Operational optimization of copper flotation process based on the weighted Gaussian process regression and index-oriented adaptive differential evolution algorithm

Concentrate copper grade(CCG)is one of the important production indicators of copper flotation processes,and keeping the CCG at the set value is of great significance to the economic benefit of copper flotation industrial processes.This paper addresses the fluctuation problem of CCG through an operational optimization method.Firstly,a density-based affinity propagationalgorithm is proposed so that more ideal working condition categories can be obtained for the complex raw ore properties.Next,a Bayesian network(BN)is applied to explore the relationship between the operational variables and the CCG.Based on the analysis results of BN,a weighted Gaussian process regression model is constructed to predict the CCG that a higher prediction accuracy can be obtained.To ensure the predicted CCG is close to the set value with a smaller magnitude of the operation adjustments and a smaller uncertainty of the prediction results,an index-oriented adaptive differential evolution(IOADE)algorithm is proposed,and the convergence performance of IOADE is superior to the traditional differential evolution and adaptive differential evolution methods.Finally,the effectiveness and feasibility of the proposed methods are verified by the experiments on a copper flotation industrial process.

Fault detection in flotation processes based on deep learning and support vector machine

Effective fault detection techniques can help flotation plant reduce reagents consumption,increase mineral recovery,and reduce labor intensity.Traditional,online fault detection methods during flotation processes have concentrated on extracting a specific froth feature for segmentation,like color,shape,size and texture,always leading to undesirable accuracy and efficiency since the same segmentation algorithm could not be applied to every case.In this work,a new integrated method based on convolution neural network(CNN)combined with transfer learning approach and support vector machine(SVM)is proposed to automatically recognize the flotation condition.To be more specific,CNN function as a trainable feature extractor to process the froth images and SVM is used as a recognizer to implement fault detection.As compared with the existed recognition methods,it turns out that the CNN-SVM model can automatically retrieve features from the raw froth images and perform fault detection with high accuracy.Hence,a CNN-SVM based,real-time flotation monitoring system is proposed for application in an antimony flotation plant in China.

Process mineralogy of copper-nickel sulphide flotation by a cyclonic-static micro-bubble flotation column

In our study we investigated a refractory copper-nickel sulfide ore separation by using a cyclonic-static micro-bubble flotation column (FCSMC). The process mineralogy of the main products was studied. Using a scanning electron microscope-energy dispersive system (SEM-EDS) and an X-ray spectrometer the mineral category and content of samples were analyzed. By using a mineral liberation analyzer (MLA) the mineral liberation characteristics were revealed. It is shown that in roughing feed the monomers liberation degree of nickel pyrite and chalcopyrite take up 84.11% and 88.82%, respectively. In tailings, the lost nickel pyrite and chalcopyrite are mainly monomers. Therefore, strengthening the micro-fine particle recovery capacity is the key to increase recovery.

Oil droplet movement and micro-flow characteristics during interaction process between gas bubble and oil droplet in flotation

Flotation is an efficient pre-treatment technology for oily water.In this work,the interaction process between the moving oil droplet and the gas bubble was studied by high-speed camera and Bassset-Boussinesq-Oseen(BBO)theoretical model,and the experimental and simulation results of the oil droplet trajectory were compared.Moreover,the micro-particle image velocimetry system was utilized to observe the flow inside and outside of the moving oil droplet.The results show that the BBO model with the mobile bubble’s surface can reflect the velocity change trend of the oil droplet during the interaction process between the moving oil droplet and the gas bubble,but there are some significant differences between the experimental and simulation results.While the oil droplet is moving on the bubble’s surface,the velocity of the area near the contact point of oil droplet–gas bubble is less than that of the other areas inside the oil droplet.Meanwhile,the flow of water above the oil drop is more biased towards the gas bubble.

Effect of mineral processing wastewater on flotation of sulfide minerals

The effects of mineral processing wastewater on sulfide minerals were investigated by flotation,infrared spectrometry and electrochemistry test. The results show that lead-concentrate water can improve the flotation of galena,while the sulfur-concentrate water has negative effect on flotation of galena compared with distilled water. The flotation behavior of pyrite is contrary to that of galena in three kinds of water. Infrared spectra indicate that the residual collector in the lead-concentrate water is beneficial to the formation of lead xanthate on the surface of galena. Electrochemistry results indicate that electrochemistry reaction on galena surface has apparent change. The anode polarization is improved and cathode polarization is depressed.

