Optimal flotation circuit design

using fast-slow recovery model.

Daniel A. Calisaya, Alejandro Lpez-Valdivieso, Marcos
Hernndez de la Cruz, Edelmira E. Glvez and Luis A. Cisternas.
INTRODUCTION
Identification of kinetic model
parameters
METHODOLOGY
Development of Mathematical
model
RESULTS AND
DISCUSSION

CONCLUSIONS
INTRODUCTION

Flotation circuit design has been studied

previously. Previous studies are conditioned
by the circuit, i.e. the number and type of
stage and their interrelationship.

The objective of these research is propose a

design methodology using real data obtained
from laboratory experiences within a model
that allows to introduce more number of
species than previous researches.
 Development
of
Mathematical
model
Identification
of kinetic
model
parameters

METHODOLOGY
Identification of kinetic model parameters

Real data was tested in a flotation laboratory to obtain different

metallurgical parameters.

Laboratory conditions tested:

Laboratory Conditions Test

Scrapes per minute 50 40 30
Frother, g/t 10 12 15
NaCN (depressant), g/t 40 60 80
Na6(PO3)6 (dispersant), Kg/t 02
Identification of kinetic model parameters
Key Stage Condition
dr1 50 scrapes per min
dr2 without Frother 40 scrapes per min
dr3 30 scrapes per min
Rougher
dr4 10 g/t
dr5 with Frother 12 g/t
dr6 15 g/t
dcs1 0 g/t Xanthate
dcs2 10 g/t Xanthate
without Dispersant
dcs3 20 g/t Xanthate
dcs4 Cleaner 40 g/t Xanthate
dcs5 Scavenger 0 g/t Xanthate
dcs6 10 g/t Xanthate
with 2 kg/t of Dispersant
dcs7 20 g/t Xanthate
dcs8 40 g/t Xanthate
dsc1 40 g/t Xanthate and 40g/t NaCN
Scavenger
dsc2 with 2 kg/t of Dispersant 40 g/t Xanthate and 60g/t NaCN
Cleaner
dsc3 40 g/t Xanthate and 80g/t NaCN
Identification of kinetic model parameters
Key Stage Condition
ds1 50 scrapes per min
ds2 without Frother 40 scrapes per min
ds3 30 scrapes per min
Scavenger
ds4 10 g/t
ds5 with Frother 12 g/t
ds6 15 g/t
dc1 0 g/t Xanthate
dc2 10 g/t Xanthate
without Dispersant
dc3 20 g/t Xanthate
dc4 40 g/t Xanthate
Cleaner
dc5 0 g/t Xanthate
dc6 with 2 kg/t of 10 g/t Xanthate
dc7 Dispersant 20 g/t Xanthate
dc8 40 g/t Xanthate
Identification of kinetic model parameters
Kelsall Recovery model was used to adjust the data obtained
from the laboratory.

= [ 1 + 1 1 ]

Fast particles Portion

Fast Kinetic Constant

Infinite Recovery
Slow Kinetic Constant

Recovery
Identification of kinetic model parameters
Each metallurgical condition is adjusted with a non linear
regression. The parameters calculated are the , and .
Development of Mathematical model

Considering the original structure of the A way to represent the structure is with a
Mine matrix of concentrate and tail streams
Development of Mathematical model

Considering the original structure of the A way to represent the structure is with a
Mine matrix of concentrate and tail streams

R C CS1 CS2 SC S1 S2 P W
R X O
C O O O X
CS1 X O X O
CS2 X X O O
SC X O O O
S1 X X X O O
S2 X X X O
 Development of Mathematical model

The mathematical model uses a superstructure that represents

each flotation stage and its feed, concentrate and tail stream.

( )
, , = , , + (, , ) 1 (, , )

, , , ,
, , = , , + 1
1 + , , 1 + , ,
Development of Mathematical model

The mathematical model uses a superstructure that represents

each flotation stage and its feed, concentrate and tail stream.

