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Presentation Overview
Introductio Introd uction n - The applica application tion at KUC Introd Int roduct uction ion - Sup SuperC erCell ell™ ™ Metallurgical Test Design WEMCO Metallurgical Results Conclusions
• Achieve design recovery and grade • Accelerated delivery
FLSM
• Demonstrate SuperCell™ in operation • Validate hydrodynamic and metallurgical scale-up
Scope
• Test cell installed on a “try before buy” basis • 9 month testing program with 3 mechanisms • KUC purchased additional cell for continuous production
Design/Construct Production Cell
Start-up Production Cell WEMCO
Start-up Test Cell Dorr-Oliver
Retro-fit Test Cell XCELL
Final Configuration
Sep 2008
Jan 2009
Apr 2009
Sep 2009
Dec 2009 6
FLSmidth Flotation Machines 8.6m
6m
WEMCO
XCELL
Dorr-Oliver
300
350
330 7
FLSmidth SuperCell™ Mechanisms
Dorr-Oliver WEMCO
XCELL
8
W EMCO Hydr odyn am ic Testing •
Machine Parameters
Submergence
Rotor Speed
Rotor Engagement
•
Measured Response
Machine Power
Aeration Rate
Pulp Circulation
9
Metallurgical Testing Program •
4-5 test campaigns on each mechanism
•
Same machine parameters for each campaign
•
Difference between campaigns related to changes in feed – Regrind size – Flowrate – Ore type
•
Pilot testing campaign in parallel to full-scale
•
Lab flotation kinetics tests for each campaign
10
Pilot Scale Testing •
1.5m3 pilot cell operated in parallel to SuperCell™ for scale-up
•
Evaluated residence time effect on parameters
•
WEMCO, Dorr-Oliver and XCELL pilot cells operated in parallel
•
Facilitated comparison between full-scale mechanisms
11
Metallur gical Test Matrix - W EMCO Machine Parameters
Froth Depth
Rotor Speed
Measured Response
Feed Assay
Concentrate Assay
Tailings Assay
Aeration Rate
Absorbed Power
Feed rate
Solids Content 12
Me tallur gical Test Ma tr ix Dorr-Oliver/X CE L L Machine Parameters
Froth Depth
Rotor Speed
Air Rate
Measured Response
Feed Assay
Concentrate Assay
Tailings Assay
Aeration Rate
Absorbed Power
Feed rate
Solids Content 13
W em co Supercell™ exceeded perform ance guarantee 100.0 95.0 90.0 y r e v o c e R u C
1s t Campaign
85.0 80.0
2nd Campaign
75.0
3rd Campaign
70.0 65.0
4th Campaign
60.0
5th Campaign
55.0 50.0 10.0
20.0
30.0
40.0
Cu Grade 14
2 nd Cam paign: Sim ilar r esults 100.0 95.0 90.0 y r e v o c e R u C
1s t Campaign
85.0 80.0
2nd Campaign
75.0
3rd Campaign
70.0 65.0
4th Campaign
60.0
5th Campaign
55.0 50.0 10.0
20.0
30.0
40.0
Cu Grade 15
3 r d Cam paign: Regr ind Mill off 100.0 95.0 90.0 y r e v o c e R u C
1s t Campaign
85.0 80.0
2nd Campaign
75.0
3rd Campaign
70.0 65.0
4th Campaign
60.0
5th Campaign
55.0 50.0 10.0
20.0
30.0
40.0
Cu Grade 16
4 th Cam paign: Low feed grade High feed ra te 100.0 95.0 90.0 y r e v o c e R u C
1s t Campaign
85.0 80.0
2nd Campaign
75.0
3rd Campaign
70.0 65.0
4th Campaign
60.0
5th Campaign
55.0 50.0 10.0
20.0
30.0
40.0
Cu Grade 17
5 th cam paign: Response on Skarn o re 100.0 95.0 90.0 y r e v o c e R u C
1s t Campaign
85.0 80.0
2nd Campaign
75.0
3rd Campaign
70.0 65.0
4th Campaign
60.0
5th Campaign
55.0 50.0 10.0
20.0
30.0
40.0
Cu Grade 18
Mo ly Recovery: a function of pow er Specific Power 100.0 95.0 y r e v o c e R o M
90.0
1s t Campaign 2nd Campaign 4th Campaign
85.0 80.0 75.0 70.0 65.0 60.0 0.50
0.60
0.70
0.80
0.90
1.00
Specific Power, kW/m3 19
Developed Respon se Sur faces •
All campaign results were statistically significant
•
Developed response surfaces for pilot vs full-scale
•
Enables scale-up to be determined SuperCell
Pilot Cell
Feed Flow
3231 gpm (22.1 min RT)
49.7 gpm (7.2 min RT)
Ore Type
Type 2
Type 2
Cu Feed Grade
10 %
10 %
20
Mo R ecovery: a function of pow er
Power
Mo Recovery
•
Can achieve design recovery at 0.8kW/m3
•
Higher energy will improve recovery further 21
Similar respon se w ith Cu Power
Cu Recovery
Feed Flow
3231 gpm (22.1 min RT)
Ore Type
Type 2
Cu Feed Grade
10 % 22
Able to qu an tify m etallur gical tr ade -off betwee n re covery and grad e SuperCell
Pilot Cell
Operations able to optimize operating conditions
23
Conclusions •
SuperCell exceeded design performance
•
DoE determined optimum operating conditions
•
Recovery improves with higher specific power input
•
Success factors for plant experimental testwork: – Circuit designed for plant stability and sampling – Robust experimental design – Focus on quality of sampling and prep
•
FLSM - foundation for new scale-up method based on pilot vs fullscale response surface
