EURUS MINERAL CONSULTANTS

THE KINCALC FLOTATION

KINETICS CALCULATOR AND
ORGANISER
BRIEF DESCRIPTION AND CAPABILITY

Martyn Hay

UPDATE 2.0, JUNE 2009

Eurus Mineral Consultants. 2002-2009

Description & Capability of KinCalc. June 2009
Page 1 of 9

CONTENTS
1.

SUMMARY OF KINCALC ............................................................................................................... 3

2.

THE VALUE OF FLOTATION KINETICS....................................................................................... 5

3.

AVAILABLE VERSIONS, PROTECTION, LICENSE AND PURCHASE.................................. 9

LIST OF TABLES
Table 1

Flotation Kinetics........................................................................................................................... 6

LIST OF FIGURES
Figure 1
Figure 2
Figure 3
Figure 4
Figure 5

Organisation of KinCalc Functions ..................................................................................... 5

Results from a Flotation Rate Test and Kelsalls Equation ................................................. 6
Physical Meaning of Kinetics in the Plant ............................................................................. 8
Simulation of Plant from Laboratory Data............................................................................ 8
Accuracy of Simulation............................................................................................................ 9

Eurus Mineral Consultants. 2002-2009

Description & Capability of KinCalc. June 2009
Page 2 of 9

1.

SUMMARY OF KINCALC

KinCalc calculates flotation kinetics from laboratory float test data in excel format. The program
employs an Import Wizard to automatically import data (test data and conditions etc) by
identifying the cells or range of cells where the data occurs. This is done by setting-up a format
which can be customised for any arrangement of data in an excel worksheet/spreadsheet
including multiple data sheets per worksheet and multiple worksheets per file. The import wizard
therefore obviates the need to type in or copy/paste testwork data. KinCalc can be set-up to
handle the importation and processing of multiple files in a folder. There is no limit to the number
of files and/or data sheets that can be imported and processed in one batch; however in practice it
is best to restrict importation to about 200 data sheets at one go.

Once data is imported, KinCalc,

1. Calculates flotation kinetics with and without boundary algorithms,
2. Generates five standard graphs for each test,
3. Produces a summary sheet containing test descriptions; kinetics; laboratory test results;
cumulative recovery, grade and mass pull; headgrade, various kinetic ratios and a measure
of SSE (sum of squared errors). These tables are formatted so that they can be copied into a
report,
4. Allows for kinetics to be calculated manually via scroll bars set-up for each kinetic
parameter. This is done in that part of the program called ScrollCalc,
5. Allows any set of data to be averaged and its kinetics calculated,
6. Allows one button generation of correlation coefficient tables and histograms which are
time consuming to generate each time by manual application of the relevant excel function,
7. Stores all data in Access or SQL where searches can be set up to collate all data according to
requirements such as ore type, reagent type, test date. etc. The data can be dumped into
excel for data mining or statistical processing.

Overall, the value of KinCalc to the client/user is that KinCalc is an integrated system capable
of handling and organising large amounts of data which can be stored in one Access or SQL file.
With mineralogical data from Qemsem or MLA it also provides the facility to dump both kinetic
and mineralogical data into Access in order to generate correlations as per the diagram below.

Eurus Mineral Consultants. 2002-2009

Description & Capability of KinCalc. June 2009
Page 3 of 9

Flotation Performance Influence Diagram (Flotation "PID")

MINERALOGY

Defines

CONTROLS

FLOTATION
KINETICS

Determines
CIRCUIT DESIGN

Affects

Correlate
Qemsem/MLA data
with flotation
kinetics

FLOTATION
PERFORMANCE
(Grade/Recovery) &
REVENUE
Link mineralogical data with circuit design
and performance

