XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 2839
benefits. In some cases, it can also lead to increased valuable
mineral losses in the cleaner circuit.
The lower copper grades in the finer size fractions were
likely due to gangue entrainment to the froth concentrate.
As mentioned previously, the copper grades in the finer size
fractions can be improved with a froth washing system.
It is interesting to note that the NovaCell ™ cop-
per grades in –710+425 µm size fraction were signifi-
cantly higher than the Agitair cell. Thus, the NovaCell ™
improved both the copper recovery and grade in the coars-
est size fraction.
In summary, laboratory results suggest that the project
objective could not be achieved. At the flotation feed grind
size (P80) of 550 µm, the NovaCell ™ achieved a copper
recovery of 75%. Although, this was 10% higher than con-
ventional flotation technology, it was still below the desired
final product recovery target of ~85%, probably due to
liberation constraints. It is well-known that as the parti-
cle size increases, there is a decline in particle surface lib-
eration, which can cause a reduction in flotation recovery.
Collection of ore particles can occur, even if the grade of
the individual grain is small, provided some of the hydro-
phobic mineral is exposed on the grain’s surface. However,
if the floatable particle is completely encapsulated within
the grain, it cannot be found by a colliding bubble and will
be lost to tailings. It is likely that the reduction in recovery
observed, is entirely caused by encapsulation.
It is recommended that further work be conducted to
investigate finer flotation feed grind sizes with P80s lower
than 550 µm. It may be possible to achieve the desired final
product recovery at a finer grind size and still achieve signif-
icant energy reductions. Secondly, the products produced
from the new rock breakage system should be submitted
for mineral liberation analysis (MLA). It would be useful
to understand the particle surface liberation characteristics
and degree of mineral locking, to determine the theoretical
grade and recovery curve.
CONCLUSIONS
The NovaCell ™ produced higher copper (and in some
cases molybdenum) recoveries than conventional flota-
tion technology i.e., mechanical agitated float cells. This
improvement was observed for all the samples investigated,
representing porphyry copper mines in Canada, Chile,
and Australia. It was also evident that the largest recovery
improvements were observed in the coarse +300, +212 and
+150 µm size fractions.
The results suggest that the NovaCell ™ is a viable
option for CPF circuits at existing and future porphyry cop-
per mines. The potential benefits of higher feed throughput
rates, improved valuable mineral recoveries and lower car-
bon emissions, can all be achieved. With the adoption of
the NovaCell ™, there is a real likelihood that the mining
sector will be able to satisfy the growing demand for cop-
per, whilst also reducing the carbon emissions produced
through mining.
ACKNOWLEDGMENTS
The authors acknowledge Hunter Process Technologies Pty.
Ltd. and Core Resources Pty. Ltd. for their assistance in
conducting the test work.
The authors also acknowledge funding support from
the Australian Research Council for the ARC Centre of
Excellence for Enabling Eco-Efficient Beneficiation of
Minerals, grant number CE200100009.
REFERENCES
Anzoom, J. S., Bournival, G., and Ata, S., 2023. Coarse
particle flotation: A review. Minerals Engineering 206.
Jameson, G.J., and Emer, C., 2019. Coarse chalcopy-
rite recovery in a universal froth flotation machine,
Minerals Engineering 134, pp 118–133.
Jera, T.M., and Bhondayi, C. A. 2022. Review on Froth
Washing in Flotation. Minerals 2022, 12, 1462.
Morgan, S., and Jameson, G.J., 2022. Improving mill
throughputs, with coarse and fine particle flotation in
the NovaCell ™ in Proceedings IMPC Asia-Pacific 2022,
pp 1101–1117.
Morgan, S., Amelunxen, P., Akerstrom, B., and Cooper, L.,
2023. Pinto Valley Mine, Copper recovery study with
the NovaCell ™ in Proceedings MetPlant 2023, pp
101–115.
Morton, J., 2023. Flotation Innovations Increase
Throughput, Recovery. Engineering and Mining
Journal, September 2023.
Mudd, G. &Jowitt, S., 2018. Growing Global Copper
Resources, Reserves and Production: Discovery Is
Not the Only Control on Supply. Economic Geology,
113(6), p. 1235–1267.
Northey, S., Haque, N. &Mudd, G., 2013. “Using sustain-
ability reporting to assess the environmental footprint
of copper mining”. Journal of Cleaner Energy, op. cit.
benefits. In some cases, it can also lead to increased valuable
mineral losses in the cleaner circuit.
