Operating practices in the beneficiation of major porphyry copper/molybdenum plants from Chile: Innovated technology and opportunities, a review

doi:10.1016/S0892-6875(98)00011-9

Minerals Engineering

Volume 11, Issue 4, April 1998, Pages 313-331

https://doi.org/10.1016/S0892-6875(98)00011-9 Get rights and content

Abstract

The operating practices in the beneficiation of porphyry copper ores from Chile are reviewed. The factors which affect plant metallurgical results are discussed including: ore mineralogy, reagent scheme and flowsheet. Over the past decade, a decline in plant metallurgy at a number of plants occurred mainly due to the changes in ore mineralogy. The importance of the application of new technology for improvement in plant metallurgical results is highlighted.

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After more than a century applying flotation to the mining industry, two completely different strategies have been introduced for processing purposes. One is the classical approach viz. grinding ores to a certain extent (fine particles) and floating them via conventional mechanical and pneumatic cells i.e., Jameson, Imhoflot™ and Reflux™. This strategy continues because mines face declining cut-off grades, complex and poly-mineralized ores, and they are required to achieve an acceptable degree of mineral liberation. The other school of thought deals with coarse particle processes mainly owing to the low energy requirements, that includes SkimAir® flash, fluidized bed and HydroFloat™ cells. There is no study in the literature to comparatively present the recent developments of flotation apparatuses versus the conventional mechanical cells. To cover this knowledge gap in the literature, the present paper endeavors to critically evaluate these concepts from several points of view, including existing technological advancements, water and energy usage, kinetics, and circuit design. A brief introduction of advanced technologies, along with their applications is presented. The data from literature and case studies showed that the Jameson, Imhoflot™ and recently developed Reflux™ flotation cells can be very effective for recovering fine particles owing to their specific hydrodynamic designs, intensive energy dissipation rate and generation of micron-sized bubbles (100–700 µm). Very low (less than a few minutes) mean particle residence time, high gas-hold up (ca. 50–70 %), no agitation and high efficiency of particle-bubble collision were identified as their main advantages compared to traditional mechanical flotation cells. In addition to their common applications in cleaner stage, these cells were used in pre-flotation and scalping (producing final concentrate from the rougher feed) duties. Their main challenges were recognized as relatively unclear procedure on their scale up/down, optimization and simulation. The HydroFloat™ cell was indicated as a promising technology for recovering coarse particle fraction sizes by taking advantage of the fluidized-bed concept with plug-flow dispersion regime, high particle residence time, and limited cell turbulence. We finally concluded that fine particle flotation may remain as the main focus of re-processing tailings dams, while coarse particle treatment should be the focus of this century to reduce total energy consumptions.
Recent progress on research of molybdenite flotation: A review
2021, Advances in Colloid and Interface Science
Molybdenum is an important alloy element for metallurgical industry because of its high temperature stability. As the major mineral reserve for molybdenum, molybdenite (MoS₂) is commonly found in porphyry copper deposits. Molybdenite is naturally floatable and can be separated from copper sulfide mineral using froth flotation. Properties of molybdenite such as mineralogy, microstructure, surface wettability, zeta potential, etc. can have a great effect on its floatability. Organic and inorganic depressants and surface pre-treatment methods are applied to improve the recovery of molybdenite. Electrochemical potential measurements using different electrodes are used to monitor process conditions and enable processing parameter adjustments to improve flotation circuit performance and reduce operating costs. Cations like Ca²⁺ and Mg²⁺ are reported to have negative effects on the flotation of molybdenite in alkaline solution, and dispersants and oil collectors need to be added to restore the flotation of molybdenite. In addition, effects of gangue minerals, particle size, and oil collectors and surfactants on molybdenite recovery are also discussed in this manuscript.
A comparison of two flotation circuits
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Two rougher-cleaner-cleaner/scavenger (R-C-CS) circuits, one with CS tails sent to final tails, designated open, and the second with CS tails recycled to the rougher, designated closed, are compared. The open structure by isolating roughing from cleaning which aids process control appears to be favoured. Linear circuit analysis was used to address whether structural differences also play a role. The solution for circuit recovery was taken for the case of equal stage recoveries which permits separation to be assessed using the differential, designated sharpness of separation. When circuit recovery exceeded ca. 50% the open circuit gave higher separation than the closed which may contribute to the open being favoured. An argument for equal stage recoveries is advanced.
Phosphatic waste clay: Origin, composition, physicochemical properties, challenges, values and possible remedies – A review
2021, Minerals Engineering
Citation Excerpt :
Slurry rheological properties also depend strongly on the surface charge of anisotropic phyllosilicate particles, as discussed earlier, their shape (i.e., plates or fibers) and swelling capacity (Ndlovu et al., 2011; Ndlovu et al., 2010). It coincides well with the reports indicating that the presence of clay minerals causes problems in treating certain ore types due to their tendency to give rise to high pulp viscosities (Bulatovic et al., 1998; Senior and Thomas, 2005). A comprehensive review of pulp rheology’s influence on the flotation process has been performed by Farrokhpay (2012) (Farrokhpay, 2012).