Correlation Analysis of Control Parameters of Flotation Process

The dosage of gold-antimony flotation process of 5 main drugs,including Copper Sulfate,Lead Nitrate,Yellow Medicine,No.2 Oil,Black Medicine,with corresponding visual features of foam images,including Stability,Gray Scale,Mean R,Mean G,Mean B,Mean Average,Dimension and Degree Variance,were recorded.Parameter correlation analysis showed that the correlation among Copper Sulfate,Yellow Medicine,Black Medicine,as well as the correlation among Gray Scale,Mean R,Mean G,Mean B,is strong,and the correlation among Dimension,Gray Scale,Mean R,Mean G,Mean B,as well as the correlation between Stability and each dosing parameter,is week.It also indicated a feasible way to decrease the complexity of flotation control system by reducing some parameters.

Modeling of fine coal flotation separation based on particle characteristics and hydrodynamic conditions

Flotation is a complex multifaceted process that is widely used for the separation of finely ground minerals. The theory of froth flotation is complex and is not completely understood. This fact has been brought many monitoring challenges in a coal processing plant. To solve those challenges, it is important to understand the effect of different parameters on the fine particle separation, and control flotation performance for a particular system. This study is going to indicate the effect of various parameters （particle Characteristics and hydrodynamic conditions） on coal flotation responses （flotation rate constant and recovery） by different modeling techniques. A comprehensive coal flotation database was prepared for the statistical and soft computing methods. Statistical factors were used for variable selections. Results were in a good agreement with recent theoretical flotation investigations. Computational models accurately can estimate flotation rate constant and coal recovery （correlation coefficient 0.85, and 0.99, respectively）. According to the results, it can be concluded that the soft computing models can overcome the complexity of process and be used as an expert system to control, and optimize parameters of coal flotation process.

Flotation Separation on Rare Earth Minerals and Gangues

The flotation process of native rare earth minerals such as bastnasite, monazite, mixed minerals of bastnasite and monazite, using the new effective collector Dh was studied, respectively, and the flotation properties were described. The good qualities of the new collector Dh were revealed through comparing with other collector of rare earth minerals. The test results of different ore samples showed that at moderate pulp pH (8.5～9.5), rare earth minerals could be effectively separated from barium, calcium and silicon bearing intergrowth minerals (barite, calcite and silicate minerals) and high quality rare earth concentrates could be obtained successfully by the new collector Dh, acid silica gel, turpentine and reagents fitting together rationally. In order to determine optimum technical conditions, the effect of pulp pH, pulp temperature, pulp density and the effect of dosage of reagents (Dh and acid silica gel) on the flotation were investigated in the test. Simultaneously, the mechanism of the flotation of rare earth minerals from intergrowth minerals was explored. The infrared spectra for Dh and rare earth cation by analysis in theory showed that Dh formed chelate complex with rare earth cation and were adsorbed on the surfaces of rare earth minerals. The mechanism of the intergrowth minerals depressed by acid silica gel can be explained as gummy colloid hydrolyzed from acid silica gel which were selectively absorbed on the gangue minerals, making them hydrophilic and depressed, with pulp pH value of alkalescent.

Upgrading graphite by flotation at Bogala Mines in Sri Lanka

Graphite is naturally floatable due to its hydrophobic pro pe rty and also soft and smears on other gangue particles, rendering the gangue mor e or less floatable too. Due to this reason it is important to concentrate on ar eas such as suitable flotation reagents, depression agents, pH modifiers, and pa rticle size to be fed during the process. The paper surveys and analyses the sui table particle size to be fed to achieve high-grade concentrate. According to t h e work carried out the author suggested the ideal cost effective flotation f low sheet for improved results at Bogala Mines in Sri Lanka.

A dynamic size-based time series feature and application in identification of zinc flotation working conditions

Conventional feature description methods have large errors in froth features due to the fact that the image during the zinc flotation process of froth flotation is dynamic,and the existing image features rarely have time series information.Based on the conventional froth size distribution characteristics,this paper proposes a size trend core feature(STCF)considering the froth size distribution,i.e.,a feature centered on the time series of the froth size distribution.The core features of the trend are extracted,the inter-frame change factor and the inter-frame stability factor are given and two calculation methods of the feature factors are proposed.Meanwhile,the STCF feature algorithm was established based on the core features by adding the inter-frame change factor and the inter-frame stability factor.Finally,a flotation condition recognition model based on BP neural network was established.The experiments show that the recognition model has achieved excellent results,proving that the method proposed effectively overcomes the limitation of the lack of dynamic information in the existing traditional size distribution features and the introduction of the two factors can improve the classification accuracy to varying degrees.