The lower copper grades in the finer size fractions were
likely due to gangue entrainment to the froth concentrate.
As mentioned previously, the copper grades in the finer size
fractions can be improved with a froth washing system.
It is interesting to note that the NovaCell ™ cop-
per grades in –710+425 µm size fraction were signifi-
cantly higher than the Agitair cell. Thus, the NovaCell ™
improved both the copper recovery and grade in the coars-
est size fraction.
In summary, laboratory results suggest that the project
objective could not be achieved. At the flotation feed grind
size (P80) of 550 µm, the NovaCell ™ achieved a copper
recovery of 75%. Although, this was 10% higher than con-
ventional flotation technology, it was still below the desired
final product recovery target of ~85%, probably due to
liberation constraints. It is well-known that as the parti-
cle size increases, there is a decline in particle surface lib-
eration, which can cause a reduction in flotation recovery.
Collection of ore particles can occur, even if the grade of
the individual grain is small, provided some of the hydro-
phobic mineral is exposed on the grain’s surface. However,
if the floatable particle is completely encapsulated within
the grain, it cannot be found by a colliding bubble and will
be lost to tailings. It is likely that the reduction in recovery
observed, is entirely caused by encapsulation.
It is recommended that further work be conducted to
investigate finer flotation feed grind sizes with P80s lower
than 550 µm. It may be possible to achieve the desired final
product recovery at a finer grind size and still achieve signif-
icant energy reductions. Secondly, the products produced
from the new rock breakage system should be submitted
for mineral liberation analysis (MLA). It would be useful
to understand the particle surface liberation characteristics
and degree of mineral locking, to determine the theoretical
grade and recovery curve.
CONCLUSIONS
The NovaCell ™ produced higher copper (and in some
cases molybdenum) recoveries than conventional flota-
tion technology i.e., mechanical agitated float cells. This
improvement was observed for all the samples investigated,
representing porphyry copper mines in Canada, Chile,
and Australia. It was also evident that the largest recovery
improvements were observed in the coarse +300, +212 and
+150 µm size fractions.
The results suggest that the NovaCell ™ is a viable
option for CPF circuits at existing and future porphyry cop-
per mines. The potential benefits of higher feed throughput
rates, improved valuable mineral recoveries and lower car-
bon emissions, can all be achieved. With the adoption of
the NovaCell ™, there is a real likelihood that the mining
sector will be able to satisfy the growing demand for cop-
per, whilst also reducing the carbon emissions produced
through mining.
ACKNOWLEDGMENTS
The authors acknowledge Hunter Process Technologies Pty.
Ltd. and Core Resources Pty. Ltd. for their assistance in
conducting the test work.
The authors also acknowledge funding support from
the Australian Research Council for the ARC Centre of
Excellence for Enabling Eco-Efficient Beneficiation of
Minerals, grant number CE200100009.
REFERENCES
Anzoom, J. S., Bournival, G., and Ata, S., 2023. Coarse
particle flotation: A review. Minerals Engineering 206.
Jameson, G.J., and Emer, C., 2019. Coarse chalcopy-
rite recovery in a universal froth flotation machine,
Minerals Engineering 134, pp 118–133.
Jera, T.M., and Bhondayi, C. A. 2022. Review on Froth
Washing in Flotation. Minerals 2022, 12, 1462.
Morgan, S., and Jameson, G.J., 2022. Improving mill
throughputs, with coarse and fine particle flotation in
the NovaCell ™ in Proceedings IMPC Asia-Pacific 2022,
pp 1101–1117.
Morgan, S., Amelunxen, P., Akerstrom, B., and Cooper, L.,
2023. Pinto Valley Mine, Copper recovery study with
the NovaCell ™ in Proceedings MetPlant 2023, pp
101–115.
Morton, J., 2023. Flotation Innovations Increase
Throughput, Recovery. Engineering and Mining
Journal, September 2023.
Mudd, G. &Jowitt, S., 2018. Growing Global Copper
Resources, Reserves and Production: Discovery Is
Not the Only Control on Supply. Economic Geology,
113(6), p. 1235–1267.
Northey, S., Haque, N. &Mudd, G., 2013. “Using sustain-
ability reporting to assess the environmental footprint
of copper mining”. Journal of Cleaner Energy, op. cit.