Performance analysis of bauxite beneficiation process in Juruti Mine. Part 2: Simulation and optimization alternatives

Abstract

The simulation process was applied to the industrial circuit of the Juruti Bauxite Mine using mathematical models calibrated for the equipment and based on information from industrial sampling. The sampling campaign, mass balance routines and quantification of the process efficiency were discussed in Part I of this study and the model calibration and simulations process were the Part II objective. Simulation scenarios were defined considering the possible particle size curves for feeding the plant. Based on the simulated results, it was possible to observe which operations may be impacted by the increase in production, impacting the percentage of contaminants in the final product, indicating the necessity of equipment interventions to support increases in capacity. Another group of scenarios were established with the objective to evaluate the possibility of increasing the mass recovery and improving the quality of the fine product, by variations in the opening diameters of the apex and vortex finder of the five cyclone stages. Considering the simulated scenarios, the points of attention identified in the simulations were: (a) the washing efficiency could be reduced, in view of a consequent reduction in residence time connected to the change in characteristics of the ore fed to the plant; (b) increase capacity of the primary and secondary screens need to be done; (c) to keep the classification efficiencies, it is necessary install more cyclone units; and (d) changes in the apex diameter and vortex finder could generate results in terms of mass recovery and product quality.