Recent studies on the application of

fluidised-bed flotation for treating

sulphide ores at a coarser grind
Massimiliano Zanin1, Bellson Awatey1 and Jaisen Kohmuench2
1 Ian Wark Research Institute, University of South Australia, Australia

2 ERIEZ Flotation Division, USA

Ian Wark Research Institute

Australian Research Council Special Research Centre
For Particle and Material Interfaces
 Coarse Particles Flotation
100

Probability of detachment is
high for coarse particles. 80

Recovery of base metals

Recovery (%)
diminishes outside 20- 60

150m range
Impeller mechanisms 40
Copper
generate turbulence, but Lead-Zinc

necessary to maintain 20
Coal
Phosphate
particles in suspension.
The froth phase also reduces 0

coarse particles recovery. 1 10 100 1000

Particle Diameter (Microns)

Gontijo et al, 2007. Can J Chem Eng, 85, 739-747
Jameson et al, 2008. Centenary of Flotation Commemorative Volume, (SME), USA, pp. 339372.
 Fluidised-bed Flotation Technology
Flotation in quiescent conditions enhances the recovery of coarse particles

- Concept originally devised in early 1990s

- First industrial installation in 2004
(ERIEZ) for the recovery of coarse potash
(+3.5x0.8-mm).
- Demonstrated advantages in the
flotation of low s.g. minerlas (potash,
phosphate, spodumene, diamonds)
- Only recently tested for base metals

In this work, flotation of sulphide ores has been

tested with HydroFloat, at very coarse grind
 Hydrodynamic Advantages

1. Reduced settling velocity,

increased probability of
collision and attachment
2. Plug flow conditions,
increased retention time
3. Absence of turbulence,
decreased probability of
detachment

The hydrodynamic environment

favours coarse particles flotation
 Mechanical vs Fluidised-bed Flotation
Fluidised-
bed Cell
Mechanical No froth layer
Cell Froth layer limits
recovery

Reduced
turbulence Water
+ AIr
High turbulence
causes particles
detachment
Grano, S., 2006, Minerals Engineering, 19, 1307-1318
Kohmuench et al, 2001. Miner & Metall Process, 18, 61-67
Fluidised-bed flotation requires
separate treatment of the fines
(max. top/bottom size ratio 1:6)
 Laboratory Setup
HydroFloat HF-150
140x600 mm DxL
300 kg/h max

Laboratory scale HydroFloat separator at

UniSA, supplied by ERIEZ
 Ores Tested
1. Highly liberated Zn ore (P80 = 750 um)
100 50
mass
80 40 Zn

Distribution, %
Mass passing, %

60 30

40 20

20 10

0 0
100 1000 -250 425 - 250 850 - 425 1180 -
850
Particle size, um Particle size range, um Mineral Mass
%
+250 um floated in HydroFloat (80% of the mass, Sphalerite 12
78% of the Zn) Dolomite 71
-250 um floated in Denver cell (20% of the mass, Quartz 10
22% of the Zn)
 Ores Tested
2. Poorly liberated Cu ore (P80 = 400 um)
100 70
mass
60
80 Cu

Distribution, %
50
Mass passing, %

60
40

40 30

20
20
10

0 0
100 1000 -150 250 - 150 425 - 600 - 425 850 - 600
250
Particle size, um Particle size range, um Mineral Mass
%
+150 um floated in HydroFloat (62% of the mass,
Chalcopyrite 6
40% of the Cu)
Pyrite 6
-150 um floated in Denver cell (38% of the mass, Dolomite 25
60% of the Cu)
Quartz 45
 Ore 2 Liberation by QEM-Scan
LIBERATION IS A
2. Poorly liberated chalcopyrite LIMITING FACTOR

30
15% of Cp is <10% liberated
33% of Cp is <40% liberated
25
Cp in the size fractions +425
20
um is mainly unliberated
15

