2555
From Microflotation To Industry—A Methodology for Upscaling
and Optimizing Reagent Systems in Froth Flotation
Borhane Ben Said, Martin Rudolph, Lucas Pereira
Department of Processing, Helmholtz-Institute Freiberg for Resource Technology,
Helmholtz-Zentrum Dresden-Rossendorf, Freiberg, Germany
ABSTRACT: Flotation is one of the most important and complex processes in mineral processing. Optimizing
the process grade and recovery can be expensive and time-intensive due to the interaction of various operating
parameters like pH and reagent dosages. Additionally, laboratory-scale investigations may not fully represent the
effects observed in intricate flowsheets.
In this paper, we propose an approach that bridges the gap between laboratory-scale and pilot/industrial-scale
optimization of reagent systems in froth flotation processes. This approach combines the statistical design of
experiments (DoE) and numerical optimization methods. We first conduct laboratory tests to identify the most
significant process parameters. Following this, we test a well-defined set of operating conditions at the pilot
scale. We use the Nelder-Mead approach to optimize the pilot-scale tests, simplifying the algorithm based on the
optimal parameter settings found at the lab scale. This significantly reduces the number of required experiments,
as well as the resources and energy consumption.
To illustrate the process, we provide a case study of a low-grade scheelite ore at different scales—from laboratory
to industry. This approach reduced the number of experiments, resources, and energy consumption by approxi-
mately 60% at the pilot scale. Moreover, we validated the effectiveness of the method through industrial trials.
Keywords: flotation process, upscaling, process optimization, design of experiments, mineral processing, mini
pilot plant.
INTRODUCTION
The mining industry is continuously working towards
improving the economic and environmental standards of its
operations. However, the increasing complexity of the ore
bodies being mined presents a challenge to the efficiency
of processing operations. It is important to optimize these
processes to achieve higher quality and yield of mineral
concentrates while reducing energy and resource require-
ments. While there have been numerous studies on the use
of new reagents in flotation processes to improve product
quality, most of this research has been limited to laboratory
studies. This creates a gap between batch and continuous
operations that needs to be addressed. Currently, there is
no known systematic and efficient approach to optimize
and scale up reagent systems in flotation processes. The
selection and optimization of reagents is often informal,
reductionist, and based on personal experience transferred
from one plant to another(Nagaraj and Farinato 2016).
From Microflotation To Industry—A Methodology for Upscaling
and Optimizing Reagent Systems in Froth Flotation
Borhane Ben Said, Martin Rudolph, Lucas Pereira
Department of Processing, Helmholtz-Institute Freiberg for Resource Technology,
Helmholtz-Zentrum Dresden-Rossendorf, Freiberg, Germany
ABSTRACT: Flotation is one of the most important and complex processes in mineral processing. Optimizing
the process grade and recovery can be expensive and time-intensive due to the interaction of various operating
parameters like pH and reagent dosages. Additionally, laboratory-scale investigations may not fully represent the
effects observed in intricate flowsheets.
In this paper, we propose an approach that bridges the gap between laboratory-scale and pilot/industrial-scale
optimization of reagent systems in froth flotation processes. This approach combines the statistical design of
experiments (DoE) and numerical optimization methods. We first conduct laboratory tests to identify the most
significant process parameters. Following this, we test a well-defined set of operating conditions at the pilot
scale. We use the Nelder-Mead approach to optimize the pilot-scale tests, simplifying the algorithm based on the
optimal parameter settings found at the lab scale. This significantly reduces the number of required experiments,
as well as the resources and energy consumption.
To illustrate the process, we provide a case study of a low-grade scheelite ore at different scales—from laboratory
to industry. This approach reduced the number of experiments, resources, and energy consumption by approxi-
mately 60% at the pilot scale. Moreover, we validated the effectiveness of the method through industrial trials.
Keywords: flotation process, upscaling, process optimization, design of experiments, mineral processing, mini
pilot plant.
INTRODUCTION
The mining industry is continuously working towards
improving the economic and environmental standards of its
operations. However, the increasing complexity of the ore
bodies being mined presents a challenge to the efficiency
of processing operations. It is important to optimize these
processes to achieve higher quality and yield of mineral
concentrates while reducing energy and resource require-
ments. While there have been numerous studies on the use
of new reagents in flotation processes to improve product
quality, most of this research has been limited to laboratory
studies. This creates a gap between batch and continuous
operations that needs to be addressed. Currently, there is
no known systematic and efficient approach to optimize
and scale up reagent systems in flotation processes. The
selection and optimization of reagents is often informal,
reductionist, and based on personal experience transferred
from one plant to another(Nagaraj and Farinato 2016).