Mineralurgy Pty Ltd

Future Mineral Processing

Challenges Based on 45 Years of
Applying Science and Engineering
to Flotation
AusIMM MetSoc G.D. Delprat Distinguished Lecture

N. W. Johnson
Senior Principal Consulting Engineer, Mineralurgy Pty. Ltd.
and Adjunct Professor, JKMRC, SMI, University of Queensland
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Structure of Presentation
1. Future needs of an important methodology for mineral
separation analysis and process improvement

2. Future mineral processing challenges

3. Key learnings from experience for successfully addressing

future processing challenges

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Section 1
Future needs of an important methodology for mineral
separation analysis and process improvement

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A Key Process Development

Methodology – Levels of Analysis
Level 1*
Mineral recovery – size relationships** for separations
(size fractions via sieves/Cyclosizer typically)

Level 2*
Mineral recovery – size – liberation class relationships for separations
(Minerals necessary in item 1, not elements, to include liberation data)

Level 3
Can be complemented with surface analysis of relevant minerals
in the necessary size fractions/products

*Normally see 3 groups of size fractions – coarse, intermediate and fine

**A. Cameron, D. Kelsall, C. Restarick and P. Stewart, 1971. A detailed assessment of concentrator performance at Broken Hill
South Limited, Proc. AusIMM, 240:53-67.

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A Key Process Development

Methodology – An Application Rarely
Utilized in Industry
Valuable mineral liberation level guidelines for:
a) plant feed (no regrinding in following flotation circuit)
b) summed plant exit streams (regrinding in flotation circuit)

Liberation Level* Possible Separation Quality

<70% Poor
70-80% Moderate
80-90% Good
>90% Very Good
*Liberation levels are for two dimensional liberation data and defined as
the category 98 to 100% + 100% liberated by volume.

N. W. Johnson and P. Munro, 2002. Overview of flotation technology and plant practice for complex
sulphide ores, Proceedings Mineral Processing Plant Design, Practice, and Control, SME, 1097-1123.

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A Key Process Development

Methodology – Future Challenges
Two situations in application of the methodology to ores exist.

1. Normal ores (liberation occurring >15 µm), as for the

vast majority of ores.
- Desirable to have additional size fractions at fine end

2. Difficult ores such as McArthur River and Century (liberation

occurring <15 µm) i.e. a minority of ores; the importance of
ores needing very fine regrinding may increase in the future.
- An insufficient number of fine size fractions can be generated
and measured for liberation.

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A Key Process Development

Methodology – Future Challenges
with Automated SEM Units at Site
Are there effective duties for automated Scanning Electron
Microscopy (SEM) technology at an operating site?

A range of specifications exist e.g. QEMSCAN MineSite is a “ruggedized”

model designed for transportation to and use at remote mining sites
(elevated dust levels and range of temperature)

- Potential uses being liberation measurements, mineral assays etc.

- Only perform selected duties at the mine/concentrator site?

- Establish broadest size fractions possible/sample not sized for some

uses at a mine site?
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Section 2
Future mineral processing challenges

(This presentation does not cover rejection of low grade

portions of the feed stream early in the processing
sequence by a range of methods.)

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Use of Liberation Data for Radical Design

Directions - More Energy Efficient Plants
Liberation data can also be used as a cheap tool for recognition
of different, sometimes radical design directions.

This approach is rarely, if ever, used in industry for design

(time/cost constraints).

The types of outcomes (next 2 slides*) require a demonstration

project as the next step.

*From research performed on Mount Isa zinc-lead ore in a PhD Thesis

(Zeljka Pokrajcic, 2010. A methodology for the design of energy
efficient comminution circuits, JKMRC/SMI/Univ. of Q’ld)

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Use of Liberation Data for Radical Design

Directions - More Energy Efficient Plants

Wide range of feed sizes and resulting liberation values (100% class)
Groupings of sulphide minerals included e.g. PbS + ZnS + Iron Sulphides
Feed sizing (P80) typically 100 µm
Note decline in liberation values with increased feed coarseness, as expected
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Use of Liberation Data for Radical Design

Directions - More Energy Efficient Plants

Y axis: “initially recoverable” category for minerals or groupings (>15% sectional area)
Grouping based on “recoverable sulphides” of high interest (values high at coarse sizes)
Requires improved ability to recover coarse sulphide bearing particles (all sulphides
hydrophobic) with a flotation process. Gravity process or combinations also possible.
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Use of Liberation Data for Radical Design

Directions - More Energy Efficient Plants
Important aspects of initial recovery of valuables at coarser sizes

1. Combined hydrophobicity of all sulphide minerals or of

at least two associated sulphide minerals, producing
a bulk rougher concentrate (requiring regrinding/separation)

2. Regrinding of the relatively low flow of rougher concentrate,

preferable to grinding finer* a much higher flow of rougher feed

*Each halving of rougher feed P80 value requires 42% extra energy.