A honeycomb-tube packing medium and its application to column flotation

We address problems in the development of large-scale flotation columns that use short cylinders. As a starting point, we investigated the packing medium to identify a highly efficient internal packing for the flotation column. The chosen packing was a honeycomb structure with an aperture diameter of 80 mm, a web thickness of 0.80 mm, a film height of 1000 mm, packed into a 400 mm diameter space, which completely filled the vessel at optimal cost. The column consisted of a modular ring of single-hole hexagonal honeycomb tube packing made from atactic polyproplene (PP-R). The packing was tested in a cyclonic, static micro-bubble flotation column. Computational fluid dynamic modeling was used to analyze the flotation fluid in a honeycomb tube packed flotation column. Our results show that the fluid axial movement was maximized and that the transverse fluid velocities were zero in the vicinity of axial flow. Using the honeycomb tube packing for copper sulfide flotation we observed that the average concentration in the product was increased to 25.41%, from an average feed concentration of 0.729%, with an average recovery of 92.92%. The demands of on-site industrial production were met.

Study on the Axial Dispersion of Liquid in Column Flotation

An experimental study on the axial dispersion of liquid was carried out in a 0.382-m-ID flotation column packed with different structured packings or free of packings. The correlations of axial Peclet numbers with the liquid and gas superficial Reynolds numbers were developed for various packings. Among the packings tested, it is found that in the column packed with 250Y or 350Y packings the axial dispersion is the lowest. The addition of frother can decrease the axial dispersion. By the simulation analysis of the one-dimension dispersion model of packed flotation column, it is found that small axial dispersion, high collection rate constant and low axial liquid velocity can increase the collection zone recovery.

Research on Effect of Magnetized Pulp on Coal Slime Flotation

Effect of magnetization on oxygen concentration, pH, surface zeta potential, and wet heat of flotation pulp were researched. The result shows that magnetization treatment can improve the floatablility of coal and increase the difference in wet heat among coal, refuse, and pyrite, which is favorable for slime flotation and for removing sulfur and ash from coal.

The Effects of Water Recycling on Flotation at a North American Concentrator—Part 1

Water chemistry and its impact on mineral processing operations are not well understood and often not adequately monitored. CanmetMINING, as part of its water management research program, has been involved in a project initiated to identify opportunities for improving water recovery, water treatment, and recycling in the mining and mineral processing operations. One of the main objectives of this work is to evaluate and assess water chemistry and identify factors that impact mineral recovery, concentrate grade, and metal extraction efficiencies in order to understand and mitigate negative impacts of water recycling and improve process efficiency. In collaboration with a North American concentrator, CanmetMINING has been involved in assessing the water chemistry in the mill and evaluating water recycling options for select process streams to reduce fresh water intake and maximize recycling. The overall goal of the project is to investigate options for water recycling (increase the thickener overflow recirculation from thickener overflow tank) without affecting nickel and copper metallurgy. The results of the sampling campaigns showed that the water chemistry of the streams was fairly consistent throughout the year with no significant seasonal variations. The laboratory tests illustrated that when higher quantities of thickener overflow from thickener overflow were used, the nickel + copper grade versus nickel recovery curves shifted towards lower values. These observations were observed for the plant water samples obtained in April, June and August 2019.

气浮旋流中油滴与气泡的运动规律

微气泡气浮旋流技术是将气浮分离与旋流分离相结合的一种新型高效分离方法。利用微气泡气浮旋流技术进行油水分离,探究了溶气水微气泡、旋流场、絮凝剂3种因素对油水分离效果的影响,并用高速成像技术考察了微气泡与油滴、微气泡与絮体的结合过程。结果表明,溶气水微气泡可大幅缩短油水分离时间,相比纯水静置缩短了50%。在油水混合物初始质量浓度为400 mg/L时,气浮+旋流+絮凝剂组合工艺的最佳实验条件为油水混合物与溶气水的体积比1∶4、旋流速度370 r/min、复合絮凝剂(PAC∶CPAM)的复配比2∶1,此条件下污水最终含油质量浓度低于10 mg/L,满足《污水综合排放标准》(GB 8978—1996)。静水条件下,微气泡-絮体结合体的平均投影面积约为微气泡-油滴结合体的6倍,投加絮凝剂有利于提升油水分离效果。交互实验证明,相比纯水静置处理,经微气泡气浮、气浮+旋流以及气浮+旋流+絮凝剂3种工艺处理后,污水含油率分别降低38.7%、71.4%、76.5%。就最终油水分离效果来说,3因素组合>溶气水微气泡+旋流场>溶气水微气泡。

