Process Evaluation of an Iron Ore Operation Using the Floatability Component Model

The Brucutu iron ore mine (Minas Gerais, Brazil) is Vale‘s largest producing operation achieving around 21 million tons per annum. Evaluation of flotation performance high importance as even small gains can lead to large monetary benefits. Cell-by-cell samples the froth products, selected feed and pulp-products were analyzed for flow rate, particle size distribution chemical composition. In addition, certain on an assay-by-size basis hydrodynamic measurements cells also performed. This detailed experimental dataset was then used calibrate a floatability component model process. Longer mainline residence time resulted in significant Fe2O3 losses while yielding little benefit terms SiO2 product grade. Scavenger 2 has twice scavenger 1 having treat only 10% SiO2, resulting recoveries poor separation. it shown that exhibits true behavior increased losses. Simulations using identified avenues process improvement address behavior. insight provided by simulations into dynamics invaluable engineers.