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Despite flotation kinetic modeling is well discussed in the literature, its evaluation from overfitting, the number of model parameters and model complexities have not been adequately addressed. Fl...

After more than a century applying flotation to the mining industry, two completely different strategies have been introduced for processing purposes. One is the classical approach viz. grinding the ores to a certain extent and floating them via conventional mechanical and recently pneumatic cells e.g. Jameson and ImhoflotTM cells. This strategy continuous because mines face up to declining cut-off grades, complex and poly-mineralized ores, and they require to achieve an acceptable degree of mineral liberation. The other school of mind deals with the coarse particle processes mainly owing to the low energy needs, that includes flash, fluidized bed and HydroFloatTM cells. The third and newest system proposes processing both fine and coarse sizes by flotation machines like oscillating grid flotation (OGC) and Reflux flotation cells. The present paper endeavours to critically evaluate these concepts from several points of view including existing technological elaborations, water and energy usages, kinetics and circuit design. Brief introduction of advanced technologies, along with their applications, were presented. It was revealed that the incorporation of coarse grinding apparatuses, mineralogical techniques together with the technologically applicable classification systems and adapted simulator tools are urgent needs for coarse flotation as the future requirements for mining industries. However, fine particle flotation may remain as the main focus of re-processing tailings dams.

The flotation beneficiation of phosphate ore is increasingly facing challenges, especially for finely disseminated sedimentary ores rich in carbonates. This study aims to optimize and assess the impact of key hydrodynamic parameters including pulp density, air flowrate and impeller speed on flotation and metallurgical responses (i.e. grade, recovery, flotation rate constant and selectivity index (SI)). We carried out locked cycle flotation tests using the best conditions from the rougher flotation test to generate an experimental simulation of a continuous circuit. The mineralogical and chemical properties were characterized by mineral liberation analysis (MLA) and inductively coupled plasma optical emission spectroscopy (ICP-OES) techniques, respectively. A modified-McGill bubble size viewer was used for measuring bubble sizes and evaluating the interaction between hydrodynamic factors and bubble diameters. Finally, the design of experiment (DOE) method was applied to determine the relative intensity of the studied factors. It was found that under optimal conditions with the targets of high recovery and maximum SI, the final apatite concentrate achieved a recovery of 86.3% at a grade of 35.5%, while the MgO content was 1.2% and 84.3% of dolomite was removed from a feed ore containing about 25% P2O5, 4.6% MgO, and 41% CaO. Furthermore, another locked cycle flotation test showed that a 0.82% MgO content in the final apatite concentrate can be achieved with an apatite recovery of 75.6% at a P2O5 grade of 36.76% , and a ratio CaO/P2O5 = 1.33. The obtained concentrate in this investigation under the optimum conditions is the highest in both apatite recovery and grade with low MgO content reported in the literature.

In flotation, the froth characteristics strongly influence the separation process as they are linked to water recovery, bubble size, entrainment of gangue particles, flotation rate constants and finally grade and recovery. In the case of a high-grade apatite ore with a high mass pull in lab-scale flotation, significant changes in pulp and froth properties occur, such that the froth stability decreases with increasing flotation time. These changes can be related to different particle and reagent concentrations. We describe the change of entrainment in a rich apatite ore batch flotation with time more precisely by measuring froth properties using a Dynamic Froth Analyzer (DFA). It is concluded that the degree of entrainment is not only dependent on particle size but also the pulp density due to its effect on particle settling and also froth properties in varying resistance to drainage. Through a combination of time-resolved dynamic froth analysis and automated mineralogy, we identify the dynamic effects governing in the froth and compare the entrainment results with existing models. Furthermore, our analyses offer novel support for the extension of the common understanding of the entrainment phenomena.

The flotation beneficiation of apatite for phosphate production is challenging for finely disseminated sedimentary ores rich in carbonates. Similarities in surface properties of the semi-soluble salt-type carbonate and phosphate calcium minerals combined with fine intergrowth are the main reasons for poor grade and low recoveries. Imperfect depression of the calcium/magnesium carbonate minerals, e.g. calcite and dolomite, will lead to weak hydrophobic surface properties and thus true flotation of this gangue. Furthermore, fine particles, even though sufficiently liberated, strongly affect the bubble-particle collection due to negative rheological effects within the pulp leading to a drop in flotation kinetics of the fine valuables and an increase in entrainment of fine gangue particles. This study presents the results and discussions based on automated mineralogy (conducted with a Mineral Liberation Analyzer – MLA) of size-by-size-by-liberation analyses for various mineral groups. In addition, results on different turbulent hydrodynamic parameters are presented based on various tests in a lab cell.