某鳞片石墨矿可选性试验研究

为了评价某石墨矿可选性,对该石墨矿开展了工艺矿物学研究和选矿工艺流程试验研究。利用X射线衍射(XRD)仪、电子显微镜等系统分析该石墨矿的工艺矿物学特征,该矿石属于鳞片石墨,主要矿物为石墨,石英、斜长石等;基于工艺矿物学研究分析结果,对石墨矿进行浮选试验。结果表明,该石墨矿具有较好的可选性,全流程闭路试验获得石墨精矿产率为4.54%,精矿固定碳含量为95.80%,回收率为90.87%。试验结果为该矿石资源的地质评价提供有力依据,为工业生产提供合理选矿工艺,具有实际意义。

秘鲁某复杂金矿工艺矿物学及选别工艺研究

随着易选金矿资源的逐渐匮乏,开发处理低品位、含硫含砷复杂金矿的高效工艺尤为关键。针对秘鲁某复杂金矿进行工艺矿物学分析,并对全浸和浸出—浮选联合工艺的处理效果进行了比较。研究结果显示:该矿石金品位为6.64 g/t,其中51.9%的金被矿物包裹,主要载金矿物为黄铁矿和石英。在优化工艺条件下,全浸法的Au浸出率可达74.1%,浸出渣中残留Au品位为1.72 g/t,说明回收效果有待提升。通过对浸出渣进行浮选处理,闭路试验获得的金精矿Au品位达到21.60 g/t, Au回收率为14.47%。采用浸出—浮选联合工艺,Au总回收率提高至88.57%,显示出该工艺在处理复杂金矿方面的显著优势。研究结果为复杂金矿的开发提供了有效的技术参考。

臭氧气浮-核晶造粒工艺处理油气田采出水与再生利用

为解决油气田采出水水量大、水质复杂等难题,实现油气田采出水处理后再利用的目标,提出一套臭氧气浮-核晶造粒组合工艺,处理后采出水可满足配制胍胶压裂液的水质要求。以COD和SS去除率为评价指标,对比了预臭氧氧化-混凝和臭氧气浮两种工艺,结果表明臭氧气浮工艺对COD和SS的处理效果更佳,二者去除率分别可达到59%和88%,处理后COD和SS均满足配制胍胶压裂液的水质要求。以Ca^(2+)、Mg^(2+)去除率为硬度指标,对比了核晶造粒和化学沉淀两种工艺的除硬效果,结果表明核晶造粒工艺在除硬方面具有显著优势,对Ca^(2+)、Mg^(2+)的总去除率能达到86%,满足配制胍胶压裂液对硬度的要求。以长庆油田4个站点采出水为实际处理对象,采出水经臭氧气浮-核晶造粒工艺处理后,配制的胍胶压裂液均表现出较好的基液黏度,可挑挂且不易断裂。臭氧气浮-核晶造粒工艺不仅可实现采出水的资源化利用,还可减少企业日常生产成本,具有较好的经济和环境效益,为油气田采出水的资源化利用提供了技术参考。

铜多金属硫化矿浮选工艺研究进展

铜多金属硫化矿嵌布关系复杂,传统的浮选工艺已不能完全满足工业生产需要,研发高效新型浮选工艺是该领域的重要研究课题。本文总结了7种新型浮选工艺在铜多金属硫化矿选别中的应用现状,分析了各种工艺的特点及适应性。新型浮选工艺具有适应性强、提质降耗明显等优点,在提高矿石处理能力、平衡循环负荷、缩短工艺流程及强化贵金属综合回收等方面具有明显的技术优势。未来,还需加强新型浮选工艺的联合应用和基础理论研究,为特效浮选药剂、高效浮选装备的研发提供理论支撑。