FLOT-ART: An integrated plant optimization tool for the flotation of copper and copper–gold ores

Abstract

Conventional flotation plant optimization procedures for copper and copper–gold ores have served the industry well over decades. But with the present trend in declining ore grades along with increase in metallurgical complexity, many flotation operations are experiencing significant challenges in sustaining design or operational budgeted recovery and concentrate quality targets. The need to use non-conventional water sources like brackish, sea water, and recycled process water has exacerbated the problem. Also with the emergence of various large mechanical cells and new non-mechanical flotation technologies, the ongoing use of traditional plant operational strategies is further adding to the challenges.This paper discusses an integrated plant optimization tool for the flotation of complex copper and copper–gold ores in addressing the present challenges, branded as FLOT-ART (Flotation Advanced Recovery Technology). This includes a cohesive flotation plant optimization approach starting with a mineral surface preparation step in grinding followed by advanced mineral-specific electrochemistry and cell hydrodynamics based circuit operation. This approach then allows an ore-specific grade-recovery control strategy for optimum flotation performance. This development is based on extensive greenfield projects, brownfield plant expansion studies along with operational optimization programs involving bench and plant campaigns. Principles of the FLOT-ART optimization system will be presented in this paper along with some commercial applications in the flotation of copper and copper–gold ores.