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By Dave Bulled

"This paper describes the design of a molybdenite flotation circuit using FLEET technology applied to kinetics data produced from laboratory flotation testing and distributed across the blocks of a mine plan using a geostatistical approach. The geostatistics assigned the statistical error that arises from having a limited amount of sample testing data to the kinetics estimates of each block of ore in the mine plan. The final design then included a quantification of risk based on the accuracy of the block flotation kinetics and model fitting. The design made reference to the extensive technical reports describing earlier metallurgical test work including some pilot plant work over thirty years ago.The testing involved conducting MinnovEX Flotation Tests (MFT) to determine the rougher flotation kinetics at the specified reagent conditions and rougher-cleaner tests to determine the change in kinetics resulting from regrind. These flotation kinetics were used within FLEET simulations to create a full-scale flowsheet and plant design including recommended equipment sizes and the forecast of operating results. Measurement of detailed flotation kinetics for a wide range of samples allowed the effect of size of grind and efficiency of classification (i.e. width of size distribution) to be predicted for the whole ore body.INTRODUCTIONAdanac Moly Corp. proposed to develop a 20,000 ton per day mill to produce high quality molybdenite concentrate from its Ruby Creek resource in north-western British Columbia. It is a relatively clean low grade porphyry-monzonite occurrence containing minimal quantities of other sulphides such as chalcopyrite, pyrite, sphalerite and galena. Molybdenite occurs mainly as coarse flakes with lesser amounts of finer sized values. An optimum plant design was required to can achieve the predicted operating results, at a known level of risk, while treating the variability inherent in the ore body."

Jan 1, 2007

By A Nugraha, H Thanasekaran, K Tatetdagat

The Kanowna Belle gold mine is located in the Eastern Goldfields of Western Australia, approximately 18 km north-east of Kalgoorlie. The processing plant is designed to process 2 Mt/y and has the capability to treat both refractory and free milling ore from the Kanowna Belle and Kundana mining operations.The Kanowna Belle ore is refractory with the gold mineralisation occurring mostly as fine-grained inclusions in pyrite or as very fine-grained gold located in pyritic arsenic rich growth zones. The Kanowna Belle refractory process includes flotation, roasting of the flotation concentrate, and calcine leaching to extract the gold from the ore.Mineralogical analysis of feed and tailings streams from the flotation circuit have shown that the gold bearing minerals are well liberated and confirmed they are mainly associated with pyrite. Nearly 40% of the flotation circuit losses are in the -38 µm size fraction. To improve the flotation circuit recovery, the fine particle gold recovery was targeted. A Cavitation Tube column was selected for the site-based pilot test work program. This paper presents data generated from the on-site test work, and the benefits of the Cavitation Tube column to improve fine particle flotation.CITATION:Nugraha, A, Tatetdagat, K and Thanasekaran, H, 2018. Flotation circuit efficiency improvement at Northern Star Resources Limited’s Kanowna Belle gold mine, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 403–412 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

Flotation Circuit Optimisation - Towards More Sustainable Practice

Sep 13, 2010

By G. S. Dobby, J. A. Finch

"A significant development in froth flotation technology has been the emerging industrial acceptance of column flotation during the past few years. Flotation columns are being employed now in several Canadian base metal concentrators and they are being considered f or a wide range of flotation applications throughout North and South America. Since the operating principles of a column differ markedly from those of conventional flotation machines, and have been poorly understood, scale-up of columns has been difficult. This paper describes a methodology f or translating laboratory column data to industrial operation.The scale-up model utilizes kin etic data that is obtained from a series of laboratory column experiments; the laboratory column can be as short as 2 m. For modelling purposes the column is considered to consist of two zones: the collection zone, where particle recovery occurs, and the cleaning zone, a packed bubble bed generated by downward flowing wash water. Mixing conditions in the collection zone have been characterized using the results of tracer experiments on plant columns at Mines Gaspe. The same experiments demonstrated the nearly complete suppression of entrained gangue minerals that is attained in the cleaning zone. The model explicitly accounts for both the collection zone and cleaning zone recoveries and allows for the effects of bubble overloading. Results of column scale-up experiments at Gibraltar Mines are presented."

