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By Z. H. Xie, D. S. He, W. M. Xie

China has rich phosphate rock resources, but with their continuous depletion, the rich ore resources have become increasingly scarce, which makes the exploration of collophane more important. Medium- and low-grade phosphate rock cannot be utilized until their impurities have been removed through mineral processing. However, due to the similar physical and chemical properties of dolomite and phosphorus minerals, the separation of dolomite from phosphate

By Donald S. Skufca

This chapter focuses attention on major factors pertaining to plant design and general arrangement of equipment. Considered are efficiency of operations, coordination of maintenance and repairs, plant testing of reagents and possible future plant expansions. The design and general arrangement of equipment considers accessibility for maintenance and isolation for repairs, minimum personnel for operations and cleanup, safe working conditions with minimum interruptions to operations. The constant introduction of new reagents requires eventual plant testing and the manner of isolating a “line” or part of the facilities to allow comparisons in the testing of new reagents is discussed. As technology improves and process changes occur, additional equipment or plant expansions are inevitable. Space for these eventualities must be considered while the general arrangement drawings are in the development stages.

Jan 1, 1986

By C McInnes

The key to successful flotation plant design, production planning and mine/mill optimisation is a solid understanding of the resource to be processed. As advocated by the authors of this paper, the main components of geometallurgical modelling of an orebody and its associated flotation plant are: an ore sampling program and subsequent laboratory testing of these samples in order to extract process model parameters; geostatistical distribution throughout the resource model of the process parameters; calibration of the plant via benchmarking (for existing operations); and plant simulation using a system of process models and the distributed metallurgical parameters (from step two) as the data set.It is important that the grinding and flotation models are linked. For example, a laboratory test conducted on a drill core sample, intended to represent a portion of the orebody, is conducted at a specific grind (represented by a P80). However, when that ore is actually processed through the plant it may well be (and in many cases most likely will be) at another P80. Additionally, the flotation plant residence time will often be determined solely by the grinding circuit capacity and feed slurry density. In the case of SAG mill û ball mill circuits, the fluctuations in tonnage and grind are known to be high. The modelling approach described in this paper allows for changes in the measured flotation kinetic parameters in order to reflect the expected grind as determined by the comminution process.

Jan 1, 2005

By Dexter C. Hatch

At MacIntyre Development of the National Lead Company, Taha s, New York,, the flotation plant was set up to recover ilmenite from the finer size fraction of the ore that cannot be efficiently treated in the main gravity-magnetic separa¬tion process. It was later expanded to handle the reground middlings from the tables wetherill magnetic separators. The ilmenite-magnetite ore is ground to minus 20 mesh in five 6 x 12 ft. rod mills in closed circuit with DSM screens. The minus 20 mesh screen undersize is pumped to four parallel sections each consisting of two rougher wet-magnetic separators and one cleaner separator for magnatite removal. The screen undersize from the fifth section is distributed to all four sections. The magnetite removed in the roughers is pumped back to the cleaners and the cleaner magnetite is dewatered in rake classifiers and carried by belt to the winter plant or the stockpile area. The nonmagnetic sands from rougher and cleaner magnetic separator are sized for table feed in eight pocket hydraulic sizers. The slime overflows from the Crocketts, the sizers, and the magnetite rakes are collected and pumped to three-inch cyclones for thickening and desliming. The cyclone underflow is the principal flotation plant feed.

Jan 1, 1962

By T. Negeri, Y. Breau, M. Plante, A. Orumwense

As part of a joint project on fine particle processing, sponsored by the Consortium de Recherche Minérale (COREM), Natural Resources Canada (NRCan) and Hydro-Quebec, two flotation plant circuits were sampled to identify and quantify the causes of mineral losses within several particle size ranges. Size distributions, size-by-size assays and global chemical assays (Cu, Zn, Fe, S) were determined for the major streams. Size distributions were measured in 13 classes by sieving, cyclo sizing (-45 µm), and laser beam diffraction analysis. BILMAT, a material balance computation software package, was used to optimise the sampling, to estimate the unmeasured variables, and to assess and improve the quality of the information generated. The methodology has been extended to correct cyclo sizer data and reduce discontinuities of up to 20% at the transition from sieves to cyclo sizer. The paper describes the methodology and the main conclusions emerging from material inventory of the flow sheets.

