Particle Size Distribution Effects that Should be Considered when Performing Flotation Geometallurgical Testing

Flotation recovery in geometallurgical modelling is usually predicted based on relationships developed from batch flotation testing of different ore types. These batch flotation tests are usually performed at a constant set of operating conditions and at a fixed feed grind size P80. Usually the laboratory feed grind P80 is that which is expected to be produced in the full-scale flotation circuit for that particular ore type. Flotation recovery will be a strong function of the valuable mineral particle size distribution, with lower recovery of ultra-fines due to poor flotation kinetics, optimum recovery for the intermediate sized particles and lower recovery for the coarser particles due to poorer liberation of this fraction. This valuable mineral particle size distribution is not characterised by the solids P80 parameter alone. The proportion of material in each class will also be a function of the slope of the size distribution and the degree of preferential grinding of the valuable mineral in comparison to the total mass of the ore. This paper will demonstrate (through example) how these other size distribution parameters can change with a change in grinding technology, the size and operating conditions used in a grinding unit and the characteristics of the classification technology used in conjunction with the grinding unit. Case studies will be presented that demonstrate how this can result in these parameters being very different in laboratory testing to that produced in the full-scale comminution circuit. A rule of thumb that laboratory rod milling rather than ball milling produces a size distribution most similar to that of the full-scale grinding circuit will be challenged. These differences can result in a significant change in flotation recovery. It is therefore important to consider these parameters when developing a laboratory geometallurgical program, to enable more accurate prediction of the flotation recoveries that will be achieved in the full-scale process. 1. Manager Flotation Process Technology, Metso Minerals, Process Technology and Innovation, Level 3 Technology Transfer Centre, 1 Technology Court, Pullenvale Qld 4069. Email: [email protected] 2. Principal Research Fellow, Julius Kruttschnitt Mineral Research Centre, University of Queensland, Isles Road, Indooroopilly Qld 4068. Email: [email protected] 3. MAusIMM, Process Engineer – Flotation Technology, Metso Minerals, Process Technology and Innovation, Level 3 Technology Transfer Centre, 1 Technology Court, Pullenvale Qld 4069. Email: [email protected] 4. General Manager – Innovation and Technology, Metso Minerals, Process Technology and Innovation, Level 3 Technology Transfer Centre, 1 Technology Court, Pullenvale Qld 4069. Email: [email protected]