The daily growing demand for critical materials has further highlighted the importance of secondary sources such as industrial waste streams. Waste clay, a phosphate ore process tailing, contains a remarkable amount of critical materials such as P and REEs so that comparing to different phosphate ore process streams, waste clay presents the highest concentration of REEs after phosphate rock. Due to the enormous volume of this waste accumulated in Florida to date, this reserve can satisfy a great portion of U.S. domestic demand for REEs, as an example. However, due to its troublesome nature, this reserve poses severe environmental problems along with economic loss. Two required attempts are the removal of extremely fine-sized clays, followed by the recovery of phosphate content, which can pave the path for the recovery of REE-bearing phases. Different possible remedies or combination of them have been considered by various research/ industrial trials, including froth flotation, selective-flocculation, floc-flotation, cycloning, gravity separation, magnetic separation, leaching, etc., most of which have shown no promising solution because of failing to address economic and of course environmental concerns. Moving from mostly chemical separation processes to the primarily physical/ physicochemical processes with low operational costs and environmental impacts could be a general solution. This requires detailed mineralogical and elemental characterization, physicochemical, rheological, electrochemistry, surface chemistry, crystal chemistry, solution chemistry, and quantum chemistry investigations on each single and then mixed-phase systems composing waste clay. Such insights can help develop the fundamental knowledge, upon which more versatile and efficient solutions can be established.
The flotation separation of molybdenite from chalcopyrite using a polymer depressant and insights to its adsorption mechanism
2020, Chemical Engineering Journal
Citation Excerpt :
Molybdenum, as a strategic rare metal, has been widely used in many fields, such as alloy materials, electronic technology, chemical catalyst, aero science, and so on. It has been reported that almost 50% of molybdenum originates from the separation of Cu-Mo concentrate [1–3], especially from porphyry Cu-Mo ores [4–6]. However, with the rapid growth of economy, the consumption of Cu and Mo grows rapidly.
In the present study, the poly(acrylamide-allyl thiourea) (PAM-ATU) with an average molecular weight of approximately 1.66 × 10⁴ g/mol was introduced as the chalcopyrite depressant in the flotation separation of molybdenite and chalcopyrite. The effects of PAM-ATU on their flotation performances were evaluated by micro-flotation and bench-scale experiments, and its adsorption mechanism to chalcopyrite was investigated by Fourier transform infrared spectroscopy (FT-IR), zeta potential tests and X-ray Photoelectron Spectroscopy (XPS) measurements. The flotation experiments results demonstrated that PAM-ATU had a stronger depressing ability than the conventional depressant thioglycolic acid (TGA) for chalcopyrite. At pH around 10.5, a good separation efficiency for artificially mixed minerals could be achieved with a 78.2% Mo recovery and a 58.9% Mo grade in the froth products, in which, the Cu grade was only 1.68%. It was also found that nearly 80.0% of Cu was depressed effectively with 150 g/t PAM-ATU after one rougher flotation in bench-scale experiments with a Mo recovery of almost 80.0%. FT-IR, zeta potential tests and XPS analysis results provided strong evidence that PAM-ATU could adsorb on chalcopyrite surface. Further, FT-IR and XPS analysis suggested that PAM-ATU might mainly chemisorb on chalcopyrite via Cu sites on surface through S and N atoms in PAM-ATU polymer. This study indicated that the synthesized PAM-ATU polymer with low molecular weight could be a promising depressant for chalcopyrite in the flotation separation of Cu-Mo ores.
Pyrogallic acid: A novel depressant for bismuthinite in Mo–Bi sulfide ore flotation
2019, Minerals Engineering
Molybdenum ore flotation techniques are constantly challenged by the emergence of complex sulfide minerals, such as bismuthinite, in the mineral processing industry. Conventional flotation depressants, such as sodium sulfide, used in Mo–Bi-containing ore flotation require high dosages, which leads to high cost and low selectivity. Therefore, in this study, pyrogallic acid (PA), a widely distributed organic source, is tested as an alternative depressant to selectively depress bismuthinite in Mo–Bi sulfide ores from Shizhuyuan. Results show that PA has a minimal effect on molybdenite recovery; by contrast, PA has a high depressing effect on bismuthinite amelioration. At 500 g/t PA, molybdenum recovery slightly decreases by 2 percentage points, and bismuth content in molybdenum concentrate sharply declines by 34 percentage points, with respect to samples floated without PA. Batch flotation tests demonstrate that PA addition affects froth stability, as indicated by the variations of solid and water recoveries. The superior selectivity of molybdenite over bismuthinite is promoted by increasing the PA dosage. On the basis of these findings, PA is a feasible option and thus can be used as a depressant for bismuthinite in the flotation of sulfide minerals.

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Operating practices in the beneficiation of major porphyry copper/molybdenum plants from Chile: Innovated technology and opportunities, a review

Abstract

Mineral Engineering

Wall Rock Alteration

The Interactive Effect of Flowsheet Design on Beneficiation of Complex Sulphide Ore.

Formation of Spheres from Finely Divided Solids in Liquid Suspension

I and EC Process Design and Development

Summary of Chilean Plant Visits

Evaluation of Flowsheet and Reagent Scheme on Chuquicamata Mill Feed Ore

R&D Report (Memorandum to Urizar D, Codelco, Chile, Chuquicamata Division)

Geological Significance of RbSr Isotopic Data of North Chile Crystaline Rocks of the Andean Orogen Between Latitudes 24 and 27 degrees south

Econ Geology

Copaquire, Chile-Its Geological Setting and Porphyry Copper Deposits

Transactions, AIME

Some Preliminary Observation on the Theoretical Geochemistry of Molybdenum Under Supergene Conditions

Arizona Geological Society Dig.

Flotation Reagent Practice in Primary and By-Product Molybdenum Recovery

Evaluation of SENMIN Collectors for Treatment of High Clay Ores

Leyes Por Fracción Granulométrica de Composites Mensuals de Relaves