Jan 1, 2003

Modelling and simulation are important aspects of flotation research, which may assist in the design of new circuits and the optimisation of existing ones. Flotation research in the AMIRA P9 project has developed a methodology for flotation plant modelling based on determination of cell (pulp) characteristics. froth characteristics, and ore floatability (using floatability components). The implementation of this methodology requires the determination of ore floatability, to which end a small flotation pilot plant known as the Floatability Characterisation Test Rig (FCTR) has been designed and then built and kindly made available to the AMIRA P9 project by Baker Process. The FCTR has a 2 tph capacity and consists of six 130 litre rougher/scavenger cells and six 50 litre cleaner/recleaner cells. The Mintek FloatStar pulp level control system is used to control the pulp level in all cells. A number of experimental procedures have been developed for using the FCTR to obtain the data required for the P9 flotation models. These procedures include how to determine the floatability parameters, Pi and mi, the bubble surface area flux, Sb, the mean residence of the pulp in the cell, t, water recovery. Rw, froth zone recovery, Rf, and the degree of entrainment, ENT. The flexibility of the FCTR allows it to be used in numerous flotation studies such as stream characterisation, reagent testing, grinding experiments, power studies, oxidation studies, and scale-up and simulation studies. This paper will describe the design and operation of the FCTR and the procedures that will be used to obtain data from the rig for modelling purposes.

Jan 1, 2000

By Roshan B. Bhappu

Based on the classical definition of optimization, flotation plants of today are far from being perfect, effective, or functional as possible. Though considerable efforts have been expanded in the optimization endeavor during the last decade, much more needs to be done in the future to optimize our flotation plants and operations. The major problem in designing an optimum flotation circuit is that the flotation process depends on the interaction of several physical and chemical parameters. In the past, there has been a tendency to only consider the effects of chemical factors such as flotation reagents: collectors, frothers, conditioning reagents, pH, etc. On the physical side, the emphasis has been limited to the liberation characteristics, grinding time, percent, solids in the pulp and flotation time. Its only recently that we are employing particle size analyses, on-stream analysis, oxidation reduction potential and the like, as operating controls. The design, operation and control of a mineral processing plant depends on costs incurred at all stages, from inception (testing for flowsheet development) through plant closure and beyond. To ensure that micro- and macro- engineering technology is transferred to operational levels, the academia, testing engineers, designers, operators, consultants and management must all get involved in the transformation process. Historically, in the 1950’s engineering empiricism was strengthened through micro-engineering based on fundamental and mechanism. Unique scientific apparatus such as zeta meter and infrasizer were used to test new hypotheses. With the advent of computers in the 60s and 70s, complex differential equations were solved to study and understand unit processes and to assess mechanism assumptions. Such efforts contributed to improved understanding of the unit operations such as comminution, flotation, thickening, filtration and the like. In the 80s and 90s with the availability of more sophisticated computer technology involving modeling procedures, advanced numerical methods, image analysis, nonlinear-curve-fitting and data adjustments, it was possible to test newly developed models under the production environments. These innovations are now available to develop simulator and sensors (such as particle size analyses) for macro-engineering purposes including plant design, automatic controls and optimization. Accordingly, it behooves the mining companies and plant operators to take advantage of these new developments to control a large number of physical and chemical parameters involved in the plant operation and optimization. This is especially important in light of declining head grades and increasing operating costs in the U.S. minerals industry if it wishes to maintain a competitive edge in the international marketplace. In regard to the future R & D activities in the field, in order to arrive at useful correlations in micro- engineering research, it is essential to consider a plant operation as an interactive engineering system representing the combined effects of physics and chemistry, equipment and operation. The important issues that needs to be addressed in the future are

