Industrial evaluation of a new flotation mechanism for large flotation cells

A new flotation mechanism was evaluated in the rougher flotation circuit at Collahuasi Concentrator Plant in Chile. For this purpose, the flotation mechanism FloatForce® was installed in one of three parallel rougher flotation lines, consisting of nine TankCell-160 (160 m3) cells, while the other two lines operate with a conventional OK-mechanism. The evaluation was carried out based on a hydrodynamic and metallurgical characterization of the flotation circuits. Three overall samplings and mass balance adjustments for kinetic flotation characterization were performed. The residence time distribution RTD, of liquid and solids (per size class) was measured in the rougher lines using radioactive tracers. Thus, the effective mean residence time as well as the mixing condition in single flotation cells and along the rougher lines were evaluated. Also, measurements of axial solids segregation (per size class), axial mineral grade profiles, local superficial gas rate, bubble size distribution, bubble load and top of froth grades were performed in cells provided with both flotation mechanisms. The comparison of the rougher flotation operation with the FloatForce® and the conventional OK-mechanism is presented and discussed in this work.

A comparison among rougher line B (FloatForce) with lines A and C, was performed. The mean residence time and maximum recovery were normalised, considering the same flow distribution and similar Cu/Mo grades, solid percent and particle size classes. It was observed that in all cases the copper recovery in line B was almost 1% higher than lines A and C. Comparison of copper recovery versus time in sampling M3: (a) rougher lines A, B, (b) rougher lines B, C.Figure optionsDownload as PowerPoint slideHighlights
► A new flotation mechanism FloatForce® was evaluated at Collahuasi Plant.
► Three overall samplings and mass balance adjustments were performed.
► The FloatForce rotor was compared with the conventional OK rotor.
► Hydrodynamic performance of OK-160 cell was similar using both rotors.
► Cu recovery in rougher line B using FloatForce was 1% higher than lines A and C.