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Future Benefits of Described Approach

Additional Very Important Benefits from Coarser Tailing

a) Assists solid/liquid separation on tailing, including by filtration*

b) Filtration* allows stable and safe “dry stacking” of tailings on surface

(no tailings dam failures possible)

c) Allows additional water recycling

* Appearing in overseas designs

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Improvement in Concentrate
Quality – Future Challenges
Existing Sales Contracts

The “messages” in the current contracts may be out of date.

Revised Future Sales Contracts with Increased Incentives

for Production of Higher Quality Concentrate*

The challenge will be to improve the plant grade recovery curve

and operate at a higher target concentrate grade on that curve.

*Topic for a Keynote Address (P. Munro) at the MetPlant 2015 Conference in Perth

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Scope for Improvement in

Concentrate Quality
Sphalerite/Marmatite concentrates (Zn,Fe S) – highest quality
sulphide concentrate in the sulphide industry (of the common ones)

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Scope for Improvement in Quality of

Concentrates – Copper Concentrates
Various concentrates from
ores with >95% of copper in
feed as chalcopyrite

Range of 40 to 84% copper

sulphides (shown in green)
in the concentrates

Note: moderate quality only

(lower quality than previous
slide)

Data from H. Johnston, Base Metallurgical

Laboratories Ltd, Kamloops, B.C., Canada.

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Approaches to Improvement in
Concentrate Quality
Improve the position of the plant grade recovery curve:

a) improve separation of liberated minerals

b) improve the liberation of the valuable mineral(s)
c) improve in both a) and b)

Note: An extra motivation – removal of As or Sb bearing minerals;

future competing technologies likely to be hydrometallurgical.

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Loss of Valuable Mineral in Tailing

Differing requirements of the two major particle groups lost (conventional cells) –
fine fractions and coarse fractions are the “TROUBLESOME FRACTIONS”

Type of Loss of Valuables Requirements

-10 µm liberated, dispersed a) Elevated turbulence to maximize

valuable mineral (fine fractions) number of collisions with bubbles
b) Collector/reagent addition freedom to raise
hydrophobicity

Coarse low quality composites a) Just sufficient turbulence for suspension of

containing valuable mineral particles, additional turbulence detrimental
(coarse fractions) b) Collector addition freedom to raise
hydrophobicity

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Loss of Valuable Mineral in Tailing

Future Challenges
All size fractions (fine, intermediate and coarse) processed together
(items 1 and 2) or “separately” (item 3)

1. Use of one conventional cell type in a bank e.g. a rougher

scavenger bank; tune for coarse or fine fractions or accept
compromise tuning. Note: NO FLEXIBILTY

2. Use of two cell types in a bank e.g. a rougher scavenger bank

with the two cell types tuned by the manufacturer differently;
perhaps one type with a radical design? Note: SOME FLEXIBILITY

3. Provision (plant design stage or retrofit) of two types of separate

treatment* for problematic size fractions. Note: HIGH FLEXIBILITY
*G. Heyes and J. Phelan, 1988. The application of separate conditioning to improve zinc metallurgy at
Woodlawn Mines, Third AusIMM Mill Operators’ Conference, Cobar, 85-89.
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Loss of Valuable Mineral in Tailing

Future Challenges
Troublesome size fraction conditioned separately with all size fractions
processed in flotation bank together (one or two cell types in bank)

Independent chemical preparation on coarse fraction (case on left) or

fine fraction (case on right); no detrimental effect on other fractions
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Loss of Valuable Mineral in Tailing

Future Challenges
Troublesome size fraction conditioned separately and then treated by
flotation separately

Independent chemical conditioning (as in previous slide) +

separate flotation banks (different chemical and physical conditions)
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Summary of Future Options

Primary Grinding Improved Alternative Cell
Sizing/Circuit Type Conventional Designs***
Cells
Same sizing & circuit  

Coarser sizing,  
same circuit

Much coarser sizing*,  

“multiple mineral** basis”
& changed circuit

*May include additional options covered in slides 19 to 21

**From the approach in slides 10 and 11 (PhD Thesis of Z. Pokrajcic)
***As a potential example, Hydrofloat technology from Eriez
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New Tool – Measurement of Froth

Recovery (Future Challenge)
Froth recovery (% of valuables entering the froth region that
reaches the concentrate launder) believed to range from 5% to
50% in industrial cells for valuable minerals.
Lowest values in important scavenger cells at end of rougher?