Jan 1, 1993

THE flotation plant at Mount Lyell was erected, primarily, for the treatment of ore from the Lyell Comstock mine. These workings are situated over a mile in a direct line north of the North Mount Lyell mine, and are connected with the Reduction Work at Queenstown by a 2-ft. gauge steel tramway via the Queen River valley a distance of 7 miles. The property was purchased from the Mount Lyell Comstock Copper Co. After the disastrous fire in the North Mount Lyell mine in October, 1912, steps were immediately taken to make Lyell Comstock ore available for treatment, in order to relieve distress caused by any prolonged stoppage of work, and subsequently 13,032 tons of ore, averaging 3.38 %copper, 0.28 oz. silver, and 0.034 oz. gold; were smelted. When operations were resumed at the North Mount Lyell mine, it was evident that there was no economic advantage in smelting Lyell Comstock ore as compared with the higher value North Mount Lyell ore, which was also a better flux for the Mount Lyell pyrites, and that the future of the Lyell Comstock ore depended upon cheap mining and successful concentration of the ore. Therefore, extensive trenching and diamond-drilling was carried out, and a sufficiently large quantity of ore proved available for cheap extraction by open-cut methods. At the same time bulk tests by flotation were carried out at the Minerals Separation testing plant in Melbourne on different classes of ore from the Mount Lyell Comstock mine proper, followed by laboratory tests at Queenstown on all classes of ore available. All these tests demonstrated that the ore was amenable to the process, provided that it was ground finely enough. Plant erection was delayed by the general dislocation of business at the outbreak of war, but finally it became...

Jan 1, 1920

By A. W. Fahrenwald

FLOTATION practice in Idaho is now about 13 years old. The advance has been steady during these 13 years. The operators have been alert to take advantage of the newest developments and they have themselves made a constant effort to improve their work. The metallurgical improvements are due to the development of (1) better equipment, (2) better reagents, and (3) better understanding and control of the process. During the eight years the writer has been in this district, there has been continuous experimentation by several companies to improve the ore dressing by flotation methods. Gravity concentration has fought hard to hold its place, and although it is true that gravity processes have been improved during this period, nevertheless, in several of the important mills of the district the few tables that managed to hang on have finally given way. On the straight-lead ores, tables and jigs are still used; and, due to better classification, their hold on this job has been strengthened. ORES OF THE DISTRICT The ores of the district are of two general classes: (1) clean lead ores, such as those from the Bunker Hill and Hecla mines, and (2) complex lead-zinc ores. The general impression prevails that the clean lead ores, class 1, are simple and that it is easy to obtain high recoveries and good grade products. This, in a way, is a false impression; there is quite a high percentage of locked middling in these ores at 100 and 150-mesh sizes. Improved classification preparatory to table treatment of this type of ore has made it possible to segregate effectively a high-grade middling which is further comminuted and floated. The complex lead-zinc ores of the district, of which the ore from the Morning mine of the Federal Mining & Smelting Co. is a typical example, always have presented a difficult problem. It always has been comparatively easy to make a clean lead concentrate, but it never has been possible to concentrate sphalerite with a-specific gravity of 4.10 from siderite of gravity 3.88. Also, a large percentage of the galena and sphalerite of this class of ore refuses to separate out until the crushing has been carried

Jan 1, 1928

By A. W. Fahrenwald

FLOTATION practice in Idaho is now about 13 years old. The advance has been steady during these 13 years. The operators have been alert to take advantage of the newest developments and they have themselves made a constant effort to improve their work. The metallurgical improvements are clue to the development of (1) better equipment, (2) better reagents, and (3) better understanding and control of the process. During the 8 years which the writer has been in this district, there has been continuous experimentation by several companies to improve the ore dressing by flotation methods. Gravity concentration has fought hard to hold its place, and although it is true that gravity processes have been improved during this period, nevertheless, in several of the important mills of the district the few tables that managed to hang on have finally given way. On the straight-lead ores, tables and jigs are still used; and, due to better classification, their hold on this job has been strengthened.

Jan 1, 1927

By Stuart McTavish

"The Brunswick Mining concentrator processes 10,000 D.S. T. per day of a complex sulphide ore. Four separate concentrates- zinc, lead, copper and bulk-are produced by selective flotation. Several major changes have been made to the Brunswick flotation circuit to improve the process and control. This paper will describe the present flotation practices at the Brunswick Concentrator. Special emphasis is given to the conversion of two of the primary circuits to an SO2-aeration flowsheet, and to the addition of a new secondary zinc flotation circuit that produces a zinc concentrate from the plant tailings. IntroductionBrunswick Mining and Smelting Corporation operates a zinclead- copper and silver mine and concentrator near Bathurst, New Brunswick. Since the start-up of operations in 1964, the flotation flowsheet has undergone major modifications to process the increased tonnages and to produce a greater number of concentrates. The flowsheet for the concentrator as it was in 1971 has been described by Neumann and Schnarru) and by Ersklneco. Since then, in 1971, the No.6 concentrator was converted from bulk flotation to selective flotation to produce a copper, lead and zinc concentrate. A separate zinc upgrading circuit was installed in 1972 and a bulk flotation or dezincing circuit, which reduced the zinc in the lead concentrate, was started in 1973. In 1976, the secondary zinc circuit was initiated.In addition to these new circuits, changes have been made to the existing circuits to simplify their operation."