Jan 1, 1986

By G. S. Dobby, J. A. Finch

"I. INTRODUCTIONA significant development in flotation over the past few years has been the increasing industrial use of flotation columns, primarily in Canada. The column differs dramatically from conventional mechanical flotation machines, both in design end operating philosophy, which has been a principal reason for its slow acceptance by the mineral industry. Boutin, Tremblay and Wheeler (1. 2) developed the concept in the early 1960's and since then plant and laboratory columns have been marketed commercially by Column Flotation Company of Canada Ltd. In 1980-81 at Mines Gaspe, Quebec, three columns replaced 13 conventional cleaners in a molybdenum upgrading circuit, with superior results (3). Since then many of the copper producers in British Columbia have installed columns for copper and molybdenum cleaning, including Gibraltar, Lornex, Highmont and Island Copper. There now appears to be widespread interest in flotation columns.The column is particularly attractive for applications involving multiple cleaning stages and can upgrade In a single stage compared with several stages of mechanical cells. This results in simpler, more controllable circuits. Importantly, the column itself is well suited to computer control. A significant problem, however, has been that of translating laboratory data to plant performance. The purposes of this communication are to address the problem of column scale-up and to describe some of the transport mechanisms of a flotation column, leading to a kinetics based model.A schematic of a flotation column is shown in Figure]. Industrial columns are up to 13 m high and 0.3 to 1.8 m in cross section (either square or circular). Three zones can be identified:a collection zone, with feed entering 2 to 3 m below the top of the column and descending against rising bubbles generated at a gas sparger; a washing zone, where a packed bubble bed is generated by a downward flow of wash water; and a conventional froth (2 - 5 cm thick), the sole purpose of which is particle transport to the launder. The tailings withdrawal at the bottom of the column is controlled at a rate slightly greater than the feed flowrate (called a positive bias).An important element is the washwater, added just below the froth zone. The component of the washwater that flows downward (to make up the bias) is sufficient to prevent coalescence of rising gas bubbles. The packed bubble beg so generated is very efficient at suppressing gangue entrainment to the concentrate."

Jan 1, 1985

By H. Kolcz, G. S. Dobby, R. Stratton-Crawley, S. W. Wilson

"The Matte Separation plant at Inco's Copper Cliff Smelter Complex is described. The continuing implementation of flotation column technology in the flowsheet in various applications is reviewed. Comparative studies on 0.038, 0.10, 1.1 and 1.8 m diameter columns have been carried out. It was demonstrated that consistent metallurgical performance was obtained with both pilot- and plant-scale units. Grade-recovery relationships for plant columns can be predicted with confidence from data obtained from test equipment. The work indicates further areas of the flowsheet in which columns present an attractive alternative to conventional cells. INCO’s MATTE SEPARATION PROCESSNickel concentrate from Inco’s Sudbury area mills has been processed in the Copper Cliff smelter for sixty years. Prior to that, Sudbury ores had been smelted directly. Historically, copper-nickel separation from smelter converter matte was achieved by the classical Orford process. In the mid-1940s Inco developed an improved separation scheme based on mineral processing methods, the Matte Separation Process. A generalized Copper Cliff Smelter Complex flowsheet is shown in Figure 1.Iron sulfide and gangue contained in the nickel concentrate are rejected in the smelting-converting process. The molten product, typically containing 50% Ni, 25% CU and 22% s, is cast at about 1000 ºC, into floor moulds and allowed to slowly cool for four days. During this period nickel sulfide (heazlewoodite, Ni,S,), copper sulfide (chalcocite, cu,S) and a copper-nickel metallic alloy precipitate and form a coarse grain structure that is amenable to separation by physical means. The phase chemistry of this system has been described previously by Sproule et al (1). This matte then becomes the feed to the Matte Separation Process.A simplified block flowsheet of the Matte Separation Process is shown in Figure 2. Matte ingots, typically weighing 20 tonnes each, are broken and crushed in a three stage crushing plant to approximately minus 0.01 m and conveyed to the Matte Separation building. Grinding is carried out in two parallel circuits each consisting of a rod and ball mill in series producing a flotation feed which is 65% minus 44 microns. Typical throughput of each grinding circuit is 650 tonnes/day. The metallic fraction of the feed is recovered by magnetic separation. This product, containing about 66% Ni and 15% CU, is a major component of the feed to the Copper Cliff Nickel Refinery."

