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How can you optimize the flotation process for maximum recovery?

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Flotation is one of the most widely used methods for mineral separation and concentration, especially for fine and complex ores. It involves the selective attachment of air bubbles to the surface of mineral particles, which are then carried to the top of a flotation cell and collected as a froth. However, flotation is not a perfect process, and there are many factors that can affect the recovery and grade of the valuable minerals. How can you optimize the flotation process for maximum recovery? Here are some tips and best practices to consider.

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Tailor your reagents:

Carefully select flotation reagents to match the unique properties of your ore. By custom-tuning reagents like collectors and frothers, you can enhance recovery rates and the quality of separation.
Monitor feed variations:

Keep a close eye on changes in mineralogy from your feed source. Consistent monitoring allows for timely adjustments, ensuring the flotation process remains optimal despite varying ore characteristics.

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1 Understand your ore

The first step to optimize the flotation process is to understand the characteristics of your ore, such as its mineralogy, particle size distribution, liberation degree, surface chemistry, and reagent response. These factors can influence the flotation kinetics, selectivity, and stability of the froth. You can use various techniques, such as mineralogical analysis, flotation testing, and modeling, to determine the optimal conditions for your ore type and grade.

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Melanie Bond, PE

Owner/Principal Engineer at Bond Minerals Services and Engineering, PLLC
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In my experience, a few things you can do are: 1. Stay on top of the mineralogy of your feed - this can change as the mine matures and gets into different zones. 2. Minimize swings in feed grades and mineralogy to keep the circuits happy. 3. And if you have access to an on-site met lab, keep a good bench testing program going on pulps pulled from the plant ("hot flots") - and from grinding fresh ore as well. #3 especially can alert you to potential incoming problems with new or changing feeds, allowing for earlier opportunity to adjust parameters in the plant to optimize performance.

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Michael McClintock, P.Eng.

Founder & Principal @ McClintock Group | Enhancing Mineral Projects, Advocating for Shareholders
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Understand the mineralogy, lithologies, clays, liberation size, ect. The geology is an excellent place to start as the geology logs will have a lot of this information. Talking with the geologist is always a good place to start. Keep the initial programs simple, focussing on liberations, mineral identification, and increase the complexity logically in a systematic way. It is important as the flow sheet develops, that the decisions are being based on evidence from the testing.

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2 Choose the right reagents

The second step is to choose the right reagents for your flotation process, such as collectors, frothers, modifiers, and depressants. Collectors are substances that enhance the hydrophobicity of the mineral surface, making it easier for the air bubbles to attach. Frothers are substances that stabilize the froth and prevent its collapse. Modifiers are substances that alter the pH, ionic strength, or surface charge of the pulp, affecting the adsorption of collectors and other reagents. Depressants are substances that prevent the flotation of unwanted minerals, increasing the selectivity of the process. You can use a combination of reagents to achieve the desired results, but you need to consider their compatibility, dosage, sequence, and interaction with each other and with the ore.

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Joseph Nyaga

Graduate Metallurgy and Mineral Processing Engineer, GEng
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Flotation reagents are substances added to the ore pulp prior to or during flotation in order to make it possible to float valuable mineral particles and not to float the gangue mineral particles. The preparation of pulp to achieve conditions for flotation is important. The quantity of reagents used in flotation varies from ore to ore and day to day or hour to hour for one ore. Small quantities of reagents are normally required. Low and high quantities of the reagents are of no use. In certain, cases increasing quantities of reagents results in other effects. For example, use of increased quantities of collector tends to float other mineral particles (other than required). Metallurgical testwork should be done to know the right reagents

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3 Control the operating variables

The third step is to control the operating variables of the flotation process, such as air flow rate, pulp level, pulp density, impeller speed, cell design, and circuit configuration. These variables can affect the bubble size, bubble-particle contact, bubble-particle detachment, froth drainage, and froth recovery. You can use sensors, instruments, and controllers to monitor and adjust these variables in real time, or use advanced techniques, such as machine learning and artificial intelligence, to optimize them automatically.

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Michael McClintock, P.Eng.

Founder & Principal @ McClintock Group | Enhancing Mineral Projects, Advocating for Shareholders
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In the flotation process, every parameter we're discussing essentially circles back to particle size. Understand the particle size distribution (PSD), and how that calibrates to every tool that you have.

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4 Monitor the performance indicators

The fourth step is to monitor the performance indicators of the flotation process, such as recovery, grade, mass pull, enrichment ratio, and metallurgical efficiency. These indicators can help you evaluate the effectiveness and profitability of the flotation process, and identify any problems or opportunities for improvement. You can use online analyzers, sampling devices, and software tools to measure and report these indicators regularly, or use key performance indicators (KPIs) and dashboards to visualize and communicate them clearly.

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5 Implement continuous improvement

The fifth step is to implement continuous improvement for your flotation process, based on the data and feedback from the previous steps. You can use various methods, such as root cause analysis, process optimization, quality control, and innovation, to identify and solve any issues, enhance the performance, reduce the costs, and increase the sustainability of the flotation process. You can also use best practices, such as benchmarking, standardization, and knowledge sharing, to learn from others and improve your skills and competencies.

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Nikolay Kolev

Project Manager
(已编辑)
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My work now has convinced me that there is a better way to increase both mill throughput and metal recovery. Normally, concnetrators increase mill throughput at the expense of product grind size (P80) and as a result a small drop in metal recovery occurs. I have found a way to increase mill throughput and actually increase metal (Cu, Au, Ag, etc.) recovery too.

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6 Stay updated and informed

The sixth and final step is to stay updated and informed about the latest developments and trends in the flotation field, such as new technologies, equipment, reagents, methods, and applications. You can use various sources, such as journals, books, conferences, webinars, podcasts, and blogs, to access and exchange information and knowledge with other experts and practitioners. You can also use networks, associations, and communities to connect and collaborate with your peers and stakeholders, and to discover new opportunities and challenges for your flotation process.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you optimize the flotation process for maximum recovery?

1

2

3

4

5

6

7

1 Understand your ore

2 Choose the right reagents

3 Control the operating variables

4 Monitor the performance indicators

5 Implement continuous improvement

6 Stay updated and informed

7 Here’s what else to consider

Mining Engineering

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How can you optimize the flotation process for maximum recovery?

1

2

3

4

5

6

7

1 Understand your ore

2 Choose the right reagents

3 Control the operating variables

4 Monitor the performance indicators

5 Implement continuous improvement

6 Stay updated and informed

7 Here’s what else to consider

Mining Engineering

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