Jan 1, 1980

By Surendra K. Mishra

Metallic and oily components are the major contaminants of industrial wastes. Underground burial and incineration have been the commonly practiced methods of waste management. To provide a relatively more permanent solution, different processes have been developed. In addition to reviewing these processes, potential of using flotation as a process to treat hazardous metal and oil contaminated wastes is discussed in this paper.

Jan 1, 1989

By J Lombardi

OZ Minerals' Prominent Hill copper-gold concentrator is located 130 kilometres south east of the town of Coober Pedy in the Gawler Craton of South Australia. The concentrator was built in 2008 and commenced commercial production in early 2009. The Prominent Hill concentrator is comprised of a conventional grinding and flotation processing plant with a 9.6Mtpa ore throughput capacity. The flotation circuit includes six rougher cells, an IsaMill for regrinding the rougher concentrate and a Jameson cell heading up the three stage conventional cell cleaner circuit. In total there are four level controllers in the rougher train and ten level controllers in the cleaning circuit for eighteen cells.Generic proportional – integral and derivative (PID) control used on the level controllers alone propagated any disturbances downstream in the circuit that were generated from the grinding circuit, hoppers, between cells and interconnected banks of cells, having a negative impact on plant performance. To better control such disturbances, FloatStar level stabiliser was selected for installation on the flotation circuit to account for the interaction between the cells. Multivariable control was also installed on the five concentrate hoppers to maintain consistent feed to the cells and to the IsaMill. An additional area identified for optimisation in the flotation circuit was the mass pull rate from the rougher cells. FloatStar flow optimiser was selected to be installed subsequent to the FloatStar level stabiliser. This allowed for a unified, consistent and optimal approach to running the rougher circuit. This paper describes the improvement in the stabilisation of the circuit achieved by the FloatStar level stabiliser by using the interaction matrix between cell level controllers and the results and benefits of implementing the FloatStar flow optimiser on the rougher train.

Aug 8, 2011

By B Firth, G OÆBrien, B Jenkins

In coal flotation, particles of different components of the coal such as maceral groups and mineral matter and their associations have different hydrophobicities and therefore different flotation responses. By using a new coal grain analysis method for characterising individual grains, more detailed flotation performance analysis and modelling approaches have been developed. The method involves the use of microscopic imaging techniques to obtain estimates of size, compositional and density information on individual grains of fine coal. The density and composition partitioning of coal processed through different flotation systems provides an avenue to pinpoint the actual cause of poor process performance so that corrective action may be initiated. The information on grain size, density and composition is being used as input data to develop more detailed flotation process models to provide better predictions of process performance for both mechanical and column flotation devices. A number of approaches may be taken to flotation modelling such as the probability approach and the kinetic model approach or a combination of the two. In the work reported here, a simple probability approach has been taken, which will be further refined in due course. The use of grain data to map the responses of different types of coal grains through various fine coal cleaning processes provided a more advanced diagnostic capability for fine coal cleaning circuits. This enabled flotation performance curves analogous to partition curves for density separators to be produced for flotation devices.