Jan 1, 1990

By Frederick Laist

I. EXPERIMENTAL FLOTATION CONCENTRATION INTRODUCTION EARLY in 1914 it was decided to test, on a fairly large scale, the treatment by flotation of Anaconda slime and mill tailing. For this purpose a standard-type Minerals. Separation machine was installed at the Washoe Reduction Works during May and June, 1914. This was followed by the. installation of a full-size Callow pneumatic machine plant. Experiments were also made, on a smaller scale, with the Froment, the Towne, the Fields, and the Anaconda flotation machines. The last-named machine was developed at this plant. In addition to the tests made in the standard-type Minerals Separation machine some tests were made using a Minerals Separation machine of the sub-aeration type. During the series of experiments a large variety of oils was tested. Experiments were also conducted using both round-table feed and tailing to determine whether it would be better to displace the round tables by flotation for the treatment of the slime, or to supplement the round tables by flotation of the round-table tailing. A series of tests was also made on the treatment of the mill tailing by grinding followed by flotation to determine the relative merits of flotation and leaching for the treatment of this product. In addition, flotation tests were made on mixtures of mill tailing and slime. The round-table feed referred to above is the total slime from the mill. It contains about 35 per cent. colloidal solids and approximately 90 to 95 per cent. of the total solids will pass through 200 mesh (0.067 mm.). It assays from 2.3 to 2.6 per cent. Cu. The mill tailing referred to above is the total discard from the mill, exclusive of the slime. It is all finer than 2 mm. and about 90 to 95 per cent. will remain on 0.25 mm. It assays about 0.60 per cent. Cu. A brief summary of the experimental flotation results follows:

Jan 3, 1916

By Frederick Laist

0. C. RALSTON, Salt Lake City, Utah.-I have merely glanced over this paper, consequently, I am hardly in a position to discuss it intelligently. There is one thing, however, that is of interest, that is, the claim that the oil mixture which they have chosen is the best adapted to the work at hand. I would like to ask Mr. Mathewson if they still feel that that is the case-if that really does give the best grade of concentration and the best extraction for the same money, compared to any particular oil mixture which they could get. E. P. MATHEWSON, Anaconda, Mont.-We are still using that mixture, and we consider it the most economical mixture used. DAVID COLE, El Paso, Texas.-I would like to ask Mr. Ralston if there are some other mixtures that would be better? E. P. MATHEWSON.-We are open to suggestions. 0. C. RALSTON.-My own paper on oils* calls attention to the fact that certain hardwood oils, especially the tars, are now being burned or wasted. A great deal of hardwood tar is available as low as 4 or 5 c. per gallon, that being its value as fuel under the boilers. As a matter of fact, a great deal of testing has been done with only the commercial products that are as a usual ride sold on the market. Very little hardwood tar is sold on the market. In asking a great many people who have tested flotation oils, I have not heard hardwood tar mentioned very often. I think I would add to that that the hardwood tars can probably be bought in quantity comparable with the sludge acid at Anaconda, and. should contain a greater proportion of the frothing constituent, and at a price fairly commensurate with what they pay for the sludge acid. E. P. MATHEWSON.-I would like to make a correction in one statement I made that there has been no change made in the mixture. This change has been made: We found that the amount of wood creosote in treating the sand from tables was extremely small, and we tried some experiments on a large scale, dropping it out and using simply the sludge acid and sulphuric acid. We found that this gave practically as good results as wood creosote. We use wood creosote in treating the slimes. We find it necessary in that operation. DAVID COLE.-I would like to ask, what is sludge acid?

