EMC FLOTATION TEST PROCEDURE 2

LABORATORY FLOTATION TEST

PROCEDURE FOR MF1 AND MF2 TESTS
AND REGRINDING OF CLEANER TAILINGS

SYNOPSIS
Performing a flotation rate test characterises the ore. The results of the test are used to
calculate the flotation kinetics of metal or mineral and gangue under chosen test
conditions. The kinetics describes the behaviour of the ore and is a numerical
representation of the ore’s mineralogical qualities and its metal – mineral – gangue
associations. Change the test conditions and the kinetics change. Change the state of the
ore and the kinetics also change. This is why rougher and cleaner rate tests should be
performed for MF1 and MF2 conditions.

Flotation kinetics are derived from Kelsall’s unmodified equation and comprise fast and
slow floating fractions and rates of metal and/or mineral and gangue. Together, these
variables define a flotation system, whether in the laboratory, pilot plant or production
plant. The numerical values of these variables change in order to define the particular
system and take into account the differences between systems under consideration – e.g.
laboratory to pilot or laboratory to plant.

An explanation is given regarding how the data from each test is used and a brief
description of any effect on a plant scale is included.

This test procedure is applicable to any ore to determine its flotation characteristics under
chosen conditions.

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Laboratory Float Procedure for MF1/2 Rate Tests.. Update2 Jan 2012.
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 FLOTATION MF1/MF2 TEST PROCEDURE FOR ORES

OBJECTIVE
The purpose of this procedure is to generate information to achieve the following;
 Characterise the ore
 Ascertain what metallurgical changes result in an improvement of recovery/grade
(this is usually confined to testing changes in grind and reagent type and/or addition)
 Generate data to simulate plant performance
 Determine metallurgical variability of samples from the deposit

OVERVIEW
In summary suggested tests are;
(note that more tests can be done at the metallurgist’s discretion)
MF1
1. Rougher rate tests at 35%, 60% and 80% -75m
2. Test changes of reagent and/or dosage depending upon knowledge of the material
3. Cleaner rate tests at 35%, 60% and 80% -75m

MF2
Regrind of primary rougher tails at same assay as expected in the plant (see “Method for
a MF2 Test” below to determine how to do this)
4. Rougher rate tests at 60% and 80% -75m
5. Test other grinds and changes of reagent and/or dosage depending upon knowledge
of the material
6. Cleaner rate tests at 60% and 80% -75m and at other grinds if tested

Regrinding of Cleaner Tails

Applies to both MF1 and MF2 tests.
7. Rate tests of cleaner tails with and without addition of extra reagents
8. At the grind(s) selected conduct rate tests of cleaner tails with and without addition of
extra reagents

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Laboratory Float Procedure for MF1/2 Rate Tests.. Update2 Jan 2012.
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METHOD FOR A MF2 TEST
1. First, conduct a MF1, ie primary stage, rate test
 Grind fresh ore to the chosen primary stage grind %- 75µm,
 Conduct a rate test under the chosen test conditions.

2. Second, conduct the MF2 test by first preparing feed to the secondary stage
 Again grind fresh ore to the chosen primary stage grind %- 75µm
 Float at the same conditions as 1 above, but this time float only for a time sufficient
to recovery the fast floating fraction of values (this is normally 3-4 minutes). See the
flow diagram in Figure 2. Note here that conducting this particular MF2 rate, the
MF1 primary rougher batch test was done for 7 minutes. This is because this
particular ore was very slow floating. For 90% of ores a primary rougher batch
flotation time of 3 minutes is standard and will generate a secondary float feed
head grade which will be close to the grade that will be seen on the plant,
 The recovery of this primary stage rougher concentrate is equivalent to the recovery
in primary stage final concentrate in an operating plant. Thus, the primary rougher
tailings generated, ie secondary mill feed, will be at a grade equivalent to that seen
in an operating plant treating this ore,
 Grind these primary rougher tails to the desired grind %- 75µm,
 Conduct a rate test under the chosen test conditions,
 Figure 1 provides an indication and guideline for time of laboratory flotation to
recover the fast floating mineral fraction and the rate of flotation. The fast floating
fraction of mineral is what the primary mill/float circuit recovers in the plant, thus
floating to this time in the laboratory will generate a secondary float feed head
grade which will be close to the grade that will be seen on the plant.