Studies of flotation kinetics are essential for understanding, predicting, and optimizing the selective recovery of minerals and metals through flotation. Recently, much effort has been made to use intrinsic ore properties to model flotation behavior. Particle-based characterization methods, e.g. SEM-based image analysis, have enabled much of this development. However, currently available methods for studies of flotation kinetics can not accommodate single-particle data, resulting in incomplete use of data that is readily available today. In this contribution, a method is introduced to apply kinetic flotation models to individual particles. This method, based on lasso-regularized multinomial logistic regression, allows for an in-depth understanding of particle flotation behavior as a function of all measured particle characteristics. With the proposed method, the joint influences of particle size, shape, as well as modal and surface compositions on the recovery of individual particles can be taken into unprecedented consideration. The results of the simulated particle behavior showed a very good agreement to the outcome of conventional empirical studies and follow well-described froth flotation recovery behavior.

Minerals can be liberated by random fracture of particles into smaller fragments or by detachment along phase boundaries. These two mechanisms represent borderline cases. When ores get comminuted the liberation of minerals is achieved to some extent by both mechanisms. This article describes a method to determine the extent of transgranular and intergranular fracture based on 2-dimensional analysis of surface exposure of minerals. The approach uses the unbiased surface information of phase specific surface area ( PSSA ), phase specific free surface ( PSFS ) and phase specific interfacial area ( PSIA ) of minerals and their change with comminution. The parameters are discussed related to the normalized grain size, which is the ratio of mineral grain size in the product to mineral grain size in the unbroken material. Finally, the amount of transgranular and intergranular fracture on surface exposure can be calculated using the phase specific surface parameters. A sedimentary rock (apatite ore), an igneous rock (nepheline-syenite) and an artificial material (copper slags) were ground to different fineness. Based on the mineral liberation analysis (MLA) of feed and products, the extent of phase boundary fracture on the surface exposure of the minerals is studied.

The depletion of ore deposits, the increasing demand for raw materials, the need to process low-grade, complex and finely disseminated ores, and the reprocessing of tailings are challenges especially for froth flotation separation technologies. Even though they are capable of handling relatively fine grain sizes, the flotation separation of very fine and ultrafine particles faces many problems still. Further, the flotation of low-contrast semi-soluble salt-type minerals with very similar surface properties, many complex interactions between minerals, reagents and dissolved species often result in poor selectivity. This study investigates the flotation beneficiation of ultrafine magnesite rich in dolomite from desliming, currently reported to the tailings. The paper especially focuses on the impact of the depressant sodium hexametaphosphate (SHMP) on the following: (i) the froth properties using dynamic froth analysis (DFA), (ii) the separation between magnesite and dolomite/calcite, and (iii) its effect on the entrainment. As a depressant/dispersant, SHMP has a beneficial impact on the flotation separation between magnesite and dolomite. However, there is a trade-off between grade and recovery, and as well as the dewatering process which needs to be considered. When the SHMP increases from 200 g/t to 700 g/t, the magnesite grade increases from 67% to 77%, while recovery decreases massively, from 80% to 40%. The open circuit with four cleaning stages obtained a concentrate assaying 77.5% magnesite at a recovery of 45.5%. The dolomite content in the concentrate is about 20%, where 80% of dolomite was removed and importantly 98% of the quartz was removed, with only 0.3% of the quartz in the final concentrate. Furthermore, the application of 1-hydroxyethylene-1,1-diphosphonic acid (HEDP) as a more environmentally friendly and low-cost alternative to SHMP is presented and discussed. Using only 350 g/t of HEDP can achieve a similar grade (76.3%), like 700 g/t of SHMP (76.9%), while obtaining a 17% higher magnesite recovery as compared to 700 g/t of SHMP. Interestingly, the proportion of hydrophilic quartz minerals ending up in the concentrate is lower for HEDP, with only 1.9% quartz at a recovery of 21.5% compared to the 2.7% of quartz at a recovery of 24.9% when using SHMP. The paper contributes in general to understanding the complexity of the depressant responses in froth flotation.