2016-Sustainable Industrial Processing Summit
SIPS 2016 Volume 5: Starkey Intl. Symp. / Mineral Processing

Editors:Kongoli F, Kumar P, Senchenko A, Klein B, Silva A.C., Sun C, Mingan W
Publisher:Flogen Star OUTREACH
Publication Year:2016
Pages:270 pages
ISBN:978-1-987820-44-7
ISSN:2291-1227 (Metals and Materials Processing in a Clean Environment Series)
CD-SIPS2016_Volume1
CD shopping page

    Modern Flowsheet Development for Mineral Processing

    Norman Lotter1;
    1FLOWSHEETS METALLURGICAL CONSULTING INCORPORATED, Sudbury, Canada;
    Type of Paper: Keynote
    Id Paper: 356
    Topic: 5

    Abstract:

    Since the advent of sulphide flotation over a century ago, the processing of sulphide ores by grinding and flotation to concentrate the economic minerals into a low-bulk product suitable for smelting and refining has become common practice. This choice places the concentrator as a key lever in the business case of the mining company, however, the final tailings produced by the concentrator carry the highest and most variable amount of paymetal loss in the entire production chain of saleable metals (Cramer, 2001). For decades, the flotation process was operated by empirical heuristics and was limited by incomplete understanding. Quite often this metals loss to the final tailings could be considerably reduced with more appropriate flowsheet design and optimisation.
    Since the 1980s, there has been much advancement in the technology used to diagnose the causes and find possible flowsheeting solutions to this problem, starting with the milestone work of Henley, 1983, in which he proposed the integration of geology, mineralogy, and mineral processing to synergise the processing information and develop more effective flowsheeting solutions. This was followed by the development and commercialisation of quantitative mineral measurement systems such as QEMSCAN, MLA and TIMA. Sampling practice, using the methods published by Pierre Gy in 1979, was also introduced for obvious reasons. There are now many publications on this modern integrated practice, which is called Process Mineralogy. In the best practice of Process Mineralogy, it is possible to quantify the process entitlement of performance. This gives a benchmark against which to compare existing plant performance and leads to an operations improvement programme that will close this performance gap.
    Moving forward into the mining and milling of future orebodies, the challenge becomes more a matter of how to treat these difficult and complex ores, since the older, simpler and richer orebodies have already been discovered and treated. Additionally, the paymetal grades of these future orebodies are lower than was the case with the older ones, implying that more efficient processing will be necessary in order to profitably treat these future ores. It is thus critical in a greenfield project to establish the performance entitlement for the ore and to develop a flowsheet that will deliver that entitlement so as to assure the project of the maximum financial return on the investment.
    This paper presents a summary of the modern toolbox and discusses some case studies in which successful flowsheeting solutions were found for both existing operations and greenfield projects.

    Keywords:

    Flotation; Metals; Mineral; Ore; Processing; Technology;

    References:

