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Geosystem Engineering
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Influence of collector dosage and pulp chemistry on


copper flotation
a
Asghar Azizi
a
Department of Mining, Petroleum and Geophysics, University of Shahrood, Shahrood, Iran
Published online: 12 Jan 2015.

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To cite this article: Asghar Azizi (2014) Influence of collector dosage and pulp chemistry on copper flotation, Geosystem
Engineering, 17:6, 311-316, DOI: 10.1080/12269328.2014.994787

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Geosystem Engineering, 2014
Vol. 17, No. 6, 311316, http://dx.doi.org/10.1080/12269328.2014.994787

Influence of collector dosage and pulp chemistry on copper flotation


Asghar Azizi*
Department of Mining, Petroleum and Geophysics, University of Shahrood, Shahrood, Iran
(Received 30 September 2014; accepted 1 December 2014)

This study was aimed to examine the influence of collector dosage, pH, solid content and water type of flotation pulp on
copper recovery. The results indicated that recovery was strongly affected by these factors and their influence on the best
composition of copper grade and recovery was in the order of water type . solid percentage . collector dosage . pulp pH.
As the value of collector dosage, pH and solid content increased to a certain value, the copper recovery was enhanced to a
peak and thereafter decreased. This may be due to the balance between reagent concentrations with pH and solid percentage.
Copper recovery significantly increased with changing the water type from tap water to distilled water. The best
combination of grade and recovery obtained was 7.26% and 81.09% in flotation tests with tap water.
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Keywords: flotation; pulp pH; collector dosage; solid percentage; copper recovery

1. Introduction processes and interactions, and is not completely under-


Flotation is an important and versatile mineral processing stood. Flotation process depends on a number of factors
step used to achieve selective separation of minerals and which include particle size, pulp density, reagent dosage
gangue. It is a physiochemical process which exploits the and pH. These factors strongly affect froth stability and
differences in the electrochemical properties of mineral floatability (Wills & Napier-Munn, 2006; Zanin, Gredelj,
surfaces. It utilizes the hydrophobic (aerophilic) nature of & Grano, 2008; Zanin, Wightman, Grano, & Franzidis,
mineral surfaces and their propensity to attach to rising air 2009). Therefore, the effects of these variables should be
bubbles in a water ore pulp as the basis for separation. fully determined to obtain an acceptable flotation process.
Flotation depends directly on the nature and properties of Hence, this study was aimed to investigate the influence of
mineral water interface. Two factors are important: (1) the collector dosage and importance of pulp chemistry (i.e. the
interaction of water molecules with the mineral surface, role of pH, solid content and water chemistry) on copper
both in liquid and gaseous environments, and (2) the rougher flotation recovery.
electrical double layer at solid water interface (Davenport, This study was carried out on the Sarcheshmeh
King, Schlesinger, & Biswas, 2002; Fuerstena, 1982; Wills porphyry copper sulphide ore which mainly consists of
& Napier-Munn, 2006). This process is based on the chalcopyrite. The Sarcheshmeh copper ore is the largest
wettability of mineral particles to recover the mineral producing copper plant in Iran which is located body in
species of interest and depress unwanted gangue. The Kerman province, at 60 km distance of the Rafsanjan city.
chemical reagents used in the flotation process to recover This mine contains 1 billion tons, averaging 0.70% copper
valuable minerals are collectors, depressants, activators, and 0.03% molybdenum. In the Sarcheshmeh processing
modifiers and frothers that condition mineral pulp in order plant after three stages of crushing, the ore with a F80 (80%
to produce metal (e.g. copper) concentrate and tailings. passing size) of 12.7 mm is fed to eight parallel ball mills
Each type of reagent plays a different role in the flotation of in closed circuit with cyclones to produce a product 70%
minerals (Herrera-Urbina, 2003). finer than 75 mm. This product is transferred to rougher
In the mineral industry, chalcopyrite (CuFeS2) is the flotation cells. The rougher flotation cells comprise eight
most abundant copper sulphide mineral and is the major rows of flotation machines, divided into two sections.
commercial source of copper. Selective flotation of Each section consists of four rows of flotation cells. The
Copper sulphide minerals (chalcopyrite, chalcocite, combined rougher flotation circuits are designed to receive
bornite) from Fe minerals (pyrite, pyrrhotite) is usually ground ore at a rate of 43,360 dry metric tons per day. The
done with xanthate, dithiophosphate or thionocarbamate concentrate of the first stage of flotation reground and the
collectors; burnt lime (CaO) for pH control; and branch tailings are discarded to the final tails. The cleaning and
chain alcohol frothers (Davenport et al., 2002). re-cleaning stages produce copper concentrate. The
The theory of froth flotation is complex, involving collectors of Nascol 1451 (dithiophosphate mercapto-
three phases (solids, water and froth) with many sub- benzothiazole), Z11 (sodium isopropyl xanthate), frothers

