Use of recovery-by-size data from batch testing in estimating the performance of continuous flotation operations

Abstract

The work title ‘Use of Recovery-by-Size Data from Batch Testing in Estimating the Performance of Continuous Flotation Operations’ seeks to validate available theories against recovery-by-size batch flotation data and to use that available batch data to scale up the flotation process. The output of such objectives will be to bridge a knowledge gap in refined empirical models and also lead to a tool capable of predicting performance of continuous flotation from batch flotation data. Batch flotation tests were done from a sulphide copper bearing ore at 2, 6, 12 and 20 min flotation times. Continuous flotation tests were also done in two sets:  Sampling overall flotation circuit samples for feed, concentrate and tails.  Sampling of each cell in a bank (roughers, cleaners and re-cleaners) for feed, concentrate and tails which is referred to as cell-by-cell sampling. A number of scale-up methods were useful in scale-up from batch flotation to continuous operation with the ModSim software used do the simulation work and this proved to be effective and dependable. A size fraction of around 102 μm (intermediate size fraction) gave the highest recoveries compared to fine size fraction (19 μm) and coarse size fraction (up to 638 μm). The Scale-up validation techniques (kinetics, concentrate grade, recovery, sizing and overall) lead to different results of batch and continuous data.