Improving Column Flotation Cell Operation in a Copper/Molybdenum Separation Circuit

"The study evaluated the impact on overall circuit metallurgy of improving the performance of the two flotation columns that make up the final Mo cleaning stage in the Cu/Mo separation circuit at Highland Valley Copper mine. The results showed that a key factor to improve the overall circuit metallurgy was to control the size of the bubbles generated in the columns. When a large proportion of small (< 1 mm) bubbles were generated, the production rate of solids-in-concentrate increased by a factor of 4-5 compared to typical production figures without compromising concentrate quality. This increase in concentrate production rate reduced the circulating load in the circuit causing a significant increase of Mo recovery. A statistical analysis of historical production data showed a strong relationship between final concentrate production rate and overall Mo recovery. This relationship along with the results from this study indicated an opportunity to increase the recovery of Mo from 90% (typical) to 94% without downgrading concentrate grade. This 4% increase represents about 14,000 lbs or $500,000 worth of Mo each month at current metal prices.To provide a rational interpretation of the results, this study also examined whether the model of Gorain et al. (1997; 1998; 1999) could explain the increase of Mo recovery seemingly resulting from the decrease of bubble size. The data showed that the model predictions did not agree with the experimental data, i.e., for a given change (decrease) of bubble size, the predictions underestimated significantly the observed recovery increase. An interpretation based on the fundamental analysis of Finch and Dobby (1990) and Hernandez-Aguilar et al. (2005) is proposed to explain the discrepancy between measurements and predictions obtained from Gorain et al.’s model.INTRODUCTIONIt is generally accepted that the size of the bubbles generated in a flotation cell – a concept usually referred to as “bubble size” – has a significant effect on metallurgical performance. However, a significant number of mineral processing practitioners often question, with valid reasons, the practical benefits of implementing process improvement strategies based on controlling bubble size. “Small” bubbles are often considered to be “favourable”, but how small they need to be for a particular case, or how to adjust operating conditions to control a target bubble size, or whether the bubbles need to be smaller in the first place are questions that usually remain unanswered. Two reasons explain this situation."