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Laboratory Float Procedure for MF1/2 Rate Tests.. Update2 Jan 2012.
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Figure 1 Laboratory Recovery-Time Profiles

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 HOW THE INFORMATION GENERATED FROM THE TESTS IS USED

Point Use of Information

1 The standard rate test. Used to characterise an ore and simulate a MF1 circuit. The
effect of grind on metallurgy is determined & simulated on a plant scale. The
simulation of an MF1 circuit at coarse grind generates the plant assay of the rougher
tails (feed to MF2 circuit).
2 Effect of changes of reagent &/or dosage on metallurgy determined & simulated on a
plant scale. Sometimes magnitude of effect seen in the lab is lost on a plant scale.
3 Used to characterise the cleaning characteristics of an ore. Sometimes there is
significant drop-out from rougher to first cleaner concentrate. This usually indicates a
liberation problem. The lab cleaner rate test is simulated using the kinetics in point 1 to
confirm the kinetic values. Also the cleaning section of a plant is simulated and the
recovery/grade relationship of the final concentrate is checked against that generated in
the MF1 simulation in point 1.
4 Lab test and simulation data from point 1 is used to conduct a rougher test for a time
necessary to generate a plant rougher tails assay. This primary rougher tailing is then
reground to characterise the ore and simulate the 2nd stage of an MF2 circuit. The effect
of grind on metallurgy is determined & simulated on a plant scale. MF1 and MF2
circuits are compared to determine the benefit of MF1 vs MF2 wrt recovery and grade.
5 Effect of changes of reagent &/or dosage on metallurgy determined & simulated on a
plant scale. Sometimes magnitude of effect seen in the lab is lost on a plant scale.
6 Same as point 3 above.
7 and A cleaner scavenger bank of various stages of roughing/cleaning and various
8 configurations is simulated using the data and kinetics form freshly generated cleaner
tails (i.e. “As Is”) and reground cleaner tails. This simulation is compared with the
simulations of this same circuit generated in points 1, 3, 4 and 6 above as a validation
procedure and to ascertain the difference between circuit conditions. For example in
point 1 the MF1 roughing kinetics is used to simulate the rougher and cleaning banks,
plus the roughing and cleaning section of the cleaner scavenger portion of the plant.

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Laboratory Float Procedure for MF1/2 Rate Tests.. Update2 Jan 2012.
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 6

DETAILS OF PROCEDURE TO CONDUCT A ROUGHER AND CLEANER RATE TEST

(Written for Platinum ore tests – equally applicable to other ores which will utilise different
reagents)

The procedure below is a guide; however the number of concentrates collected should not be
less than that specified because the accuracy of the flotation kinetic values calculated becomes
suspect. The first concentrate should always be collected after 1 minute because this has a
marked influence on the value of the fast floating fraction and rate. The time of the last
concentrate can be extended or an additional collection made if the material is particularly slow
floating.

Flotation Test
 Roughing: The test is performed on 1.0kg of milled ore in a 2.5l Denver cell. Pulp density
will be about 35% solids
 Roughing: Conditioning is done at 1500 rpm. For Merensky ore condition for 1 min with
50g/t CuSO4 then 3 min with 150g/t SIBX then 3 min with 150g/t CMC and finally 1 min
with 15g/t frother. For UG2 ore condition for 1 min with 50g/t CuSO4 then 3 min with
150g/t SIBX then 1 min with 15g/t frother.
 The rougher rate test is normally conducted at 1200 rpm. 5 concentrates are collected; 0-
1min; 1-3min; 3-9min; 9-20min; 20-30min. It is ideal to collect the first concentrate at 1min. If this
is not possible (e.g. for UG2 ores where there is not enough material for assay) then collection from 0-
2min is acceptable but no longer. The test must be run long enough to ensure that the cumulative
recovery-time curve flattens out and is at or is approaching a plateau. Note, extra concentrates at
extended times may be collected if desired. Froth should be collected every 15 seconds.
The first concentrate has 4 collections, at 15, 30, 45 and 60 seconds. The second concentrate
also has 4 collections at 75, 90, 105 and finally 120 seconds and so on. During the test pulp
level should be maintained at 1.5 to 2.0 cms below the cell lip.
 Cleaning: Conditioning is done at 1200 rpm (if it is chosen to add reagents).
 The cleaner rate test is normally conducted at 1000 rpm. 4 concentrates are collected; 0-
1min; 1-3min; 3-9min; 9-15 or 20min.
 Tests are performed at ambient temperature and natural pH. Tap water is used.

Concentrate and Tailings treatment and assay

The concentrates and tailings are prepared in the normal way and assayed for elements of
interest.

