Optimizing Flotation Circuit Recovery by Effective Stage Arrangements: A Case Study

Radmehr, Vahid; Shafaei, Sied Ziaedin; Noaparast, Mohammad; Abdollahi, Hadi

doi:10.3390/min8100417

Cited by 8 publications

(4 citation statements)

References 23 publications

(34 reference statements)

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“…This simplification does not allow researchers to examine the whole behavior of a concentration circuit because it reduces a multidimensional function of the transfer functions of all the units to one dimension [72]. For example, differences of up to 10% have been observed in the overall circuit recovery for two-and three-stage circuits in the case of identical and non-identical stage recovery [73]. Rigorous methods are based on optimization procedures.…”

Section: Design and Optimizationmentioning

confidence: 99%

Trends in Modeling, Design, and Optimization of Multiphase Systems in Minerals Processing

2019

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Multiphase systems are important in minerals processing, and usually include solid–solid and solid–fluid systems, such as in wet grinding, flotation, dewatering, and magnetic separation, among several other unit operations. In this paper, the current trends in the process system engineering tasks of modeling, design, and optimization in multiphase systems, are analyzed. Different scales of size and time are included, and therefore, the analysis includes modeling at the molecular level (molecular dynamic modeling) and unit operation level (e.g., computational fluid dynamic, CFD), and the application of optimization for the design of a plant. New strategies for the modeling, design, and optimization of multiphase systems are also included, with a strong focus on the application of artificial intelligence (AI) and the combination of experimentation and modeling with response surface methodology (RSM). The integration of different modeling techniques such as CFD with discrete element simulation (DEM) and response surface methodology (RSM) with artificial neural networks (ANN) is included. The paper finishes with tools to study the uncertainty, both epistemic and stochastic, based on uncertainty and global sensitivity analyses, which is present in all mineral processing operations. It is shown that all of these areas are very active and can help in the understanding, operation, design, and optimization of mineral processing that involves multiphase systems. Future needs, such as meso-scale modeling, are highlighted.

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Section: Design and Optimizationmentioning

confidence: 99%

Trends in Modeling, Design, and Optimization of Multiphase Systems in Minerals Processing

2019

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“…In general, the flotation process comprises a complex multistage closed circuit, which improves the grade and recovery of concentrates such as roughers, scavengers, and cleaner circuits [13][14][15]. Hence, the installation and operation of a plant through an optimal design for a highly efficient separation process is crucial, particularly in the froth flotation step [16][17][18][19][20][21][22][23][24][25]. Therefore, it is believed that the overall energy-saving effect should be achieved through an optimized flotation process owing to the improvement in productivity.…”

Section: Introductionmentioning

confidence: 99%

Diagnosis and Optimization of Gold Ore Flotation Circuit via Linear Circuit Analysis and Mass Balance Simulation

et al. 2021

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The aim of this study is to diagnose and optimize a closed multistage gold ore flotation circuit in an operational industrial plant. Linear circuit analysis (LCA), a partition-based model, and a mass balance model using flotation first-order kinetics are employed to diagnose the current process. The result shows that the current circuit operates with high recovery but the gold grade of the final concentrate is low owing to the low buoyancy ratio. Hence, several alternative circuits with different streamlines and cell arrangements are proposed and simulated using LCA and a mass balance model. The result suggests that if the current process is changed to an alternative circuit in which the floated product stream of the rougher bank is changed, then the gold grade of the concentrate can be improved by 128%. Finally, the current circuit is optimized by changing it to an alternative circuit. This study provides a methodology for adapting the simulation of optimization for the flotation circuit of an industrial plant via LCA and mass balance simulation.

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“…An increase of 1−2% in these parameters is economically very significant [17] and plays a remarkable role in the desirability of the flotation plants. In fact, an inefficient operation can cause an incorrect balance between grade and recovery, which leads to adverse shifts in the grade-recovery curve [21,22].…”

Section: Introductionmentioning

confidence: 99%

Parametric Optimization in Rougher Flotation Performance of a Sulfidized Mixed Copper Ore

et al. 2020

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The dominant challenge of current copper beneficiation plants is the low recoverability of oxide copper-bearing minerals associated with sulfide type ones. Furthermore, applying commonly used conventional methodologies does not allow the interactional effects of critical parameters in the flotation processes to be investigated, which is mostly overlooked in the literature. To tackle this issue, the present paper aimed at characterizing the behavior of five key effective factors and their interactions in a sulfidized copper ore. In this context, dosage of collector (sodium di-ethydithiophosphate, 60–100 g/t), depressant (sodium silicate, 80–120 g/t) and frother (methyl isobutyl carbinol (MIBC), 6–10 g/t), pulp pH (7–11) and agitation rate (900–1300 rpm) were examined and statistically analyzed using response surface methodology. Flotation experiments were conducted in a Denver type agitated flotation cell at the rougher stage. The experimental results showed that increasing the pH (from 8 to 10) at low agitation rate (1000 rpm) enhanced the recovery from 80.36% to 85.22%, while at high agitation rate (1200 rpm), a slight declination occurred in the recovery. Meanwhile, increasing the collector dosage at a lower frother value (7 g/t), caused a reduction of about 4.44% in copper recovery owing to the interactions between factors, whereas at a higher frother level (9 g/t), the recovery was almost unchanged. The optimization process was also performed using the goal function approach, and maximum copper recovery of 92.75% was obtained using ~70 g/t collector, 110 g/t depressant, 7 g/t frother, pulp pH of 10 and 1000 rpm agitation rate.

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Optimizing Flotation Circuit Recovery by Effective Stage Arrangements: A Case Study

Cited by 8 publications

References 23 publications

Trends in Modeling, Design, and Optimization of Multiphase Systems in Minerals Processing

Trends in Modeling, Design, and Optimization of Multiphase Systems in Minerals Processing

Diagnosis and Optimization of Gold Ore Flotation Circuit via Linear Circuit Analysis and Mass Balance Simulation

Parametric Optimization in Rougher Flotation Performance of a Sulfidized Mixed Copper Ore

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