Note - Methods for direct measurement now exist; this new tool is
expected to be a major source of valuable new information and
insights leading to process improvements.

Problem - It appears that plant metallurgists are:

1. Not aware of this option and its potential usefulness
2. Not aware that external providers can obtain the value
or provide instruction on measuring the value
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Determination of Dispersion State

of a Pulp – Future Challenge
Relevance of Dispersion State of a Pulp
A poorly dispersed pulp results in additional process
weaknesses – adhering gangue diluting the concentrate
and lowered hydrophobicity of valuables causing losses

Current Situation
The Mineral Industry has no agreed standard procedures
for its quantification in a relative or an absolute fashion.

Future Challenge
A standard procedure needs to be developed (one possible
application given in next slide).
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Determination of Dispersion State

of a Pulp – Future Challenge
Size reduction devices with high internal shear now exist for:
a) regrinding to normal and very fine product sizings
b) final stage of primary grinding
Examples are the IsaMill and the Outotec regrinding mill.

Question on an effect “beyond size reduction”:

Does a surface cleaning effect equivalent to high intensity conditioning
occur in the residence time of such mills?

Initial Paper on Topic for Such Mills:

X. Ye, S. Gredelj, W. Skinner and S. Grano, 2010. Evidence for surface
cleaning of sulphide minerals by attritioning in stirred mills, Minerals
Engineering, 23, 937-944.

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Deliberate Flocculation
Potential applications exist in the literature:

1. Alleviation of <10 µm valuable particle-bubble collision problems by

selective flocculation of the valuable particles to produce floccules of a
size avoiding this problem.
The step would occur on a fine fraction hydrocycloned from the feed or
on a very finely reground product?

2. Alleviation of gangue entrainment in recovered water by selective

flocculation of fine gangue particles to produce floccules of sufficient
size to avoid largely the gangue entrainment problem.
(Perhaps a complicated method for dealing with entrainment for which
other solutions exist in typical systems.)

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Pulp Potential in Sulphide Mineral

Flotation - Introduction
The important role of pulp potential in collector uptake and the
actions of depressants has been demonstrated over the last 50 years
(adopted earlier in corrosion, hydrometallurgy and other areas)

The next three slides consider the role of pulp potential:

1. An example of values for a conventional grinding/rougher circuit

2. Description of past/current areas of activity
3. Future needs and challenges

R. Woods, 2010. Electrochemical aspects of sulfide mineral flotation, in Flotation Plant Optimisation
(ed. C. Greet), AusIMM Spectrum Series, No. 16, 123-135.
Y. Hu, W. Sun and D. Wang, 2009. Electrochemistry of Flotation of Sulphide Minerals, Tsinghua
University Press and Springer, 304 pp.
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Role of Pulp Potential in Sulphide

Mineral Flotation
Diagram of pulp potential
vs pH from survey
measurements at Mount
Isa Cu Concentrator
(Pt electrode/reference electrode)

Modified from:
N. W. Johnson, 1988. Application of
electrochemical concepts to four sulphide
flotation separations, Electrochemical
Soc. Conference on Electrochemistry in
Mineral and Metal Processing ll, Atlanta,
May.

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Pulp Potential in Sulphide Mineral

Flotation – Past/Current Activities

Diagram of pulp potential

vs pH for general illustration
of past and current activities

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Pulp Potential in Sulphide Mineral

Flotation – Future Challenges
Evaluate multiple mineral electrodes and pulp potential
measurements for:

a) suitable on-line cleaning methods of electrodes to ensure

integrity of data over time
b) improved separation efficiency from application of reliable
values in a)

Development/operation of new separations in Eh-pH regions away

from the equilibrium line X-Y.

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Minimization of Use of Water at an

Operating Site – Future Challenges

1. Important at an operating site in a region due to existing uses

for the population and farming

2. Important for obtaining project approvals in arid areas

3. Important for cost minimization where input water has to be

pumped long distances or to high altitudes

Note: Minimization of water use = Maximization of water recycling

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General Effects of Recycling Water

Recycling water often increases in the plant the concentration of:

1. Frother (plant must be in control by ensuring some frother addition)

2. Collector species and their decomposition products
3. Other organic species from the tailing dam region
4. Inorganic ions
5. Anaerobic and aerobic microbiological species

From the literature, the effects on flotation are detrimental, in general,

with only occasional examples of beneficial effects.
Formal methods for evaluation of the size of the detrimental effects
needed (existing plants and during circuit development).