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Flotation MF1/MF2 test procedure for ores. Feb 2003. Updated Nov 2007
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VARIABILITY TESTS
The objective is to analyse each sample or borecore to determine its milling and flotation
characteristics so that it can be compared to the bulk sample and to other samples taken from
different areas of the deposit. It is important to;
 Measure the sample’s hardness either by a direct method (Bond and/or Mintek Grindmill
tests) or by comparison (slope of the % -75m – time relationship in the laboratory mill
obtained during milling for float tests compared against slopes of ores of known hardness),
 Measure the sample’s response to flotation.

Assuming the bulk sample has been subjected to all or any combination of Bond, JK and Mintek
Grindmill laboratory scale tests and a bulk sample has been campaigned through a pilot plant
to obtain its milling and flotation performance, then each variability sample should be tested as
follows;

Milling and Flotation

If sufficient sample is available then Bond and/or Mintek Grindmill tests can be done at the
discretion of the metallurgist. If sufficient sample is not available (i.e. at least 20kg) to conduct
Bond and/or Mintek Grindmill tests then the following may be done (this assumes that only
borehole sample of normal reef width is available of approximately 6 kg);
1. Based on the bulk sample, or any other appropriate sample, which has a % -75m – time
relationship previously measured in the laboratory mill an appropriate milling time is
chosen to grind to the required % -75m. This time is applied to all the variability samples
2. Conduct a rougher rate test at 35% -75m (5 or 6 concentrates for 30 minutes as per page 3
above). From the results estimate IMF (the fast floating fraction of mineral, in this case
PGMs). As a percentage, this is approximately the recovery in the first stage mill/float of a
production plant MF2 circuit.
3. Repeat 2 above, but float only for a time necessary to achieve a recovery equal to IMF. This
is to generate a primary rougher tailings assay equal to what would be produced in a
production plant. These tailings are then reground to 80% -75m and a rougher rate test
conducted (5 or 6 concentrates for 30 minutes as per page 3 above). This test may need the
use of 2kg of sample to obtain enough to for the subsequent regrind flotation test.
4. Screen the tailings from points 2 and 3 above to obtain the actual % -75m. Select the
hardest and softest samples and perform a milling test on them.

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Flotation MF1/MF2 test procedure for ores. Feb 2003. Updated Nov 2007
 8

If more sample is available, cleaning rate tests can be done and/or the testing of conditions
found to be appropriate to treat the bulk sample or other cores i.e. such as depressant addition
etc.

The use of reagents and their addition rates for these tests will be based on previous work and
what has been found to be appropriate.

Summary re MF2 lab test

The MF2 test is to determine the kinetics and flotation response of a secondary mill-float section
of an MF2 circuit. The kinetic rate data is used to simulate the performance of a production
plant. To do this feed to the secondary mill-float must be at the same grade expected in the
plant.

The lab primary float is run to generate a plant primary rougher tail – so lab rougher flotation
may be only 3 to (say) 7 minutes. Lab primary rougher tails are reground to the desired grind
and a full rougher rate test is done as per “Flotation test” above.

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Flotation MF1/MF2 test procedure for ores. Feb 2003. Updated Nov 2007
Suggested Standard test

1. A milling curve will be constructed on Core BBW 56.

This core seems not to have many faults and could be classified as a good core.
2. All subsequent cores will be grind, based on this milling curve.
A primary grind of 35%-75um will be aimed for and a Secondary grind of 80% -75um.
3. An MF 1 as well as MF 2 circuit will be tested, as shown in Figure 1 and 2.
4. The PRT and SRT will be sized repectively.
Based on the size distribution obtained for the cores, two or three cores,
based on it's relative hardness will be chosen for Grindmill testwork.

Reagents Primary Secondary

Rougher Rougher
SIBX [g/t] 150 75
M82 [g/t] 40 40
Dow 200 [g/t] 40 40

MF 1 Primary Rougher Rate Test

Grind: 35% -75um
Primary Rougher
Sizing of PRT
Tailings

IPF = approx 0.70, ie recovery in plant primary mill/float

0-1min 3-7 min 7-20 min 20-30 min section will be about 70%. This recovery is achieved in
a lab float in 7 mins, hence the lab primary float time
in the MF2 test to produce a primary Ro tails grade
which will be equal to that produced in the plant.
MF 2 Secondary Rougher Rate Test (IPF = fast floating fraction of PGMs)

Grind: 35% -75um Grind: 80% -75um

Primary Rougher Secondary Rougher
Sizing of SRT
Tailings
7 minutes

0-1min 3-7 min 7-20 min 20-30 min

Bulk Primary
Rougher Conc.

Figure 2 Diagram describing MF2 Test

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Laboratory Float Procedure for MF1/2 Rate Tests.. Update2 Jan 2012.
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