Post on 04-Apr-2015
Metallurgical Evaluation of the Wemco SuperCell™
Flotation 2009Cape Town11th Nov 2009
M. Dunn - Rio TintoD. Lelinski, A. Weber, B. Dabrowski and F. Traczyk – FLSM
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Presentation Overview
Introduction - The application at KUC
Introduction - SuperCell™
Metallurgical Test Design
WEMCO Metallurgical Results
Conclusions
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Kennecott Utah CopperCopperton Concentrator
56 Mtpa Throughput
SABC circuit
Bulk Cu/Mo flotation
Moly separation
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Copperton Bulk Flotation Flowsheet
Bulk Concentrate
TailingsScavengerRougher
Flotation Feed
Rougher CleanerColumns
Rougher Regrind
ScavengerRegrind
ScavengerCleanerColumns
Cleaner Scavenger
ScavengerMechanical Cleaner
SuperCell™
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Opportunity at KUC
• Additional Scavenger Cleaner capacity required
– Improve copper & moly recovery
– Reduce re-circulating load
• Mechanical cells have proven recovery performance
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Project Objectives
Start-up Production Cell WEMCO Jan 2009
Start-up Test Cell Dorr-Oliver Apr 2009
Retro-fit Test Cell XCELL Sep 2009
Final Configuration
Dec 2009
KUC • Achieve design recovery and grade
• Accelerated delivery
FLSM • Demonstrate SuperCell™ in operation
• Validate hydrodynamic and metallurgical scale-up
Scope • Test cell installed on a “try before buy” basis
• 9 month testing program with 3 mechanisms
• KUC purchased additional cell for continuous production
Design/Construct Production Cell
Sep 2008
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WEMCO
300
Dorr-Oliver
330
XCELL
350
FLSmidth Flotation Machines
8.6m
6m
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FLSmidth SuperCell™ Mechanisms
WEMCODorr-Oliver
XCELL
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WEMCO Hydrodynamic Testing
• Machine ParametersSubmergence
Rotor Speed
Rotor Engagement
• Measured ResponseMachine Power
Aeration Rate
Pulp Circulation
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Metallurgical Testing Program
• 4-5 test campaigns on each mechanism
• Same machine parameters for each campaign
• Difference between campaigns related to changes in feed
– Regrind size
– Flowrate
– Ore type
• Pilot testing campaign in parallel to full-scale
• Lab flotation kinetics tests for each campaign
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Pilot Scale Testing
• 1.5m3 pilot cell operated in parallel to SuperCell™ for scale-up
• Evaluated residence time effect on parameters
• WEMCO, Dorr-Oliver and XCELL pilot cells operated in parallel
• Facilitated comparison between full-scale mechanisms
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Metallurgical Test Matrix - WEMCO
Machine ParametersFroth Depth
Rotor Speed
Measured ResponseFeed Assay
Concentrate Assay
Tailings Assay
Aeration Rate
Absorbed Power
Feed rate
Solids Content
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Metallurgical Test MatrixDorr-Oliver/XCELL
Machine ParametersFroth Depth
Rotor Speed
Air Rate
Measured ResponseFeed Assay
Concentrate Assay
Tailings Assay
Aeration Rate
Absorbed Power
Feed rate
Solids Content
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Wemco Supercell™ exceeded performance guarantee
50.055.060.065.070.075.0
80.085.090.095.0
100.0
10.0 20.0 30.0 40.0
Cu Grade
Cu Recovery
1st Campaign
2nd Campaign
3rd Campaign
4th Campaign
5th Campaign
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2nd Campaign: Similar results
50.055.060.065.070.075.0
80.085.090.095.0
100.0
10.0 20.0 30.0 40.0
Cu Grade
Cu Recovery
1st Campaign
2nd Campaign
3rd Campaign
4th Campaign
5th Campaign
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3rd Campaign: Regrind Mill off
50.055.060.065.070.075.0
80.085.090.095.0
100.0
10.0 20.0 30.0 40.0
Cu Grade
Cu Recovery
1st Campaign
2nd Campaign
3rd Campaign
4th Campaign
5th Campaign
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4th Campaign: Low feed gradeHigh feed rate
50.055.060.065.070.075.0
80.085.090.095.0
100.0
10.0 20.0 30.0 40.0
Cu Grade
Cu Recovery
1st Campaign
2nd Campaign
3rd Campaign
4th Campaign
5th Campaign
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5th campaign: Response on Skarn ore
50.055.060.065.070.075.0
80.085.090.095.0
100.0
10.0 20.0 30.0 40.0
Cu Grade
Cu Recovery
1st Campaign
2nd Campaign
3rd Campaign
4th Campaign
5th Campaign
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Moly Recovery: a function of power
Specific Power
60.0
65.0
70.0
75.0
80.0
85.0
90.0
95.0
100.0
0.50 0.60 0.70 0.80 0.90 1.00
Specific Power, kW/m3
Mo Re
covery
1stCampaign2ndCampaign4thCampaign
2020
Developed Response Surfaces
SuperCell
Feed Flow 3231 gpm (22.1 min RT) 49.7 gpm (7.2 min RT)
Ore Type Type 2 Type 2
Cu Feed Grade 10 % 10 %
Pilot Cell
• All campaign results were statistically significant
• Developed response surfaces for pilot vs full-scale
• Enables scale-up to be determined
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Mo Recovery: a function of power
Power
• Can achieve design recovery at 0.8kW/m3
• Higher energy will improve recovery further
Mo Recovery
2222
Similar response with Cu
Power Cu Recovery
Feed Flow 3231 gpm (22.1 min RT)
Ore Type Type 2
Cu Feed Grade 10 %
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Able to quantify metallurgical trade-off between recovery and grade
SuperCell Pilot Cell
Operations able to optimize operating conditions
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Conclusions
• SuperCell exceeded design performance
• DoE determined optimum operating conditions
• Recovery improves with higher specific power input
• Success factors for plant experimental testwork:
– Circuit designed for plant stability and sampling
– Robust experimental design
– Focus on quality of sampling and prep
• FLSM - foundation for new scale-up method based on pilot vs full-scale response surface
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Questions?