1124 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
the rheological constraints of the mill. It is well known that
once the hydrocyclones start roping the grinding product
exhibits a bimodal size distribution due to over-grinding.
This over-grinding creates finer particles that are difficult
to recover by conventional flotation cells and present dif-
ficult flocculation results. The typical P80 measures does
not account for the tail of the size distribution. A detailed
analysis conducted by the plant shows a bimodal particle
size distribution which causes flocculation problems and
water losses in the tailing ponds.
In this case, the thickener output was getting 55%
solids in the underflow. When, the mill operated with the
right size distribution the detailed analysis of the water
recovery showed an increase in the three thickeners to 60%
solids in the underflow, augmenting the water recovery by
a factor of 42%. This increase in the water recovery allows
Figure 9. Digital twin showing DynaThick mass water balance and predictions (updated 12/2023)
Figure 10. Integrated mineral processing plant for dynamic water management
the rheological constraints of the mill. It is well known that
once the hydrocyclones start roping the grinding product
exhibits a bimodal size distribution due to over-grinding.
This over-grinding creates finer particles that are difficult
to recover by conventional flotation cells and present dif-
ficult flocculation results. The typical P80 measures does
not account for the tail of the size distribution. A detailed
analysis conducted by the plant shows a bimodal particle
size distribution which causes flocculation problems and
water losses in the tailing ponds.
In this case, the thickener output was getting 55%
solids in the underflow. When, the mill operated with the
right size distribution the detailed analysis of the water
recovery showed an increase in the three thickeners to 60%
solids in the underflow, augmenting the water recovery by
a factor of 42%. This increase in the water recovery allows
Figure 9. Digital twin showing DynaThick mass water balance and predictions (updated 12/2023)
Figure 10. Integrated mineral processing plant for dynamic water management