The value of KinCalc lies in clients/users being able to,

1. Calculate kinetics from float tests they have performed and as a result be able to
benchmark one test, ore type or set of test conditions against another,
2. Automatically import, process and store large quantities of data,
3. Have a customised graphing facility and one touch generation of r2 correlation tables and
histogram/ cumulative frequency graphs,
4. Use KinCalc to graph test data and determine r2 correlations without having to use the
kinetics calculation section of the program,
5. Conduct an array of statistical analysis on the data having previously been conveniently
arranged in the KinCalc summary sheet or in the Access database,
6. Load Qemsem mineralogical data into the Access database and link with the associated
kinetic data for a particular test. This provides the possibility of being able to correlate
Qemsem data with flotation kinetics which are correlated with plant design and
performance,
7. Collate all tests into one database and vehicle for easy access and processing,
8. Generate tables and graphs which are report quality and can be copied and pasted to a
word document.

Figure 1 summaries KinCalc main functions in flowsheet format,

Eurus Mineral Consultants. 2002-2009

Description & Capability of KinCalc. June 2009
Page 4 of 9

Test data

Re-input of
processed test data

Average
Page

Input Page
Raw data and sample description
Detailes of test conditions
Checkboxes to omit specific analytes
Checkboxes to change analyte units

Results Page
Test descriptions
Summary of test results
Kinetics calculated without boundary tests
Kinetics calculated with boundary tests
Boundary test conditions
Recovery-time graph

Calcs Sheet
Measured individual mass
Measured individual recovery
Measured cumulative mass
Measured cumulative recovery
Measured cumulative grade
Measured cumulative conc mass/head grade
Calculated cumulative recovery
Calculated cumulative mass
Calculated cumulative grade
Calculated cumulative conc mass/head grade
Linear Regression

Data Sheet
Test information
Miscellaneous Parameters
Analyte names
Concentrate times
Concentrate masses
Feed assays
Tails assays
Concentrate assays
Analytes selected
Analyte abbreviations
Analyte units
Analyte category ID
Other parameter IDs
Other parameter values
Other parameter order indices

Graphs
For each analyte & mineral:
Grade/time & recovery/time
Recovery/grade
Mass/time
Recovery/mass
Recovery/(Cum mass/head grade)

Figure 1

2.

ScrollCalc

Summary Sheet
Miscellaneous Parameters
Kelsall Parameters
Kelsall Parameters after boundary tests
Kelsall Parameters after ScrollCalc
Liner correlation coefficients
Sum of the squared errors
Sum of the squared errors (boundary tests)
Sum of the squared errors (after ScrollCalc)
Slow floating ratios
Selectivity
Boundary tests
Floatability
Slow floating ratios
ScrollCalc
Selectivity
Floatability
Measured recovery
Measured conc grades
Measured head grades

Correlation
Coefficient tables
& Histograms
Summary Tables:
Results
Kinetic Ratios
Values of 1st Concs
Sum of Squared Errors

KinCalc
Database

Organisation of KinCalc Functions

THE VALUE OF FLOTATION KINETICS

How an ore responds to milling and flotation is determined by laboratory-scale batch milling and
flotation tests. Under chosen conditions a flotation rate test is performed which generates a
recovery, grade and concentrate mass profile over time. A graph showing typical recovery-time
profiles of two good ores and one bad ore is shown in Figure 2 below. The shape of these
profiles and the relationship between recovery, grade and mass with time is described
mathematically by Kelsalls equation where R equals recovery and t equals time. The equation
describes fast and slow floating components which relate to material that is easily and quickly
recovered at the beginning of the process and material that is not (ie the slow and difficult to
recover component).

Eurus Mineral Consultants. 2002-2009

Description & Capability of KinCalc. June 2009
Page 5 of 9

The equation has four unknowns (kinetics), a fast fraction, a fast rate, a slow fraction and a slow
rate. These are estimated from the testwork data in Excel by using the Solver facility. Accuracy is
improved by use of additional algorithms derived from experience.