Jan 1, 2005

Flotation science and technology are related to three major sub- processes which are organized in a hierarchical structure as shown in Fig. 1. The basic sub-process is the chemical process which affects the attachment of air bubbles to mineral particles. In particular, the chem- ical process is related with the adsorption of surface active sub- stances at the gas-liquid, liquid- solid, and gas-liquid-solid inter- faces. This field has been most intensively explored in flotation research. The second domain in flotation research is concerned with the mineral particle to air bubble attachment sub- process in the system. This sub- process represents the dynamics of particle and bubble encounter where the contact angle and the induction time, determined by the surface chem- istry of the system, are among the most significant parameters. This sub-process can be referred to as the micro-process as against the third sub-process, or the macro-process, which corresponds to the integral behaviour of the system. Two other sub-processes are integrated into the macro-process in which they may not reveal themselves explicitly in the details. The third sub-process does not entail surface-chemical or physi- cal events any more, but it represents them all inclusively. To represent this sub-process we use mathematical equations, called models. Only in some simple or simplified cases can the models be solved exactly to find out the behaviour of the flotation system in which we are interested. Digital

Jan 1, 1984

By James C. Conti

A surface charge sensor has been developed that responds to changes in the double layer properties of colloidal silica during the cationic flotation of silica from taconite ores. Sensor design allows for the measurement of two aspects of the electrical double layer surrounding all solids immersed in ionic solutions. One aspect responds to a flow induced change in the double layer properties of a solid. The other is a function of the chemical composition of the aqueous phase. Evaluation of sensor performance during froth flotation experiments has been encouraging. Process monitoring capabilities are indicated.

Jan 1, 1981

By Heikki Laurila, Sirkka-Liisa Jämsä-Jounela, Jarkko Karesvuori

"Artificial Intelligence includes excellent tools for the control and supervision of industrial processes. Several thousand industrial applications have been reported worldwide. Recently, the designers of the A1 systems have begun to hybridize the intelligent techniques, expert systems, fuzzy logic and neural networks, to enhance the capability of the A1 systems. Expert systems have proved to be ideal candidates especially for the control of mineral processes.As successful case projects, an expert system based on on-line classification of the feed type using neural data analysis is described in this paper. The essential feature of this expert system is the classification of different feed types and their distinct control strategies at the plant. In addition to the classification, the expert system has a database containing information about how to handle the determined feed type. This self-leaming database scans historical process data to suggest the best treatment for the ore type under processing. The system has been tested in the Outokumpu Finnmines Oy, Hitura mine. Other projects have been reported to be in progress.INTRODUCTIONIn the past ten years considerable researches have been done in the application of artificial intelligent methods in process industry. The technologies of fuzzy logic, neural networks and expert systems have received several thousand applications worldwide: monitoring and analysis of process operations, fault diagnosis, supervisory control, feedback control and scheduling and planning of operations. Recently, the designers of these systems have begun to hybridize these intelligent techniques to enhance the current capability of expert system. Complex signal processing, neural networks, fuzzy logic and rule-based systems are also implemented to develop new so-called smart or intelligent sensors, actuators or components. Field buses are playing a more and more important role in automation systems and in imbedded systems. The development of field buses has allowed the distribution of smart components over networks."

Jan 1, 2000

By Leming Ou, Qiming Feng, Yiping Lu, Pengyu Zhang, Qing Shi, Kun Liu, Guofan Zhang

"This paper introduces the mineralogical analysis of certain polymetallic copper-zinc ore in China with the aim of improving the flotation process. The main valuable elements, mineral phases and compositions of run-of-mine ore were inspected by the X-ray Fluorescence (XRF) and chemical analysis. For a deep known of the old process defects, Mineral Liberation Analysis system (MLAs) was employed to investigate the minerals liberation degree of selected key slurry points. Analysis results show that the run-of-mine ore belongs to the original copper-zinc polymetallic symbiotic ore at low oxidative level, which mainly contains 0.16% Cu, 4.43% Zn and 0.88% Sn. Gangue minerals are mainly silicate minerals, and zinc mineral is sphalerite. MLAs test illustrates that about 86% sphalerite has been dissociated in zinc flotation feed. In the current flotation process, over grinding of sphalerite monomer and insufficient liberation of intergrowths are the key problems need to be solved imminently. Up to this point, a new process consisted of two steps roughing unit is submitted in this research. It contributes two positive effects on zinc flotation performance: (i) separating sphalerite monomer timely to decrease overgrinding; (ii) improving zinc minerals intergrowths liberation efficiency. Flotation results indicate that the zinc concentrate grade increased 0.90% and the recovery improved 0.96% in the new flotation processINTRODUCTION Mineralogical analysis mainly focusses on solving mineralogy problems in minerals processing, assisting in minerals behaviors prediction and control for separation engineering (Falkovich, et al., 2001; Hillier, et al., 2003; Schouwstra and Smit, 2011). Process defects searching becomes its ordinary work, and flotation optimization appears to be its targets gradually. For example, Lucky Friday mine company (Idaho America) fails to obtain qualified lead concentrate as the change of ore properties (Nadoll, et al., 2011). Mineralogical analysis ascertains that there are too many dissociated sphalerite, pyrite and gangue particles exist in lead concentrate. According to this, more cleaning units are added to solve problems effectively. Kanowna Belle mine (Australia) takes a flash circuit in operation successfully with the aim of optimize flotation process, under the helps of mineralogical analysis and industrial test (Newcombe, et al., 2013). Lotter N.O. (2011) gives a deep description on how mineralogical data assisting mineral processing engineers to design and optimize flowsheet. For decades, quantitative and automated mineralogy techniques (Andersen, et al., 2009; Gu, et al., 2012; Oghazi, et al., 2009; Yu, et al., 2007) get well developed and hugely improve the veracity and repeatability of minerals properties measurement. Among these, MLAs (Gu, 2003) provided by JKMRC (Julius Kruttschnitt Mineral Research Center) is critically acclaimed all over the world. This analysis system can measure mineral phases composition and content, particles size, minerals occurrence and liberation degree directly."