Jan 10, 1916

By Patrick Pelletier, Pierre-Alexandre Bossé, Julie Fournier, Gianni Bartolacci, Jayson Tessier, Ahmed Bouajila, Carl Duchesne

"This paper summarizes research into the study of the control of flotation processes based on froth images. The use of numerical image analysis techniques for the extraction of significant patterns (froth structure and colour) from industrial flotation froths is discussed.First, the froth was analysed by the use of the Multivariate Image Analysis (MIA) method to extract the spectral variation contained in a RBG image. The Partial Least Squares (PLS) was applied to develop the empirical model for the prediction of froth grade. The results of this application are illustrated using one industrial case study.Second, the froth was also analysed by Gray Level Co-occurrence Matrix (GLCM) and Wavelet Transform Analysis (WTA) to extract features related more to morphological aspects. Since there is useful information hidden in froth texture, these methods are used as texture descriptor to classify different types of froths.Third, a control strategy based on a froth structure indicator was developed and implemented on an industrial zinc flotation circuit. The feedback controller uses a reagent flow-rate in order to maintain the froth structure at its set point. Process improvements obtained with the implemented control strategy are highlighted.Finally, the feasibility to implement a hybrid control strategy consisting in a froth structure supervision controller based on the froth concentrate grade estimated by MIA and recovery inferred by image analysis is discussed.INTRODUCTIONThe development of control strategies to achieve satisfactory control performance has always been a great challenge for engineers and the need for improved process diagnosis, control and optimization has become more and more evident for the mineral processing industry in the last decades. That is why new process variables need to be measured particularly in highly multivariable processes such as flotation. This industrial process is subject to a wide variety of disturbances mainly generated by frequent and sometimes abrupt changes in physical and/or chemical ore characteristics and also, due to some irregularities in manual process operating procedures. A flotation circuit scheme is always a complex network of more than two dozens slurry streams. Information about those streams (% solid, metal content analysis and flow rates) is important for process diagnosis performance evaluation and control. Also, because of the grade decrease and increasing complexity of the new processed ores, more instrumentation outputs and more powerful and significant pr"

Jan 1, 2005

By C Smith, J Cilliers, K Hadler

Unstable flotation froths, that burst before they overflow, produce no concentrate. Increasing the froth stability to improve recovery is therefore an obvious control strategy. Froth stability can be measured readily as the fraction of air entering the flotation cell that overflows as froth, rather than bursting on the surface; the ‘air recovery.’ Air rate is one of the most significant variables affecting froth stability. It is interesting that froth stability (air recovery) is maximised at a specific air rate, above or below which it decreases. It is important for metallurgists to realise that this maximum froth stability also produces the maximum mineral recovery, without compromising concentrate grade. Flotation cells must be operated at the air rate that produces the highest air recovery. The peak air recovery (PAR) to maximum mineral recovery relationship was first demonstrated by Hadler and Cilliers in 2009. Since then, the relationship between PAR and flotation performance has been widely explored; varying air rate, froth depth and particle size. Industrially, reducing the flotation bank air rate to achieve PAR yielded better mineral recoveries than other down-the-bank air rate profiles. In this paper, we present an overview of these key developments and findings in flotation optimisation based on PAR. Furthermore, using new industrial data, we show that PAR is not just applicable to rougher-scavenger cells, but also to flotation columns. Finally, we consider the future application of such an optimising control concept. CITATION:Smith, C, Hadler, K and Cilliers, J, 2018. Flotation control using froth stability: past, present and future, in Proceedings 14th AusIMM Mill Operators' Conference 2018, pp 441–454 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 29, 2018