*Corresponding author. Email: azizi.asghar22@yahoo.com


q 2014 The Korean Society of Mineral and Energy Resources Engineers (KSMER)
312 A. Azizi

Table 1. Mineralogical composition and chemical analysis of the feed of the flotation circuit (wt.%).

Chemical composition (wt.%)


Product Mineralogical composition Cu Fe Mo S SiO2 Al2O3
Feed of flotation Quartz, illite, biotite, chlorite, orthoclase, albeit, 0.74 4.34 0.032 3.05 55.07 14.35
muscovite, pyrite, chalcopyrite and chalcocite

of Dow 250 (polypropylene glycol methyl ether) and 2.2 Flotation


methyl isobutyl carbonyl (MIBC) are the reagents used After grinding, the pulp was transferred to a 5 l flotation
in the flotation circuit (Banisi & Farzaneh, 2004; cell. Flotation tests were conducted using a Denver
Barkhordari, Jorjani, Eslami, & Noaparast, 2009). flotation machine at the impeller speed of 1400 rpm. The
pulp density was adjusted to 28% solids by volume at the
beginning of each test. CaO was used to adjust the slurry
2. Materials and methods pH to 11.8. Then 40 g/t collectors of Z11 (15 g/t) and
2.1 Materials mercaptobenzothiazole (25 g/t) were added to the cell, and
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The copper ore samples used in this study were prepared after 1 min, 30 g/t frothers of MIBC (15 g/t) and F742
from the ball mills feed of the Sarcheshmeh concentrator (polypropylene glycol) (15 g/t) were added to the cell and,
plant. The samples were prepared after two stages of finally after 2 min, air was opened and flowed inside the
laboratory comminution including crushing and milling. cell and the collecting of the froth was started. The
First, the samples were crushed in a jaw crusher (Fritsch concentrated froth samples were collected at the intervals
01.703, Idar-Oberstein, Germany). As input feed to ball of 0.5, 2, 4 and 8 min. The flotation froth was scraped
mill was in range of 250 2000 mm in the Sarcheshmeh every 10 s. Finally, the concentrate and tailing samples
concentrator plant, this size fraction was collected for were filtered, dried and assayed. Also, water type and the
experiments of grinding, thereafter samples were then values of pH, solid percentage and collector dosage for
homogenized and sealed in polyethylene bags. Samples different experiments changed, but other parameters were
were chemically analysed and their chemical compositions constant.
are presented in Table 1. Then, the grinding experiments
were conducted on 1460 g representative samples by a
laboratory ball mill (the standard bond ball mill) at 3. Results and discussion
grinding time of 7.5 min. Samples were ground with 20 kg Since the recovery at the rougher stage has a significant
ball in mixing of 12.7, 19.05 and 25.4 mm in diameter by effect on the overall copper recovery, the effect of some of
steel balls such as 70% of particles were finer than 75 mm the operating parameters including collector dosage, water
in diameter. type, pH and solid content of flotation pulp on copper
Sodium hydroxide was used as pH modifier to recovery and performance of rougher cells was investi-
maintain the pH at the targeted value during grinding. gated. Recovery of Cu was calculated using the mass
Lime (CaO) was also used as modifier of pH in the balancing method described by Wills and Napier-Munn
flotation process. (2006) by the following formula:
Z11 (sodium isopropyl xanthate) and mercaptoben-
zothiazole were used as collector, and MIBC and F742 Cc
R 100; 1
(polypropylene glycol) were applied as frother. These C Tf
mixed chemicals are used in rougher flotation circuit of the
Sarcheshmeh copper concentrator plant. Hence compo- where R is percentage recovery of Cu, C is dry weight of
sition of these chemicals was applied. concentrate, c is percentage grade of concentrate, T is dry
Two types of water (tap water and distilled water) were weight of tailing and f is percentage grade of feed.
also applied in flotation experiments, and chemical
analysis of tap water is given in Table 2.
3.1 Effect of solid content
It is well known that the solid content of the flotation pulp
Table 2. Chemical analysis of tap water used in flotation tests is an important parameter in the flotation of sulphide ores,
(ppm).
so flotation experiments were carried out at different solids
Compositions Cl2 Ca2 SO22
4 Fe Mg2 concentration (15 40%) in the Denver flotation cell to
determine its effect on the Cu recovery and grade.
Tap water 37.8 24.3 40 0.03 4.03
Experiments were performed at pH 11.5, the value of
Geosystem Engineering 313