    [1] Cramer, L.A., 2001. The extractive metallurgy of South Africa’s platinum ores. Journal of Metallurgy (October), 14–18.
    [2] Henley, K.J., 1983. Ore-dressing mineralogy: a review of techniques, applications and recent developments. Spec. Publ. Geol. Soc. South Africa 7, 175–200.
    [3] Gy, P.M., 1979. Sampling of Particulate Materials, Theory and Practice. Elsevier, Amsterdam.
    [4] Lotter, N.O., Monnapula, R., Oliveira, J.F., Fragomeni, D., and Bradshaw, D.J., 2011a. Formulation and plant trial of a mixed collector for Eland Platinum, proc. Canadian Mineral Processors, Ottawa, January 2011, Paper 10, pp. 161-183.
    [5] Napier-Munn, T.J., 1995. Detecting performance improvements in trials with time-varying mineral processes – three case studies, Minerals Engineering, 8, (8)pp. 843-858.
    [6] Lotter, N.O., Di Feo, A., Kormos, L.J., Fragomeni, D., and Comeau, G., 2010. Design and measurement of small recovery gains – a case study at Raglan concentrator, Minerals Engineering, 23, (2010), pp. 567-577.
    [7] Bond, F.C., 1952. The third theory of comminution. Trans. AIME Miner. Eng. 193, 484–494.
    [8] Rowland, C.A., 1976. The tools of power: the bond work index, a tool to measure grinding efficiency, Denver SME Meeting.
    [9] Rowland, C.A., 2002. Selection of rod mills, ball mills, and regrind mills, Mineral Processing Plant Design, Practice, and Control, SME, pp. 710-754.
    [10] McIvor, R., Lavallee, M., Wood, K., Blythe, P., 1990. Functional performance characteristics of ball milling. In: Proc. Canadian Mineral Processors, Ottawa, pp. 100–126.
    [11] Starkey, J. H., 2015. Achieving SAG Mill Design Production at Start-Up Using Best Practices - Fact or Fiction. International Comminution and Classification Congress 2015. San Luis Potosi, Mexico.
    [12] McIvor, R.E., Finch, J.A., 1991. A guide to interfacing of plant grinding and flotation operations. Miner. Eng. 4 (1), 9–23.
    [13] Martin, C.J., McIvor, R.E., Finch, J.A., and Rao, S.R., 1991. Review of the Effect of Grinding Media on Flotation of Sulphide Minerals, Minerals Engineering, 4, 2, 1991, pp. 121-132.
    [14] Greet, C.J., 2008. The significance of grinding environment on the flotation of UG2 ores. Third International Platinum Conference ‘Platinum in Transformation’, The Southern African Institute of Mining and Metallurgy, 2008.
    [15] Greet, C.J., Kinal, J., and Steinier, P., 2005. Grinding Media – its Effect on Pulp Chemistry and Flotation Behaviour – Fact or Fiction?, proc. Centenary of Flotation, Brisbane, June 2005, pp. 967-972.
    [16] Lotter, N.O., Bradshaw, D.J., and Barnes, A.R., 2015. Flotation of the Major Copper Sulphide Minerals – an Electrochemical Viewpoint, proc. MEI Flotation ’15, Cape Town, November 2015.
    [17] Lotter, N.O., Bradshaw, D.J., and Barnes, A.R., 2016a. Flotation of the Major Copper Sulphide Minerals – an Electrochemical Viewpoint, proc. Canadian Mineral Processors, Ottawa, January 2016, pp. 242-256.
    [18] Lotter, N.O., Bradshaw, D.J., and Barnes, A.R., 2016b. Classification of the Major Copper Sulphides into Semiconductor Types, and associated flotation characteristics, Minerals Engineering, doi:10.1016/j.mineng.2016.05.016, in press, 2016.
    [19] Gaudin, A.M., 1939. Principles of Mineral Dressing. McGraw-Hill, New York.
    [20] Petruk, W., 1976. The application of quantitative mineralogical analysis of ores to ore dressing. CIM Bull. 767, 146–153.
    [21] Petruk, W., Hughson, M.R., 1977. Image analysis evaluation of the effect of grinding media on selective flotation of two zinc–lead–copper ores. CIM Bull. 787, 128–135.
    [22] Cabri, L.J., 1981. Relationship of mineralogy for the recovery of PGE from ores. In: Cabri, L.J. (Ed.), Platinum-Group Elements: Mineralogy, Geology, Recovery, special vol. 23. Canadian Institute of Mining, Metallurgy and Petroleum, pp.233–250.
    [23] Petruk, W., Schnaar, J.R., 1981. An evaluation of free and unlibarated mineral grains, metals and trace elements in the concentrator of Brunswick Mining and Smelting Corporation Limited. CIM Bull. 833, 132–159.