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Future Treatment of Recycled Water

1. Will assist maximization of water recycling

2. May improve metallurgical performance

3. Lessens recycled water as a source of plant disturbances

4. Recognize that some common water treatment reagents are used

also as flotation reagents; a more effective co-ordinated design of
mineral processing and water treatment plants may result at a site

Note: “Water company” to operate such water treatment plants.

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Future Treatment of New Water

Low quality new water supply - increased need
for water treatment before use in the process
New Water Quality – Australia and surrounding region

Source of Water Total Dissolved Solid (ppm)

High quality tropical water 100 - 500

Semi-arid water 1000 - 5000
Sea water 35,000
W. Australian bore water < 300,000

Note: Sewage plant effluent from a regional town/city can have total
organic carbon levels > 1000 ppm

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Section 3
Key learnings from the past for successfully addressing
processing challenges

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Requirements for Success

Property Example

Pressing/urgent need Retention of leases/company

as a precursor government interactions; delays from
very fine grained ore (1955 – 1989) for
McArthur River deposit; required new
regrinding technology (IsaMill –
P80 = 7 µm, 1990-1994)

Initial development of various forms of

the flotation process at Broken Hill
(mining field faced closure).
Major contribution from G. D. Delprat.

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Requirements for Success (cont.)

Property Example
Flexibility in approach Lower output U/G mine (not pit) for
McArthur River project
Single zinc-lead concentrate

Wide range of very able Mount Isa operating site for

engineering skills and various phases of IsaMill
sources of feed-stock development

Utilization of current “know Evaluation of washed froth column

how” if available elsewhere technology at Mount Isa during
1986 and later installations

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Requirements for Success (cont.)

Property Example
High level strong support McArthur River project - IsaMill
from management over technology development
several years

Extra information measured McArthur River project - clearly

or new insights available defined problem by use of
detailed liberation data based on
new Mount Isa analysis system
(mineral recovery/size/liberation)

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Conclusions – Future Challenges

Future needs/challenges of an important methodology (based on
mineral recovery/size/liberation data) for mineral separation analysis
and process improvement

1. Increase the technical application of the methodology, particularly for

understanding the contribution of each grinding step to the total liberation.

2. Develop routine liberation measurement on additional fine size fractions.

3. Establish the effective applications of an automated SEM at an operation.

4. Demonstrate the innate value of such process information for a wide

range of uses, making it non-discretionary in the management system.

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Conclusions – Future Challenges

Future mineral processing challenges
1. Increase recovery of coarse low quality composites with some valuable
mineral using improved conventional cells and other types of cells with:

a) feed to rougher at current feed sizing values

b) feed to rougher deliberately at moderately coarser sizings than now

2. Use liberation data in unconventional ways for the design of energy

efficient separation circuits, utilizing 3 themes for greatly coarsened
feed sizings for some ores*:

a) hydrophobicity from multiple sulphide minerals

b) techniques of separate conditioning/separation (slides 19-21)
c) matching of latest/future cell designs to particle properties

*Note: Demonstration project(s) needed (pre-competitive basis?) 40

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Conclusions – Future Challenges

Future mineral processing challenges

3. Utilize the resulting benefits from items 1 and 2 in related areas

- assisting solid/liquid separation on tailing, including by filtration
- facilitating safe “dry stacking” of tailings on surface
- allowing additional water recycling

4. Utilize froth region recovery measurements in process improvement.

5. Develop and utilize a standard procedure for measurement of the

state of dispersion of a pulp.

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Conclusions – Future Challenges

Future mineral processing challenges

6. Evaluate/utilize multiple mineral electrodes and pulp potential

measurements for:
a) on-line cleaning of electrodes to ensure integrity of data over time
b) improved separation efficiency using reliable measurements via a)
Develop and operate new separations away from the equilibrium line.

7. Maximize water recycling assisted by treatment of the recycled water*;

extend the treatment to low quality water input water if warranted.

*Aided by formal testing methods for detrimental effects from recycling.

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Acknowledgements
The Metallurgical Society of the AusIMM and the AusIMM
are thanked gratefully for the opportunity to deliver this
lecture.

The arrangements made by Dr. Andrew Newell on behalf of

the Metallurgical Society of the AusIMM are gratefully
acknowledged.

Ms. S. Munro is thanked for her work on preparation of

diagrams for this presentation.

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