100 100
y = 0.0626x2+4.1869x+13.9133 y = 0.9439x29.2711x16.281
R2= 0.9835 R2= 0.959
Cu Recovery (%) 90 90

Cu Recovery (%)
80 80

70 70

60 60

50 50

10 20 30 40 50 6 8 10 12 14
Solid percentage pH

Figure 1. Influence of solid percentage on Cu recovery. Figure 2. Influence of pH on Cu recovery.


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collector dosage 40 g/t, the value of frother dosage 30 g/t Wills and Napier-Munn (2006) believe the pulp
and conditioning time 3 min with tap water. Results of alkalinity plays a very important role in flotation. They
flotation experiments are plotted in Figure 1. As can be also point that in practice, the separation is selectively
seen, when the solid percentage increases from 15% to dependent on a delicate balance between reagent
30%, the Cu recovery (%) increases from 63.42% to concentration and pH. Therefore, the rougher flotation
84.89%, respectively. Increasing solid percentage to 40% behaviour of the Sarcheshmeh porphyry copper ore as a
results in reducing the Cu recovery. function of slurry pH was investigated from pH 7 to 12,
According to Mehrotra and Singh (1995) and Singh and the results obtained are shown in Figure 2.
and Sinha (2005), increasing recovery at higher solids Experiments were carried out at 28% (solids) pulp
concentration could be to enhanced recovery of coarse concentrate, the value of collector dosage of 40 g/t, the
particle and also the higher probability of collision of value of frother dosage of 30 g/t and conditioning time of
particles with air bubbles. In reality, an excessive high 3 min with tap water. It indicated that with the increase of
solid concentration causes over-crowding of particles, and the pH values from 7 to 11, the Cu recoveries increased,
this hinders effective flotation and affects the selectivity. while recovery at pH 12 reduced. The variation change of
Also, an increase in solid concentration lowers the recovery of copper is probably because of reducing the
combustible content of the product. This is attributed to collection capacity of collectors (xanthates) when they
the decrease in dispersion of particles resulting in loss in become more stable at higher pH values (pH 12).
selectivity of adsorption of reagents and also the enhanced In addition, the slow formation rate and decreased stability
gangue recovery by the entrainment and entrapment of dixanthogen in the more alkaline solutions are
phenomena (Mehrotra & Singh, 1995). responsible for the drop in chalcopyrite recovery. Since
dixanthogen is the effective hydrophobic species for
chalcopyrite, anything that would decrease its effective
3.2 Effect of pulp pH concentration or rate of formation would decrease the
The pH is one of the most important factors in flotation floatability of chalcopyrite (Ackerman, Harris, Klimper,
or depression of minerals. pH affects the surfaces of the & Aplan, 1987a, 1987b). On the other hand, increase of
solids (hydration, excess charge density, zeta potential and recovery in pH 11 can also be attributed to the chemical
surface coating), the ionization or solubility of a reagent, type used in the experiments. Sulphide minerals flotation
the concentration of inorganic ions, the electrochemical is enhanced at alkaline pH in the presence of sodium
potential and the corresponding oxidation reduction isopropyl xanthate, as xanthate molecules decompose at
potential (Leja, 1983). The extent of ionization and highly acidic pH and iron sulphide minerals are depressed
hydrolysis of reagents, i.e. their adsorption at the ionized in alkaline pH. Therefore, in alkaline pH good selectivity
solid liquid interfaces, affects the selectivity of flotation. is obtained for copper sulphide minerals (Bulatovic, 2007).
Also, the pH determines hydrolysis and precipitation of As can be considered in Figure 2, the condition of the
metal ions in solution and at the solid liquid interfaces by flotation is directly dependent on pH. As observed, the
changing the concentration of hydrogen and hydroxyl ions optimum pH is 11. This indicates the balancing of reagents
(Leja, 1983; Yarar & Dogan, 1987). suites with pH occurs in pH 11.
314 A. Azizi

