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Andrzej Luszczkiewicz, Tomasz Chmielewski Wroclaw University of Technology, Wroclaw, Poland
Andrzej Konieczny KGHM „Polish Copper”, Lubin, Poland
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Main copper producers
KGHM (Poland)
Aitik (Bolinden) Highland Valley
(Teck/Cominco/Billiton)
Bingham (Rio)
Morenci (Phelps D)
Caridad (Grupo M.)
Kidd Ck. (Falconbridge)
Palabora (Rio/Anglo)
Nchanga (ZCCM/Anglo)
Norilsk
Erdenet
Dexing Sharcheshmeh
Batu Hijau (Newmont)
Grasberg (Rio/F’port)
OK Tedi (BHP)
Mt Isa (MIM)
Olympic Dam (WMC)
Chuquicamata (Codelco)
Escondida (BHP/Rio)
Los Pelambres (Antofagasta)
El Teniente (Codelco)
Neves Corvo (ex Rio)
Collahuasi (Anglo/F’bridge)
Cu mine production (2011) – 16.0 mln t KGHM „Polish Copper” (2011) – 571 kT
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
KGHM deposit’s location
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
KGHM Lubin-Glogow Mining Area Deposit
UK
F
D
I
PL KGHM
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Generalized
lithostratigraphic
section
of the basal Zechstein
and the position of the
Kupferschiefer ore
series
Geology of the Lubin- -Glogow Basin
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Typical Cu-Ag section containing grey sandstone (A), boundary dolomite
(B), dolomitic shale (C), black shale (D) and dolomite (E).
Cross section of sandstone - shale - dolomite
Dolomite ore
Shale ore
Sandstone ore
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Current limiting conditions in Polish copper industry
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings …. Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Difficulties in the flotation processes caused by the presence of the black shale in the processing plant
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
How to elevate both the metals recovery
and the concentrate grade?
enhance mechanical comminution as a method of liberation
intensify froth flotation as a method of beneficiation
limit of features has been reached
Current flotation parameters
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
New approach required
superior chemical alteration of the ore,
by-product or concentrate by means
of inexpensive and environmentally safe medium – sulphuric acid
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
FEED
(middlings from cleaning flotation)
LEACHING WITH
H2SO4 (~70%)
CLEANING
FLOTATION
H2SO4
from smelter
Final concentrate
Final
tailings
General concept of hybrid FLF process of ore beneficiation
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Leaching of carbonate intergrowths in H2SO4
Leaching time
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Principle:
Chemical reaction of H2SO4 with carbonates of calcium
(CaCO3) and magnesium (MgCO3) - major components of
intergrowth with metals bearing minerals:
CaCO3 + H2SO4 + H2O = CaSO4·2H2O + CO2
MgCO3 + H2SO4 = MgSO4 + CO2
Chemistry of acidic carbonate leaching
Decomposition of acid-consuming components
Liberation of disseminated sulphide particles
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Beneficial role of CO2 in non-oxidative leaching
CO2 creates the non-oxidative atmosphere in
the leaching slurry and prevents the
digestion of sulphide minerals.