Feed Tail
M stage i s

Concentrate
s
Development of Mathematical model

The model is able to:

choose between different concentrate/tail streams
Concentrate streams: 162
Posible estructures: 11,664
Tail streams: 72

choose which metallurgical parameter use at each stage

R: 6 C: 8 CS1: 8 CS2: 8 SC: 3 S1: 6 S2: 6

Posible disjunctions: 331,776

RESULTS AND DISCUSSION
RESULTS AND DISCUSSION
Kf

Possible
disjunctions
at each
stage

T Ks
RESULTS AND DISCUSSION
Optimal structure obtained from the optimization. Change the scavenger 1 and
scavenger 2 concentrate stream. This structure with the metallurgical disjunction will
improve the concentration plant.
RESULTS AND DISCUSSION
Results of grade and recovery comparing the mine and the model optimization.
Different residence times were tested to know which one is the best. Its convenient to
reduce the residence time. The best residence time is at 5 minutes
RESULTS AND DISCUSSION
Results of grade and recovery comparing the mine and the model optimization.
Different residence times were tested to know which one is the best. Its convenient to
reduce the residence time. The best residence time is at 5 minutes
RESULTS AND DISCUSSION
Results of grade and recovery comparing the mine and the model optimization.
Different residence times were tested to know which one is the best. Its convenient to
reduce the residence time. The best residence time is at 5 minutes
RESULTS AND DISCUSSION
Different metallurgical parameters are calculated depending on the residence time.
This table shows the results from 1 to 10 minutes of residence time. The disjunctions
of 5 minutes are chosen.

Residence Mine Disjunction Selection Model Disjunction Selection

Time
(min) R C CS1 CS2 SC S1 S2 R C CS1 CS2 SC S1 S2
1 dr6 dc7 dcs8 dcs8 dsc2 ds1 ds1 dr1 dc2 dcs7 dcs8 dsc2 ds1 ds1
2 dr1 dc2 dcs7 dcs8 dsc1 ds1 ds1 dr1 dc7 dcs7 dcs8 dsc2 ds1 ds1
3 dr1 dc6 dcs8 dcs7 dsc2 ds1 ds1 dr1 dc7 dcs7 dcs8 dsc2 ds1 ds1
4 dr1 dc1 dcs8 dcs8 dsc1 ds6 ds1 dr1 dc7 dcs6 dcs8 dsc2 ds1 ds1
5 dr1 dc1 dcs7 dcs8 dsc1 ds1 ds1 dr1 dc2 dcs7 dcs8 dsc2 ds1 ds1
6 dr1 dc1 dcs8 dcs8 dsc1 ds1 ds1 dr1 dc7 dcs7 dcs7 dsc2 ds1 ds1
7 dr1 dc1 dcs7 dcs8 dsc1 ds1 ds1 dr1 dc7 dcs7 dcs7 dsc2 ds1 ds1
8 dr1 dc2 dcs6 dcs8 dsc2 ds1 ds1 dr1 dc7 dcs7 dcs1 dsc2 ds1 ds1
9 dr1 dc1 dcs8 dcs8 dsc1 ds1 ds1 dr1 dc3 dcs7 dcs7 dsc2 ds1 ds1
10 dr1 dc3 dcs7 dcs8 dsc2 ds1 ds1 dr1 dc3 dcs7 dcs7 dsc2 ds1 ds1
RESULTS AND DISCUSSION
Mine Model

R without Frother 50 scrapes per minute

C without dispersant 0 g/t Xanthate without dispersant 10 g/t Xanthate

CS1 with 2 kg/t Dispersant and 20 g/t xanthate

CS2 with 2 kg/t Dispersant and 40 g/t Xanthate

with 2 Kg/t Dispersant, 40 g/t with 2 Kg/t Dispersant, 40 g/t

SC
xanthate and 40 g/t NaCN xanthate and 60 g/t NaCN

S1 without Frother 50 scrapes per minute

S2 without Frother 50 scrapes per minute

 CONCLUSION
An optimal circuit design was achieved with the best condition for
each stage.

VAN 117,000 MUS$ 122,000 MUS$

Revenues 32,000 MUS$ 34,000 MUS$

Recovery 92% 95%

Grade 82% 85%

Because the mathematical model optimizes the Circuit design and

operational condition at the same time, it makes it difficult to solve
using commercial solver for mathematical programming. Despite
the model has a lot of circuit design choices very few changes were
made out between the model and mine design.
Ing. Daniel A. Calisaya Azpilcueta
E-mail: calisaya.daniel@Hotmail.com