3.3 Effect of collector dosage Experiments were carried out at 28% (solids) pulp
The types and quantity of the reagents are the most concentrate, pH 11.5, the value of frother dosage of 30 g/t
important factors of the flotation process. In commercial and conditioning time 3 min with tap water. It is seen that
plants, the control of reagent additions is the most 40 g/t collector dosage gives the best results for copper
important aspect of the flotation strategy (Bulatovic, recovery, while with a further increase in the amount of
2007). collector, recovery reduces. According to Sis and Chander
Reagent schemes used for the treatment of porphyry (2003), the reason could be explained by the interactions
copper ores are relatively simple and usually include lime between bubble and solid. When the bubble is in contact
as a regulator, xanthate as the primary collector and a with the solid surface, the local surface concentration and
secondary collector that involves dithiophosphates, hydrophobic character of the surface increase. This is due
mercaptans, thionocarbamates and xanthogen formates. to the penetration of collector and frother molecules at the
The frothers, such as MIBC, TEB (alkoxy paraffin and air liquid interface into the diffuse monolayer of the solid.
pine oil), Dow 250, Dow 1012 (glycols), HP700 and The attachment of particles to air bubbles thus becomes
HP600 (alcohols in amine oxide), are typically used in the stronger with a slightly more condensed mixed monolayer
flotation of porphyry copper ores (Bulatovic, 2007). at the liquid air interface. If the solid is completely
In copper flotation plants, an increase of 1 2% in recovery covered with an immobilized collector monolayer, then
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and/or grade is economically remarkable (Vazifeh, Jorjani, the frother molecules cannot penetrate, and consequently
& Bagherian, 2010). Among the reagents, the collector the bubble adhesion is suppressed.
dose is a critical parameter in the flotation. Adjusting the
collector dose can change the surface characteristics of
the particles and thereby influences metal recovery and 3.4 Effect of water type
separation efficiency in the flotation process. On the other Water represents 80 85% of the volume of mineral pulp
hand, it has been shown that the use of mixtures of processed in flotation circuits (Levay, Smart, & Skinner,
collectors can have benefits over the use of pure collectors 2001). Water is a medium in which flotation takes place
(Bradshaw, Harris, & OConnor, 1998; Bradshaw & and flotation efficiency is strongly dependent on water
OConnor, 1994, 1996; Rao & Forrsberg, 1997). These quality (Castro & Laskowski, 2011; Liu, Moran, & Vink,
benefits include lower dosage requirements, improved 2013). Bc ak, Ekmekc i, Can, and Ozturk (2012) showed
selectivity, rates and recovery, and an increase in the that water chemistry had a significant effect on froth
recovery of coarse particles. It has been proposed that stability and surface chemistry of the flotation. In order to
these benefits derive from the differences in the behaviour evaluate the influence of water chemistry on the recovery
of the collectors on mineral surfaces (Bradshaw & of copper, two types of water including tap water and
OConnor, 1996). Thus mixture of two collectors was distilled water were employed in the flotation experiments.
used in experiments and their effects on flotation of copper The experimental conditions are presented in Table 3.
were investigated. The effect of collector on copper Table 3 indicates that copper recoveries in distilled
recovery of flotation is shown in Figure 3. water are higher than in tap water. As observed, when
experiments of flotation are performed with tap water,
recovery of copper reduces with increasing pH from 11 to
90 12, but when distilled water was used as fluid in flotation
y = 0.0523x2+4.4413x13.6489 tests, copper recovery increases in this range of pH. This
R2= 0.966 may be due to the presence of metal ions in the pulp when
85 experiments on flotation are done with tap water. Because
Cu Recovery (%)

metal ions in flotation water can alter the surface charge of


80 particles and consequently affect interactions between
particles and waste gangue or between particles and

