3638 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
identify bottlenecks and introduce improvements in these
complex circuits.
METHODOLOGY
For this study, a case study was considered based on a Cu, Pb,
and Zn polymetallic plant from the Eureka Mine described
in the book “Flotation Plant Optimization,” whose main
mineral components are Chalcopyrite (Cp), Galena (Ga),
Sphalerite (Sp), Pyrite (Py), and Nonsulfur gangue (NSG)
(Greet 2010). The original design was modified considering
a lower grade mineral and with lower recoveries than those
reported by Greet (2010), so that it better represents the
current reality.
The feed mass flowrates and grades, as well as the stage
recoveries, are shown in Table 1, and Figure 1 shows the cir-
cuit. The circuit considered is the original one reported by
Greet (2010), but a second cleaner stage has been included,
given the reduction in recoveries considered in this case
study.
The process is the traditional one, consisting of three
flotation circuits, the first to recover Cp using a rougher
stage and two cleaners. The tail of the first circuit is fed
Table 1. Minerals and stage recoveries in the Eureka concentrator (Modified from Greet 2010)
Name Chalcopyrite Galena Sphalerite Pyrite Nonsulfur
Gangue
Identification Formula CuFeS₂ PbS ZnS FeS₂ —
Symbol Cp Ga Sp Py NSG
Feed tonne/h 0.98 3.52 13.73 35.12 66.65
composition,% 0.82 2.93 11.44 29.27 55.54
Stages Recoveries
Copper circuit Rougher 0.54 0.07 0.02 0.01 0.01
Cleaner 1 0.76 0.13 0.31 0.07 0.44
Cleaner 2 0.76 0.13 0.31 0.07 0.44
Nickel circuit Rougher 0.63 0.85 0.65 0.41 0.22
Cleaner 1 0.48 0.52 0.32 0.28 0.64
Cleaner 2 0.39 0.35 0.16 0.13 0.20
Cleaner 3 0.45 0.30 0.19 0.08 0.12
Scavenger 0.22 0.47 0.19 0.07 0.01
Sulfur Circuit Rougher 0.57 0.59 0.83 0.14 0.13
Cleaner 1 0.65 0.60 0.77 0.42 0.29
Cleaner 2 0.64 0.67 0.69 0.55 0.36
Scavenger 0.22 0.27 0.43 0.05 0.04
Figure 1. Eureka plant flotation circuit. Modified flowsheet from Greet (2010) with the addition of a second cleaning stage in
the copper circuit
identify bottlenecks and introduce improvements in these
complex circuits.
METHODOLOGY
For this study, a case study was considered based on a Cu, Pb,
and Zn polymetallic plant from the Eureka Mine described
in the book “Flotation Plant Optimization,” whose main
mineral components are Chalcopyrite (Cp), Galena (Ga),
Sphalerite (Sp), Pyrite (Py), and Nonsulfur gangue (NSG)
(Greet 2010). The original design was modified considering
a lower grade mineral and with lower recoveries than those
reported by Greet (2010), so that it better represents the
current reality.
The feed mass flowrates and grades, as well as the stage
recoveries, are shown in Table 1, and Figure 1 shows the cir-
cuit. The circuit considered is the original one reported by
Greet (2010), but a second cleaner stage has been included,
given the reduction in recoveries considered in this case
study.
The process is the traditional one, consisting of three
flotation circuits, the first to recover Cp using a rougher
stage and two cleaners. The tail of the first circuit is fed
Table 1. Minerals and stage recoveries in the Eureka concentrator (Modified from Greet 2010)
Name Chalcopyrite Galena Sphalerite Pyrite Nonsulfur
Gangue
Identification Formula CuFeS₂ PbS ZnS FeS₂ —
Symbol Cp Ga Sp Py NSG
Feed tonne/h 0.98 3.52 13.73 35.12 66.65
composition,% 0.82 2.93 11.44 29.27 55.54
Stages Recoveries
Copper circuit Rougher 0.54 0.07 0.02 0.01 0.01
Cleaner 1 0.76 0.13 0.31 0.07 0.44
Cleaner 2 0.76 0.13 0.31 0.07 0.44
Nickel circuit Rougher 0.63 0.85 0.65 0.41 0.22
Cleaner 1 0.48 0.52 0.32 0.28 0.64
Cleaner 2 0.39 0.35 0.16 0.13 0.20
Cleaner 3 0.45 0.30 0.19 0.08 0.12
Scavenger 0.22 0.47 0.19 0.07 0.01
Sulfur Circuit Rougher 0.57 0.59 0.83 0.14 0.13
Cleaner 1 0.65 0.60 0.77 0.42 0.29
Cleaner 2 0.64 0.67 0.69 0.55 0.36
Scavenger 0.22 0.27 0.43 0.05 0.04
Figure 1. Eureka plant flotation circuit. Modified flowsheet from Greet (2010) with the addition of a second cleaning stage in
the copper circuit