Particle size, um
10
-250/150
5
-425/250 Mineral Mass
0 -600/425 %
<= 10% -850/600
10%-40%
40%-90% Chalcopyrite 6
>= 90%
Liberation Pyrite 6
Dolomite 25
Distribution of Cp in the coarse flotation
Quartz 45
feed (+150 um) by size and liberation class
 Flotation Tests and Conditions
Two series of tests:
1. Comparison between mechanical cell and fluidised-bed flotation cell
on the coarse flotation feeds (recovery by size)
2. Split flotation of coarse and fine feed fractions for improved overall
flotation performance

ORE Ore 1 (Zn) Ore 2 (Cu)

pH 10 10.5
Activator CuSO4 -
Prim. collect. SIPX PAX
Sec. collect. - Diesel Oil
(*) 30 g/t PPG425 in mechanical cell
Frother PPG425* PPG425* 1 g/t PPG425 in Hydrofloat
Flotation Results
 Ore 1 (Zn ore): Mechanical vs Fluidised-bed
(a) (b)
DENVER CELL

FLUIDISED-BED
Increasing FLOTATION
collector
5-80 g/t
SIPX

Increasing
collector
5-80 g/t
SIPX

Fluidises-bed flotation outperformed mechanical cell for particles > 250 um

Zn recovery up to 88% for 1 mm particles (@ 250 g/t CuSO4 and 80 g/t SIPX)
 Ore 2 (Cu ore): Fluidised-bed Flotation
RESULTS IN
FLUIDISED-BED
DENVER CELL
FLOTATION
NOT AVAILABLE

Recovery of the coarse particles is lower compared to the Zn ore (<60% above
250 um)
Liberation is a limiting factor (significant fully locked particles in tailings)
 Split Flotation (Lab Scale)
d80= 750 um DENVER CELL
d80= 400 um

FINES

Aim: COARSE

Early rejection of
gangue and low-grade
composites FLUIDISED-BED DENVER CELL
FLOTATION
Reduction of energy and
reagents consumption

Increased throughput to
the plant
 Results: Ore 1 (Zn ore)
Denver cell
d80-750 m 9.71 21.2 1.3 1.1
9.37 100 Tails
-250 m
Screen

+250 m
Con 63.2 20.1
9.26 78.8

FLUIDISED-BED
HydroFloat
FLOTATIONcell
95% Zn Recovery Con
56.3 75.1 3.1 3.0

d80-250 m Tails

Regrind
circuit Con
Final Tails 66.4 72.1 Final
0.52 3.7 Rghr Con tails
(combined)
Legend 65.7 92.2
2.4 4.1
Zn grade, Zn Distribution,
% %
Rghr Con (Combo)
92% Zn Recovery
 Results: Ore 2 (Cu ore)
Denver cell
d80-400 m 3.74 60.1 0.07 0.8
2.11 100 Tails
-150 m
Screen

+150 m
Con 10.06 59.3
1.56 39.9

FLUIDISED-BED
HydroFloat
FLOTATION cell
60% Cu Recovery Con
3.19 23.5 0.11 0.4

d80-150 m Tails

Regrind
circuit Con
Final Tails 6.81 23.1 Final
0.9 16.4 Rghr Con tails
(combined)
Legend 8.93 82.4
0.08 1.2
Cu grade, Cu Distribution,
% %
Rghr Con (Combo)
82% Cu Recovery
 Conclusions
Coarse sulphide particles up to 1 mm can be efficiently recovered in
fluidised-bed flotation, in spite of the high s.g.
In general, fluidised-bed flotation outperforms mechanical cells as particle
size increases > 250 um
There is potential for using fluidised-bed flotation as a scalper before
conventional rougher flotation to produce a low-grade throw away tailing
stream
Energy for grinding and reagents consumption can be significantly reduced

The only limitation is the feed

mineralogy. Selectivity drops for finely
disseminated ores (e.g. porphyry
copper) at very coarse grind, due to
liberation issues
 Acknowledgements

The authors kindly acknowledge the Australian Research Council (ARC)

(LP100200533) and the AMIRA International P260F project for the financial
support.

P260 - Flotation