75 Table 3. Experimental conditions of flotation tests.

Solid Collector Copper


70 pH (%) Water type dosage (g/t) recovery (%)
8 28 Tap water 40 69.93
65 11 28 Tap water 40 82.03
30 40 50 60 12 28 Tap water 40 81.09
8 28 Distilled water 40 75.93
Collector dosage (g/tonne) 11 28 Distilled water 40 89.31
12 28 Distilled water 40 92.33
Figure 3. Influence of collector dosage on Cu recovery.
Geosystem Engineering 315

60
50 Solid percentage Tap water
pH Distilled water
Collector dosage
70
Cu Recovery (%)

Cu Recovery (%)
60

80
70

90
80

100
90
5 6 7 8 9 10
5 6 7 8 9
Cu Grade (%)
Cu Grade (%)
Figure 4. Influence of collector dosage, pH and solid
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percentage on Cu grade recovery curve. Figure 5. Influence of water type (tap and distilled water) on Cu
grade recovery curves.

collectors. This could affect particle bubble attachment investigate the influence of pulp chemistry of flotation
and also formation of stable particle bubble aggregates (pH, solid content and water type) and the amount of
(Ali, Gauglitz, & Rossen, 2000; Johansson & Pugh, 1992; collector dosage consumption on copper recovery and
Moolman, Eksteen, Aldrich, & Van Deventer, 1996) separation efficiency of flotation. The conclusions
indicated that (1) the collector dosage, pH and solid
content were strongly effective on copper recovery and
3.5 Effect of parameters investigated on grade separation efficiency of flotation, (2) copper recovery
recovery curve increased with increasing pH from 7 to 11, while
increasing pH to 12, copper recovery reduced. This was
The curves of Cu grade recovery were used to investigate due to its balancing with reagent dosages to improve
the influence of parameters studied on separation recovery, (3) in range solids concentration investigated,
efficiency of flotation, and the results are presented in the best recovery of copper obtained in solid percentage
Figures 4 and 5. Figure 4 presents Cu recovery versus Cu 30, (4) with increasing collector dosage, the copper
grade for different values of pH, solid percentage and recovery increased up to 81.09% with 7.26% Cu grade at
collector dosage, when experimental conditions were 40 g/t collector dosage. In addition, a further increase in
constant and only one factor varies. collector dosage decreased the recovery since very high
According to Wills and Napier-Munn (2006), the best collector concentrations are detrimental for the flotation
separation efficiency of rougher flotation cells (i.e. the best process, (5) the higher compositions of grade and recovery
separation of the valuable mineral from gangue) is to achieve were achieved with changing of water type from tap water
both high grades and recoveries. As can be observed, the to distilled water, (6) the influence degree of factors
influence of solid content (pulp density) is higher than in studied on the best composition of copper grade and
collector dosage and pulp pH. It is also seen that the best recovery was obtained in the order of solid percentage .
combination of grade and recovery obtains 7.26% and collector dosage . pulp pH when flotation experiments
81.09%, respectively. This optimum condition was obtained were conducted with tap water, and finally the results
when flotation tests were performed with tap water. While obtained from this study provide useful guidance for
separation efficiency is improved by using distilled water. modification of the Sarcheshmeh processing plant circuit.
Figure 5 indicates the influence of the two types of water,
including tap water and distilled water on grade and recovery
of copper. It is considered that water type significantly affects
Disclosure statement
the grade and recovery of copper and consequently results in
No potential conflict of interest was reported by the author.
the higher grades and recoveries.

Funding
4. Conclusions
The authors gratefully acknowledge the Sarcheshmeh copper
A series of batch scale flotation experiments were carried mine (Research and development division) funded by National
out on samples of the Sarcheshmeh porphyry copper ore to Iranian Copper Industries Company, for supporting this research.
316 A. Azizi

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