By A. Eslami

When producing high grade mattes in smelter plants, copper losses in the slag are inevitable. Hence, the recovery of copper from slag has been the focus of many research projects, copper flotation being a widely used process. In the Khatoonabad converter, 200 t/d of slag are presently produced with a grade of 2.3% Cu. Assuming a 85% recovery by flotation, about 3.9 t/d copper could be produced, which is of prime importance economically. In the present work, a sample of this slag was crushed and ground in the laboratory to liberate the copper-bearing minerals. Following mineralogical studies, optimum laboratory flotation parameters were obtained, resulting in 90.27 % recovery and 9.42% of copper grade for the rougher stage. At pilot scale, a pulp of 28% solids was floated at ph 10.5 using 40 git of Z6, 25 git of R407 and 20 git of MIBC and A65. A recovery of 83.52% was obtained for a concentrate grade of 28.36% Cu. In the rougher cells, the feed consisted of particles 94% finer than 74 microns whereas in the cleaning stage, particles were 95% finer than 44 microns. Based on the obtained results, the Sarcheshmeh Khatoonabad converter slag is presently being fed to the Chargonbad flotation plant, where a concentrate of 32% copper at 86% recovery is being produced.

Jan 1, 2007

By Grano S. R, Ralston J

It is the perennial problem most metallurgists face when examining data collected from laboratory float tests and plant surveys - there are more numbers than we know what to do with! The objective of this paper is to analyse and interpret a set

Jan 1, 1994

By B. Yu, Y. O. Oyediran, M. Robart

"This paper presents the latest flotation development testwork conducted in 2015 on the ‘B Zone’ samples from the Strange Lake Alkalic Complex (SLAC). Since the discovery by Iron Ore Company of Canada (IOC), metallurgical development has been under taken by a number of mining companies targeting various value metals, including yttrium, zirconium, niobium, and rare earths.Most recent, Quest Rare Minerals Ltd. (Quest) completed a Pre-Feasibility Study (PFS) in 2013 where the flowsheet was relatively complex and led Quest to explore alternative options. In 2014, the PFS flowsheet was simplified and one of the features introduced was pre-concentration by rougher flotation. The combined rougher flotation concentrate and slimes successfully recovered >90% TREE in 60% mass thus reducing capital cost and technical risks of the downstream hydrometallurgical processes. The latest flotation development testwork focused on achieving a pre-concentrate in which >80% TREE are recovered in 20% mass. Two separate reagent schemes, based on an ester phosphate collector (Clariant 1682) and a benzoylhydroxamic acid collector (Florrea 7510), were developed. Parameters evaluated in the development testwork included desliming, secondary yttrium and zircon collectors, depressants, temperature, conditioning temperature, time, and density, pH, sodium silicate type, cleaning, and flowsheet configuration. Both developed reagent schemes achieved the targeted metallurgy.INTRODUCTIONThe Strange Lake Alkalic Complex (SLAC) was discovered after geological survey and mapping studies by Geological Survey of Canada and Newfoundland and Labrador Department of Natural Resources between 1967 and 1980. Subsequent exploratory drilling programs by Iron Ore Company (IOC) in the 1980s found that the REE and high field strength element (HFSE) mineralization were within the central region of the SLAC which was named A Zone by IOC and later renamed Main Zone by Quest Rare Minerals Ltd. (Quest). Additional exploratory drilling outside the Main Zone by IOC and later by Quest, led to the discovery of B Zone, which was recognized as the most significant deposit of rare earth elements, yttrium, and zirconium in the SLAC. The B Zone Indicated Resources are estimated at 278.13 Mt at 0.93% total rare earth oxide (TREO) and Inferred Mineral Resources are estimated at 214.35 Mt at 0.85% TREO (Oyediran et al., 2014)."