100
95

LABORATORY RECOVERY

90
85
80
75
70

FAST SLOW

65
60
55

Kelsall's Equation:

50

R = (100 - ) [1 exp(-kf*t)] + (1 - exp(-ks*t)]

45
40

FAST COMPONENT + SLOW COMPONENT

35
30
0

10

12

14

16

18

20

FLOTATION ROUGHER RATE TIME (min)

Figure 2

Results from a Flotation Rate Test and Kelsalls Equation

The outcome of using Kelsalls equation is that the behaviour and response of the ore as in Figure 2
is now described by a set of numbers or kinetics. The various components of the ore that have
been measured by assay (floatable gangue, economic metals and minerals and other gangue or
metal contaminants if desired) each have their own set of kinetics. An example is shown below in
Table 1. If each set of kinetics was put back into Kelsalls equation then it would recreate the
recovery-time curves in Figure 2 as well as grade-time, mass-time and floatable gangue-time
curves (not shown).

Line
Pink
Red
Dark Blue

IPF
0.9011
0.7705
0.5135

kPF
1.6263
1.8396
1.1383

Table 1
Where,

I
k
P
G

kPS
0.1158
0.1493
0.0554

IGF
0.0496
0.1062
0.2493

kGF
0.3586
0.2201
0.5582

kGS
0.0063
0.0021
0.0043

Flotation Kinetics

= fraction
= rate
= Platinum Group Metals (PGMs)
= Gangue

Thus, IPF = fast floating fraction of PGMs and kGS = slow floating rate of gangue.
Eurus Mineral Consultants. 2002-2009
Description & Capability of KinCalc. June 2009
Page 6 of 9

The usefulness of flotation kinetics is that the flotation response of both minerals/metals and
gangue can be reduced to a set a numbers. Different ores will have a different set of flotation
kinetics as will the same ore under different test and/or operating conditions.

This makes

benchmarking of one ore or one condition against another possible and it then becomes easy to
determine which the better is by simply comparing one set of numbers against the other.

Taking this further, each parameter of rate and fraction has a specific physical meaning in terms of
recovery, grade and mass in the laboratory test. Since the laboratory-scale test cell is merely a
scaled-down version of much larger cells in operation in the industry, the kinetics are also an
accurate description of the ore under full-scale, continuous plant conditions when allowance has been
made for the difference in efficiencies between laboratory-batch and plant-continuous modes. The
difference between batch and continuous systems is described by a set of scale-up factors (or froth
factors). An illustration of the link between each kinetic parameter and operating plant design and
performance is shown in Figure 3).

The importance of flotation kinetics is that understanding of the flotation process, whether in the
laboratory, pilot plant or operating plant, is increased and the process can then be optimised1.
Laboratory flotation kinetics are used by Eurus Mineral Consultants to simulation plant
performance (see Figure 4 and Figure 5).

Using the SUPASIM flotation model to diagnose and understand flotation behaviour from
laboratory through to plant. Proceedings 37th Annual Meeting of the Canadian Mineral Processors
Conference, Ottawa 2005.
Eurus Mineral Consultants. 2002-2009
Description & Capability of KinCalc. June 2009
Page 7 of 9

Physical Meaning of Kinetics in the Plant

Laboratory Ro.conc after 25 min

Clean ore

Fractions
Rates

Fractions
Highly
altered ore Rates

Fast
Gangue

Slow
Gangue

Fast
PGMs

Slow
PGMs

0.0473
0.0473
0.0659
0.0659

0.9527

0.9213
0.9213

0.0787

0.0028
0.0028

2.7811
2.7811

0.0560

0.1151
0.1151
0.2902

0.8849

0.5422
0.5422

0.4578

0.0057
0.0057

0.7215

0.0273
0.0273

%
Mass

Grade
g/t

Rec. %

10.3

47.8

98.1

23.3

16.5

76.9

Recovery
kPS/kGS: incremental recovery, residence
time, use of scavengers, regrinding?
IPF/IGF: grade, nos of stages of cleaning
Circulating load
Selectivity: 1st Ro to final conc, regrinding?

