XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 1123
fines entrain the water to the tailings rather the been recov-
ered by the thickeners.
DYNAMIC WATER RECOVERY
OPTIMIZATION
The previous models have shown the importance of provid-
ing the best quality grinding product for Rougher Flotation
to recover the valuable minerals and minimize the metal
losses in the tails. In a concentrator, for lower grade ores,
99% of the contained solids will report to the Rougher
Flotation tailings and the thickeners feed. Therefore, hav-
ing the right particle size distribution shape during grind-
ing is the key. The two important controls of a thickener are
related to the properties of the thickener feed and under-
flow. For example, the presence of very fine particles in
the feed greatly affects the flocculation for the best settling
velocity with the appropriate flocculant addition is neces-
sary. The principal property of the underflow is the solid
concentration which is properly controlled by maintaining
defined level of the sediment in the thickener by manipu-
lating the underflow rate.
Figure 9 shows the underflow manipulation to keep
the right inventory in the thickener to compress the pulp
obtaining the highest underflow concentration compatible
with an adequate pulp transport (viscosity) to recover as
much water as possible. It shows the water recovery from
the three thickeners with the right flocculation of the best
particle size distribution product from the grinding circuit
enabling the optimization of both the copper production
rate and the water recovery in low grade ore mineral pro-
cessing plants.
The optimal tonnage processed is function of the min-
eral type, the mineralogical characteristics of the pulp,
rheology, the asset availability and the operating mode of
process units interacting in an industrial complex. The
objective is to find the optimal cut of grade at the mine and
the optimal cut size at the comminution to achieve the best
recovery grade combination to maximize profits.
Figure 10 shows a typical integrated mineral processing
plant including the water and tailings water recovery system
to enable to maximize copper production while increasing
the water availability. These low-grade ores mineral pro-
cessing plants require large investment costs and they need
additional energy and water resources making the process-
ing of the low grade’s ores less sustainable. As such, many
of the operating practices for grinding have been to push
Figure 8. Rougher flotation hydrodynamic profiles to maximize the metal production based on the plant schedule values (Blue
line actual, Black line planned production, updated 12/2023)
fines entrain the water to the tailings rather the been recov-
ered by the thickeners.
DYNAMIC WATER RECOVERY
OPTIMIZATION
The previous models have shown the importance of provid-
ing the best quality grinding product for Rougher Flotation
to recover the valuable minerals and minimize the metal
losses in the tails. In a concentrator, for lower grade ores,
99% of the contained solids will report to the Rougher
Flotation tailings and the thickeners feed. Therefore, hav-
ing the right particle size distribution shape during grind-
ing is the key. The two important controls of a thickener are
related to the properties of the thickener feed and under-
flow. For example, the presence of very fine particles in
the feed greatly affects the flocculation for the best settling
velocity with the appropriate flocculant addition is neces-
sary. The principal property of the underflow is the solid
concentration which is properly controlled by maintaining
defined level of the sediment in the thickener by manipu-
lating the underflow rate.
Figure 9 shows the underflow manipulation to keep
the right inventory in the thickener to compress the pulp
obtaining the highest underflow concentration compatible
with an adequate pulp transport (viscosity) to recover as
much water as possible. It shows the water recovery from
the three thickeners with the right flocculation of the best
particle size distribution product from the grinding circuit
enabling the optimization of both the copper production
rate and the water recovery in low grade ore mineral pro-
cessing plants.
The optimal tonnage processed is function of the min-
eral type, the mineralogical characteristics of the pulp,
rheology, the asset availability and the operating mode of
process units interacting in an industrial complex. The
objective is to find the optimal cut of grade at the mine and
the optimal cut size at the comminution to achieve the best
recovery grade combination to maximize profits.
Figure 10 shows a typical integrated mineral processing
plant including the water and tailings water recovery system
to enable to maximize copper production while increasing
the water availability. These low-grade ores mineral pro-
cessing plants require large investment costs and they need
additional energy and water resources making the process-
ing of the low grade’s ores less sustainable. As such, many
of the operating practices for grinding have been to push
Figure 8. Rougher flotation hydrodynamic profiles to maximize the metal production based on the plant schedule values (Blue
line actual, Black line planned production, updated 12/2023)