    [24] Peyerl, W., 1983. The metallurgical implications of the mode of occurrence of platinum-group metals in the Merensky Reef and UG-2 chromitite of the Bushveld complex. Spec. Publ. Geol. Soc. South Africa 7, 295–300.
    [25] Gottlieb, P., Wilkie, G., Sutherland, D.N., Ho-Tun, E., Suthers, S., Perera, K., Jenkins, B., Spencer, S., Butcher, A., Rayner, J., 2000. Using quantitative electron microscopy for process mineralogy applications. JOM 52 (4), 24–25.
    [26] Grant, G., Hall, J.S., Reid, A.F., Zuiderwyk, M., 1976. Multi-compositional particle characterisation using the SEM-microprobe. In: Proc. Scanning Electron Microscopy/1976, Part III, Workshop on Techniques for Particulate Matter Studies in SEM, ITT Research Institute, pp. 401–408.
    [27] Barbery, G., Huet, G., Gateau, G., 1979. Liberation analysis by means of image analysers: theory and applications. In: Proc XIII IMPC, vol. 2, pp. 568–599.
    [28] Gu, Y., 2003. Automated Scanning Electron Microscope Based Mineral Liberation Analysis, Journal of Minerals & Materials Characterization & Engineering, Vol. 2, No.1, pp33-41, 2003.
    [29] Fandrich, R., Gu, Y., Burrows, D., Moeller, K., 2007. Modern SEM-based mineral liberation analysis. Int. J. Miner. Proc. 84 (1–4), 310–320.
    [30] Wightman, E.M., and Evans, C.L., 2012. Representing and interpreting the liberation spectrum in a processing context, proc. MEI Process Mineralogy 12, Cape Town, November 2012.
    [31] Gottlieb, P., Motl, D., Dosbaba, M., and Kopriva, A., 2015. The use of the TIMA automated mineral analyser for the characterisation of ore deposits and optimisation of process operations, proc. MinPet 2015.
    [32] Restarick, C.J., 1976. Pulp sampling techniques for steady state assessment of mineral concentrators. In: Sampling Symposium, Australasian Institute of Mining and Metallurgy, Melbourne, pp. 161– 168.
    [33] Lotter, N.O., Laplante, A.R., 2007. Statistical benchmark surveying of production concentrators. Miner. Eng. 20, 793–801.
    [34] Lotter, N.O., Whittaker, P.J., Kormos, L.J., Stickling, J.S., and Wilkie, G.J., 2002. The development of Process Mineralogy at Falconbridge Limited, and application to the Raglan mill, CIM Bulletin, 95, No. 1066, Nov-Dec 2002, pp. 85-92.
    [35] Baum, W., Lotter, N.O., and Whittaker, P.J., 2004. Process Mineralogy – a new generation for ore characterisation and plant optimisation, proc. SME annual meeting and exhibit, Denver, CO., preprint 04-12.
    [36] McKay, N., Wilson, S., Lacouture, B., 2007. Ore characterisation of the Aqqaluk deposit at Red Dog. In: 39th Annual Meeting of the Canadian Mineral Processors, Ottawa, Paper No.5, January 23–25, 2007, pp. 55–74.
    [37] Schouwstra, R., and Smit, J., 2011. Developments in mineralogical techniques – What about mineralogists?, Minerals Engineering, 24, (2011), pp. 1224-1228.
    [38] Lotter, N.O., 1995. A quality control model for the development of high-confidence flotation test data, proc. SME annual meeting and exhibit, Denver, CO., 1995, preprint 95-40.
    [39] Lotter, N.O., and Fragomeni, D., 2010. High confidence flotation testing at Xstrata Process Support, Minerals and Metallurgical Processing, 27, 1, paper MMP-09-011, pp. 47-54.
    [40] Napier-Munn, T.J., 2012. Statistical methods to compare batch flotation grade-recovery curves and rate constants, Minerals Engineering, 34, (2012), pp. 70-77.
    [41] Lotter, N.O., Bradshaw, D.J., and Whiteman, E., 2014. Modern practice of laboratory flotation testing for flowsheet development – a review, Minerals Engineering, 66-68, (2014), pp. 2-12.
    [42] Lotter, N.O., and Bradshaw, D.J., 2010. The formulation and use of mixed collector suites for sulphide flotation, Minerals Engineering, 23, (2010), pp. 945-951.
    [43] Plaskin, I.N., Zaitseva, S.P., 1960. Effect of the combined action of certain collectors on their distribution between galena particles in a flotation pulp. (Mintek Translation No. 1295, June 1988). Naachnye Soobshcheniya Institut Gonnogo dela Imeni AA Skochinskogo, Akademiya Nauk SSSR, Moskva, No. 6, pp. 15–20.
    [44] Adkins, S.J., Pearse, M.J., 1992. The influence of collector chemistry on the kinetics and selectivity in base metal sulphide flotation. Minerals Engineering 5 (3–5), 295–310.
