Evaluation of flotation circuits design using a novel approach

Vallejos, Paulina; Yianatos, J.; Grau, Rodrigo; Yañez, A.

doi:10.1016/j.mineng.2020.106591

Cited by 6 publications

(4 citation statements)

References 17 publications

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“…A more detailed description of this simulation tool was developed by Yianatos et al [15]. Additionally, calibration and testing studies of the simulation tool have been reported [16][17][18][19]. This tool is currently implemented in the HSC Chemistry ® software [20].…”

Section: Metallurgical Prediction By Using An Industrial Simulation Toolmentioning

confidence: 99%

Size-by-Liberation Characterisation of an Industrial Flotation Bank in Rougher and Cleaner–Scavenger Operation

Vallejos

Yianatos

Rodríguez³

et al. 2023

Minerals

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The flotation process characterization is typically based on the mineral properties and related to the feed particle size. Laboratory testing allows for the evaluation of the batch flotation kinetics, while plant surveys are carried out for the plant evaluation, and sometimes the rougher flotation stage is also characterized by kinetics, considering either the full sampling of the circuit or the short-cut method. Comparisons of plant and batch results are useful for identifying the scale-up factors. The kinetic evaluation of cleaner stages is less common in plant surveys, and usually, only the overall cleaner and scavenger results are reported. This condition limits a more comprehensive understanding of these stages, which have significant differences from the rougher operation. In this study, the effect of main operating variables in cleaner and scavenger stages, such as finer particle size, higher mass recoveries, higher liberation, particles entrainment, froth recoveries, mineral grades, froth depth, gas rate, and others, was analysed by using an industrial simulation tool that was built from a wide industrial database. For this purpose, data from plant kinetic surveys was used to characterize the mineral feed entering the cleaner–scavenger stage, which allowed for calibrating the simulation tool and predicting the overall circuit performance. The metallurgical results of the cleaner–scavenger bank were compared with those when the bank was operating at a rougher stage (previous operation). The results allowed for evaluating the differences in metallurgical results of the cleaner–scavenger and rougher banks, mainly related to the differences in particle size and liberation as well as in the mass flowrate of collected particles, which affects bubble loading and consequently froth stability, that in turns impacts on froth recovery. The operating conditions and mineral characteristics of each stage also impacted the water recovery and gangue entrainment along the banks. The comparison of predicted recoveries and grades in rougher, cleaner, and scavenger stages showed a good agreement with plant data. These results validated the simulation tool, which is useful and flexible enough to characterize different stages, predict performance and explore new operating conditions.

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Section: Metallurgical Prediction By Using An Industrial Simulation Toolmentioning

confidence: 99%

Size-by-Liberation Characterisation of an Industrial Flotation Bank in Rougher and Cleaner–Scavenger Operation

Vallejos

Yianatos

Rodríguez³

et al. 2023

Minerals

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show abstract

“…Cells in Bank B had shorter froth transport distances than those in Bank A, which favoured the recovery of coarser particles. The effect of shortening froth transport distances by modifying launders' configuration on the metallurgical performance was evaluated in some simulation studies [15], as well as in plant studies [16][17][18][19],…”

Section: Characterization Of Cu Recovery Per Particle Size and Libera...mentioning

confidence: 99%

Kinetic Response of Industrial Flotation Banks: Effect of Particle Size and Mineralogy

Vallejos

Yianatos

Rodriguez³

et al. 2023

Minerals

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One of the main problems in current flotation plants and new projects is the significant decrease in feed grades and changes in the mineral composition, which has an important effect on the mineral liberation and associations. Additionally, flotation plants usually operate with a feed throughput higher than the original design, which has a significant impact on the feed particle size. All these conditions affect the metallurgical performance, and they must be evaluated and addressed by improving the control strategies for the optimization of banks. For this purpose, the flotation of valuable minerals along the circuits requires better understanding, considering the compromise between performance and selectivity in flotation circuits. This paper presents a characterization of the different minerals recovered along industrial flotation circuits. Plant sampling campaigns, performed in a copper industrial concentrator in Chile, provided the data for the study. Two rougher flotation banks consisting of cells of 130 m3 and 300 m3, were evaluated. All the samples from the industrial surveys were analysed by screening and mineralogy, and the mineral recovery along the circuits was evaluated per particle size class, liberation class, type of associations, and others. Additionally, operating data on froth depth profiles complemented the evaluation of the mineral composition of concentrate streams along the circuit. The results allowed for identifying and quantifying the main factors that affect the copper recovery and concentrate grade along the flotation banks. We found that minerals with liberation lower than 50% have a significant impact on the recovery. On the other hand, the decrease in the Cu grade in concentrates along the flotation circuits is mainly due to the relative increase of middling minerals (less liberated), non-valuable floatable minerals, such as free pyrite, and gangue entrainment. The characterization of the gangue entrainment flowrate along the flotation banks showed a strong relationship with froth depth, which becomes more critical towards the last cells of the banks.

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“…Although retrofits have been widely incorporated into industrial operations and there are several studies of their effect on flotation performance, − the influence of retrofit designs on turbulence has not yet been explored. This gap in the literature may relate to the technical challenges associated with the measurement of the turbulent fluid dynamics of opaque multiphase systems.…”

Section: Introductionmentioning

confidence: 99%

Effect of Retrofit Design Modifications on the Macroturbulence of a Three-Phase Flotation Tank─Flow Characterization Using Positron Emission Particle Tracking (PEPT)

Cole

Mesa

Heerden

et al. 2023

Ind. Eng. Chem. Res.

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Turbulence in stirred tank flotation tanks impacts the bulk transport of particles and has an important role in particle−bubble collisions. These collisions are necessary for attachment, which is the main physicochemical mechanism enabling the separation of valuable minerals from ore in froth flotation. Modifications to the turbulence profile in a flotation tank, therefore, can result in improvements in flotation performance. This work characterized the effect of two retrofit design modifications, a stator system and a horizontal baffle, on the particle dynamics of a laboratory-scale flotation tank. The flow profiles, residence time distributions, and macroturbulent kinetic energy distributions were derived from positron emission particle tracking (PEPT) measurements of tracer particles representing valuable (hydrophobic) mineral particles in flotation. The results show that the use of both retrofit design modifications together improves recovery by increasing the rise velocity of valuable particles and decreasing turbulent kinetic energy in the quiescent zone and at the pulp−froth interface.

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Evaluation of flotation circuits design using a novel approach

Cited by 6 publications

References 17 publications

Size-by-Liberation Characterisation of an Industrial Flotation Bank in Rougher and Cleaner–Scavenger Operation

Size-by-Liberation Characterisation of an Industrial Flotation Bank in Rougher and Cleaner–Scavenger Operation

Kinetic Response of Industrial Flotation Banks: Effect of Particle Size and Mineralogy

Effect of Retrofit Design Modifications on the Macroturbulence of a Three-Phase Flotation Tank─Flow Characterization Using Positron Emission Particle Tracking (PEPT)

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