral Processing of Scale-up from Bench to Pilot Plant to Full Production

Calibration and Validation of a Cone Crusher Model with Industrial Data

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