    [45] 44 Plaskin, I.N., Glembotskii, V.A. and Okolovich, A.M., 1954. Investigations of the possible intensification of the flotation process using combinations of collectors. (Mintek translation Feb. 1989). Naachnye Soobshcheniya Institut Gonnogo dela Imeni AA Skochinskogo, Akademiya Nauk SSSR, No. 1, pp. 213–224.
    [46] 45 Bradshaw, D.J., 1997. Synergistic effects between thiol collectors used in the flotation of pyrite. Ph.D. (Chem. Eng.) Thesis. University of Cape Town.
    [47] 46 Mingione, P.A., 1984. Use of dialkyl and diaryl dithiophosphate promoters as mineral flotation agents. In: Jones, M.J., Oblatt, R. (Eds.), Reagents in the Minerals Industry. Institution of Mining and Metallurgy, London, pp. 19–24.
    [48] 47 Critchley, J.K., Riaz, M., 1991. Study of synergism between xanthate and dithiocarbamate collectors in flotation of heazlewoodite. Transactions of the Institution of Mining and Metallurgy 100, C55–C57.
    [49] 48 Valdiviezo, E., Oliveira, J.F., 1993. Synergism in aqueous solutions of surfactant mixtures and its effect on the hydrophobicity of mineral surfaces. Minerals Engineering 6 (6), 655–661.
    [50] 49 Deng, T., Yu, S., Lotter, N.O., Di Feo, A., 2010. Laboratory testwork of mixed xanthates for the Raglan ore. In: Proceedings of Canadian Mineral Processors, Ottawa, January 2010, Paper No. 16, pp. 253–268.
    [51] 50 Bradshaw, D.J., The role of “process mineralogy” in the processing of complex sulphide ores, proc. Procemin, Santiago, Chile, October 2014.
    [52] 51 Lesher, C.M., 1999. Komatiic Peridotite–Hosted Ni–Cu(PGE) Deposits of the Raglan Area. Cape Smith belt, New Québec, Laurentian University Mineral Exploration Research Centre, p. 205.
    [53] 52 St. Onge, M., and Lucas, S.B., 1986. Structural and metamorphic evolution of an early Proterozoic thrust-fold belt, eastern Cape Smith belt (Ungava Trough). Quebec Ministry of Energy and Resources, DV 86-16, p. 31-39.
    [54] 53 Dillon-Lietch, H.C.H., Watkinson, D.H. and Coats, C.J.A., 1986. Distribution of platinum group elements in the Donaldson West deposit, Cape Smith belt, Quebec. Economic Geology, 81, p. 1147-1158.
    [55] 54 Barnes, S.J. and Barnes S., 1990. A new interpretation of the Katiniq nickel deposit, Ungava, northern Quebec. Economic Geology, 85, p.1269-1272.
    [56] 55 Fragomeni, D., Boyd, L.J., Charland, A., Kormos, L.J., Lotter, N.O., Potts, G., 2005. The use of End-Members for grind-recovery modelling, tonnage prediction and flowsheet development at Raglan. Canadian Mineral Processors, Ottawa, January 2005, Paper No. 6, pp. 75–98.
    [57] 56 Langlois, P., Holmes, J., 2001. Process development at Raglan concentrator. Canadian Mineral Processors, January 2001, Paper No. 30, pp. 427–451.
    [58] 57 Lotter, N.O., Kormos, L.J., and Oliveira, J.F., 2016. Raglan Concentrator operations, in: Process Mineralogy, JKMRC Monograph Series in Mining and Mineral Processing, No 6, chap. 22., 2016, Becker, M., Wightman, E., and Evans, C., (eds).
    [59] 58 Lotter, N.O., 2011b, Modern Process Mineralogy – Two Case Studies, Minerals Engineering, 24, (2011), pp. 638-650.
    [60] 59 Friedland, R., Broughton, D.W., 2009. Keynote address, 8th World Copper Conference, Santiago, Chile, April 2009.
    [61] 60 Lotter, N.O., Oliveira, J.F., Hannaford, A.L., and Amos, S.R., 2013, Flowsheet Development for the Kamoa Project – a Case Study, Minerals Engineering Special Edition: Process Mineralogy ’12, (52), 2013, pp. 8-20.
    [62] 61 Whiteman, E., Lotter, N.O., and Samos, S.R., 2015. A practical Process Mineralogy approach to advancing the flowsheet for the Kamoa project, proc. MEI Flotation ’15, Cape Town, Nov 2016.

    Full Text:

    Click here to access the Full Text

    Cite this article as:

    Lotter N. Modern Flowsheet Development for Mineral Processing. In: Kongoli F, Kumar P, Senchenko A, Klein B, Silva A.C., Sun C, Mingan W, editors. Sustainable Industrial Processing Summit SIPS 2016 Volume 5: Starkey Intl. Symp. / Mineral Processing. Volume 5. Montreal(Canada): FLOGEN Star Outreach. 2016. p. 59-74.