Jan 1, 2018

By M. Mononen, J. Huuskonen, M. Vauhkonen, J. Kourunen, A. Lehikoinen

"A new approach to measure process conditions in flotation cells is presented. Real scale flotation cells in a Zinc circuit are imaged using Outotec LevelSense sensors based on electrical resistance tomography. The latest results from long period plant tests show that the sensors together with FrothControl analysis give new information that correlates well with other process parameters. The sensors can compensate for electrical contact contamination using an automatic calibration technique and they are basically maintenance free. The results indicate that using the LevelSense sensors and FrothControl solution, the process control and optimization can be done automatically, stabilizing and improving the metallurgical performance of the flotation process.INTRODUCTIONThe froth flotation process is widely used in mineral industry for the separation of minerals from low-grade ore slurry. Different property parameters of froth and slurry could be measured to monitor and control the flotation process: air bubble size distribution, flow dynamics, thickness of the froth bed, amount of solids in the froth, etc. Some techniques already exist that can be utilized in studying these important parameters on-line. Examples of the techniques are the high-speed video imaging, simple conductivity probes, ultrasound techniques, floats and pressure transducers (Maldonado et al., 2008). These techniques, however, often suffer from some limitations. For example, the video imaging only gives information from the surface of the froth, simple conductivity probes suffer from contamination and the floats may get stuck and therefore do not give reliable signal for process control and optimization."

Jan 1, 2013

By Manlapig EV, Mackinnon IDR, Laudr DW

Orebodies at Ok Tedi contain a number of different fluorine bearing minerals. Some of these minerals report to concentrate and are responsible for the presence of the penalty element, fluorine, within the concentrate. Previous analytical work has tended to examine geological samples for content, rather than determine the metallurgical behaviour of the different mineralogical species. This investigation utilised X-Ray Diffraction combined with Scanning Electron Microscope / Electron Microprobe to identify the fluorine bearing minerals in flotation test products. Seven fluorine bearing minerals were identified, viz., talc, phlogopite, amphibole (tremolite and actinolite), sphene, apatite, biotite and clay. Talc was found exclusively in the skam ore type. Phlogopite and amphiboles (tremolite and actinolite) were found to occur in both skarn and porphyry ores, while sphene, apatite, biotite and clay were found only in the porphyry ores. Of the fluorine bearing minerals observed, only talc exhibited natural hydrophobicity to any significant degree. Phlogopite and the amphibole minerals were found to be hydrophillic, whilst the remaining minerals occurred in insufficient quantities to determine the flotation behaviour. Ok Tedi copper concentrate fluorine content prior to skarn ore treatment in the mill (typically 350ppm) was previously identified as deriving from phlogopite, while talc was believed to be the source of intermittent high concentrate fluorine contents when skarn ores were treated. This paper provides supporting evidence for this belief, and reports the nature of fluorine bearing mineral flotation behaviour.

Jan 1, 1997