Liberation

1st Ro conc to final conc?, air rates

Degree of alteration/oxidation, pulp density

Figure 3

Physical Meaning of Kinetics in the Plant

Measurement to Prediction
SIMULATION
PROGRAM
SUPASIM

SCALE-UP
FACTORS

+ NECESSARY
INPUTS

SGS
Figure 4

Simulation of Plant from Laboratory Data

Eurus Mineral Consultants. 2002-2009

Description & Capability of KinCalc. June 2009
Page 8 of 9

CIRCUITS SIMULATED & PREDICTED vs ACTUAL

EURUS MINERAL
CONSULTANTS

ACTUAL vs SIMULATED PLANT RECOVERY

PLATINUM, PHOSPHATE & BASE METAL SULPHIDE ORES
100

PRIMARY STAGE

1 - Foskorite (SA)
VALUES
2 - Canadian Cu ore
3 - Maranda Cu (SA)
4 - Palabora Cu ore (SA)
5 - Palabora Cu ore (SA)
6 - Gt Dyke Pt ore (Zimbabwe)
7 - Northam Merensky ore Pt (SA)
8 - Maranda Zn (SA)
9 - BMM Pb (SA)
10 - BMM Zn (SA)
11 - BMM Cu (SA)
12 - Gt Dyke PGM ore Oxidised (Zimbabwe)
13 - O'Okiep Cu Slag (SA)
14 - R/burg PGM UG2 #1 (SA)
15 - R/burg PGM UG2 #2 (SA)
16 - Palabora Cu Slag (SA)
17 - Oxidised PGM Merensky (SA)

95
90
85

SIMULATED PLANT RECOVERY

80
75
70
65
60
55
50
45
40
35

20

Pb in Zn circuit (SA)

Predicted plant recovery

= 0.937*(actual recovery) + 5.2638
R2 = 0.977
12 11

23
16

18

Cu in Merensky

- PGM Merensky (SA)

- R/burg PGM UG2 #1 (SA)
- R/burg PGM UG2 #2 (SA)
- Silicate PGM (SA)

SECONDARY STAGE
(REGRIND) MF2 VALUES
22 - Lac
23 - Lac
24 - Lac
25 - Lac
26 - Lac

Zn in Pb circuit (SA)

SECONDARY STAGE
(REGRIND) MF2 VALUES
18
19
20
21

Cu in Zn circuit (SA)

20
10

25

10

Ni in Merensky

Cu in Pb circuit (SA)

Cu in Zn circuit (SA)

15

15

24 14

Ni in UG2

21

3
2

13
17

26

30
25

22

Cu in
UG2

19

4
1

Zn in Cu circuit (SA)

des Iles PGM Pd (Canada)

des Iles PGM Pt (Canada)
des Iles PGM Au (Canada)
des Iles PGM Cu (Canada)
des Iles PGM Ni (Canada)

0
0

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

95

100

ACTUAL PLANT RECOVERY

Figure 5

3.

Accuracy of Simulation

AVAILABLE VERSIONS, PROTECTION, LICENSE AND PURCHASE

KinCalc is available in 2003 and 2007 excel versions as a single-user, standalone version or as a
network installation for multiple-users.
Protection is afforded using the Aladdin HASP Software Protection System. On purchase and
receipt of the installation package, software is included for the HASP drivers. Included with this is
a HASP key otherwise known as a dongle. The program will not operate unless the dongle is
inserted into the USB port of the users computer.
There is no license or license agreement required for KinCalc.
KinCalc

may

be

purchased

from

Martyn

Hay

at

Eurus

Mineral

Consultants

at

martynhay@worldonline.co.za. Cost will depend upon number of users, version and whether the
KinCalc database resides in Access or SQL.
KinCalc and ScrollCalc are registered trademarks of Eurus Mineral Consultants.

Eurus Mineral Consultants. 2002-2009

Description & Capability of KinCalc. June 2009
Page 9 of 9