Jan 1, 2016

By M. Kerr

Background- History The most significant change in mining since the late 1970?s has been the emergence of very large scale mining operations , which have been developed to ensure profitability with relatively low grade ores. These large tonnage operations have resulted in the development of larger unit sized machines in all operations of beneficiation, solid-liquid separation and dewatering. Often only a few flotation lines are installed and tonnages up to 25 ktpd and beyond are not uncommon. The increased throughputs have led to the development of circular, reactor type tank designs. The reactor cell system is the most up to date flotation cell design to utilise the principles of circular cell design. The Svedala DV mechanism was specially developed to suit the RCS machine giving good solids handling characteristics and excellent metallurgical performance. Development of UG2 ore type flotation equipment The equipment was developed and optimised by Svedala process from 1995. A higher energy specification was requested by industry. This amounted to 3kW/m3 for installed volume. Existing designs were at 1.5kW/m3. Hence various modifications were required to achieve the required power input. The first 50m3 machines were installed and developed at Impala Platinum?s UG2 circuit over a one year period. Once reliability and performance was achieved, over 300 large volume flotation cells were installed at Anglo Platinum and Lonmin operations as well. Pilot Plant Development The Impala Platinum High Energy pilot plant was commissioned in 2002 and had an installed power exceeding 5kW/m3. It was operated for over a year at the tailings dam booster station and was fundamental to the large scale scavenging plant design. All experience in overcoming mechanical and operational problems was applied in scale up design principles. A very robust mechanism was designed to accommodate the additional power input from installed motors, as well as the high SG (>1.5) of the feed source. The pilot plant flowsheet is shown in the figure below.

Jan 1, 2007

By B Murphy

Traditionally comminution optimisation has been focused on energy minimisation, whereas flotation optimisation has been focused on recovery improvement. One of the largest, if not the largest, operating cost over the life of a flotation circuit is electrical energy. With increasing pressure on operators to lower production costs and the cost of energy increasing, reducing the energy consumption of the flotation circuit can be beneficial to site economics. This paper reviews the use of energy by mechanically agitated flotation machines and discusses the measurement and benchmarking of energy consumption in modern flotation concentrators. Opportunities for improving flotation energy efficiency are also identified.CITATION:Murphy, B, 2013. Flotation energy consumption and opportunities for improvement, in Proceedings MetPlant 2013 , pp 399-412 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Jul 15, 2013

By Claude Bazin

"Laboratory semi-batch flotation tests were conducted using two different sulphide ore samples. The size reduction was adjusted to cover a wide range of flotation feed size distributions. Results show that similar recoveries can be achieved independently of the fineness of grind. This result suggests that possible energy savings could be achieved by a redistribution of the power between the grinding and regrinding mills. The behaviour of the selectivity curves shows that some gangue minerals are more sensitive to particle size than other ones, implying the existence of preferential associations between minerals in the ore.INTRODUCTIONInteractions between grinding and flotation have been studied for many years, and still a robust model to link the two processes lacks to be developed (Girard et al., 2005; Bazin et al., 2001). The ore size reduction liberates mineral grains, while flotation separates them into valuable minerals and gangue. The more size reduction that is applied to the ore the more important is the mineral liberation but also the production of fine particles that can pose problems during flotation (Trahar and Warren, 1976). The definition of the grinding requirement for flotation is a complex problem (Rickelton and Dell, 1977; Sosa Blanca et al., 2000; Morrison, 1993; Wei and Gay, 1999).This paper analyzes the effect of the fineness of grind using semi-batch flotation test results. The first two sections describe the test procedure and the results. The third section analyzes the results in terms of liberation and selectivity, and proposes a possible redistribution of power between grinding and regrinding mills."

Jan 1, 2006

By Q. Cui, B. Z. Zhou, Z. G. Song, Y. G. Zhu, G. B. Zheng

The complex refractory Cu-Pb-Zn polymetallic ore in Xinjiang, China is a massive sulphide ore with complex mineral components. In the past two years, the ore mineralogy has changed, resulting in a decline in metallurgy, with too much zinc reporting to the lead and copper concentrates. A detailed mineralogical study indicating the presence of secondary copper minerals, which could be activating the sphalerite early in the present circuit, was used to develop a novel reagent and flotation flowsheet termed “Pb-Cu co-flotation, Cu intensified flotation, Zn flotation”. It was tested and found to significantly contribute to improving the flotation performance of the ore. In the Pb-Cu co-flotation circuit, successful depression of pyrite and sphalerite was achieved using a BK612- Na2S based depressant system. Most of the galena and some of the Cu bearing minerals with excellent floatability were collected with the use of the selective collector BK906. The rest of Cu bearing minerals were floated in a copper Z200 circuit using a BK537-lime-zinc sulphate based depressant scheme. Zinc flotation from the copper tailing was performed in a SIBX circuit using lime as a pyrite depressant. Using the proposed flowsheet, overall Pb, Cu, and Zn recovery increased significantly to 88%, 87%, and 90% respectively. Keywords: Complex polymetallic ore, Cu-Pb-Zn, Pb-Cu co-flotation, particle size

Jan 1, 2020

By Priyanka Dhar, Kurt Aasly, Hanumantha Rao Kota, Hassan Bouzahzah, Maria Thornhill

The interest in investigating the processing characteristics of mineral deposits in Norway has seen an upsurge in the last decade. One of the major areas of interest is a huge copper deposit, operated by NUSSIR ASA located in the Repparfjord Tectonic Window in the caledonides of west Finnmark. This study reports analysis of ore from the deposit for development and modifications in the flotation flowsheet for the NUSSIR ASA copper ore. The mineralogical characterization for the ore sample was achived by optical microscopy and Zeiss automated mineralogy while grinding characteristics were tested using Bond Index tests. The results confirmed the presence of Cu minerals in the form of chalcocite, chalcopyrite and bornite in the samples, which are mainly liberated in the – 105 µm size range. The majority of non-liberated copper sulphides associated with silica and the carbonates varies from 3 to 28 percent in the –250 µm samples . It is also observed that the copper minerals are uniformly distributed in all size ranges. Selective flotation of NUSSIR copper ore was performed in different size fractions with a motive to identify the correct liberation size and thus to obtain a copper concentrate meeting the quality requirements. The flotation experiments are essentially performed in two stages: the rougher and the cleaner stage. Mass balance calculations were performed showing that approximately 88 percent of copper can be obtained at the end of the process. Ultimately, overall circuit copper recoveries ranged between 83.5 to 88.1 % with a concentrate grade of 35 to 48 % Cu.

Jan 1, 2018

By Wen Tao Liu, Tong Tian, Fu Sheng Niu, Xiu Man Liang

The level of automation employed in flotation production is relatively low. In an actual concentrator, operators use their judgment to adjust the production state based on the visual characteristics of the flotation froth surface. There are shortcomings, such as strong subjectivity and lagging process operation, that easily cause the waste of manpower and material resources. Machine vision technology is introduced to replace human visualization, achieving a quantitative description of the visual characteristics of the froth surface. The state variable parameters are provided for the identification of the flotation conditions.

By Wen Tao Liu, Tong Tian, Fu Sheng Niu, Xiu Man Liang

In order to address the difficulty of accurate segmentation of froth images of different sizes, a method of froth image segmentation based on highlight correction and parameter adaptation is proposed. First, a machine vision system on a single-cell flotation machine is built to collect froth images. Homomorphic filtering is used to improve the uneven brightness and shadow of the images. Fuzzy c-means (FCM) clustering is then utilized to classify similar highlights that belong to the same froth. After Otsu threshold segmentation, a parameter-adaptive morphological operation is used to extract the marker points and edge bands and correct the froth edges in the original image. Finally, the modified image is filtered by morphological reconstruction, and the highlight mark is used as the local minimum point for watershed segmentation. Three sizes of froth images are segmented in comparative experiments. The results show that the proposed method is suitable for the segmentation of froth images of different sizes. The position of the extracted segmentation line is close to reality, with average over-segmentation and under-segmentation rates for froth images of 2.6% and 6.8%, respectively. The froth image segmentation performance is stronger than that of the other methods examined.