The redox potential is to low to leach out
copper and other metals in sulphidic form
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Flowsheet of laboratory procedure (both unleached and leached with H2SO4)
Sample of commercial product from the plant
Slurry mixing and batch test samples preparation
Determination of maximum H2SO4 consumption for
carbonates decomposition
Leaching with H2SO4 with 70% carbonate decomposition
Flotation for gypsum removing
Fractional flotation tailings
midlings C-3 C-2 C-1
Refe
rence e
xperim
ents
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Flowsheet of pilot plant tests of chemical modification and subsequent flotation of the feed in a continuous system
with indicated points of sampling
Repulpator
H2SO4
Reactor 3
Reactor 1
Reactor 2
Concentrate
Feed to flotation after leaching
K
De-gypsing flotation
Scavenger flot.Cleaning flotation
Tailing
Feed to leachingFeed to comparative
experiment(without leaching)
Feed (middlings - by-product from 1st cleaning operation)
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
FEED (middlings from cleaning flotation)
tailings
CaSO4·2H2O, MgSO4
CO2 To the atmosphere
LEACHING
concentrate
ΔβCu= +3.5%, ΔεCu= +4.0%
ΔβAg= +250 g/t, ΔεAg= +3.5%
H2SO4, from smelter
CLEANING
FLOTATION
Pilot plant tests - setup
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Commercial application
Final tailingsFinal
concentrate
regrindHC
C M
M
C
2nd cleaning
Middlings cleaning
1st cleaning
Rougher-scavenger
Rougher flotation
BM
C
Feed from grinding
circuit 85% - 45mm
M
HC
T
Flowsheet of the Polkowice Concentrator
Hard-to-tread middlings
was selected to leaching
and flotation operation
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Final tailingsFinal
concentrate
regrindHC
C M
M
C
2nd cleaning
Middlings cleaning
1st cleaning
Rougher-scavenger
Rougher flotation
BM
C
Feed from grinding
circuit 85% - 45mm
M
HC
T
Analysis of industrial process at the Polkowice Concentrator. Flowsheet of the 1st and 2nd technological line
C - concentrate BM - ball mill
M - middlings HC - hydrocyclone
T - tailing
Final
concentrate
1st cleaning
Rougher-scavenger
C
BM
C
M
C1
T
C
HC
Feed from grinding
circuit 85% - 45mm
Scavenger de-gypsing
Rougher flotation
Leaching
2nd cleaning
C3
T
regrind
De-gypsing flotation
Final tailings
M2C2
T1
M1
flotation-leaching-flotation (FLF) node
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
C - concentrate BM - ball mill
M - middlings HC - hydrocyclone
T - tailing sampling points
Final
concentrate
1st cleaning
Rougher-scavenger
C
BM
C
M
C1
T
C
HC
Feed from grinding
circuit 85% - 45mm
Scavenger de-gypsing
Rougher flotation
Leaching
2nd cleaning
C3
T
regrind
De-gypsing flotation
Final tailings
M2C2
T1
M1
Analysis of industrial process at the Polkowice Concentrator. Flowsheet of the 1st technological line with chemical treatment of middlings (by-product
from I cleaning) with sampling points indicated
Product samples selected from
technological FLF node
C-1 Tailing
Fractional flotation
C-2 C-3 C- n .
Fractions of concentrate
. . .
Feed to leaching
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
C - concentrate BM - ball mill
M - middlings HC - hydrocyclone
T - tailing sampling points
Final
concentrate
1st cleaning
Rougher-scavenger
C
BM
C
M
C1
T
C
HC
Feed from grinding
circuit 85% - 45mm
Scavenger de-gypsing
Rougher flotation
Leaching
2nd cleaning
C3
T
regrind
De-gypsing flotation
Final tailings
M2C2
T1
M1
Product samples selected from
technological FLF node
C-1 Tailing
Fractional flotation
C-2 C-3 C- n .
Fractions of concentrate
. . .
Analysis of industrial process at the Polkowice Concentrator. Flowsheet of the 1st technological line with chemical treatment of middlings (by-product
from I cleaning) with sampling points indicated
Leached products
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Grade-recovery curves of flotation analysis of industrial products samples selected
from flotation-leaching-flotation (FLF) node
0
5
10
15
20
25
30
35
0 20 40 60 80 100
Co
pp
er
co
nte
nt
in
co
nce
ntr
ate
, %
Copper recovery, %
Flot. feed to leaching Rw=26%
Flot. feed to leaching Rw=86%
Flot. leached products Rw=26%
Flot. leached products Rw=86%
Rw – degree of
carbonates
decomposition
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Fuerstenau recovery-recovery curves of flotation analysis of industrial products samples selected from FLF node
0
20
40
60
80
100
0 20 40 60 80 100
Reco
very
of
barr
en
part
of
ore
in
ta
ilin
g, %
Copper recovery in concentrate, %
Lack of upgrading
Flot. feed to leaching Rw=26%
Flot. feed to leaching Rw=86%
Flot. leached products Rw=26%
Flot. leached products Rw=86%
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Final tailingsFinal
concentrate
regrindHC
C M
M
C
2nd cleaning
Middlings cleaning
1st cleaning
Rougher-scavenger
Rougher flotation
BM
C
Feed from grinding
circuit 85% - 45mm
M
HC
T
Comparison of industrial process on 1st and 2nd technological line at the Polkowice Concentrator
C - concentrate BM - ball mill
M - middlings HC - hydrocyclone
T - tailing
Final
concentrate
1st cleaning
Rougher-scavenger
C
BM
C
M
C1
T
C
HC
Feed from grinding
circuit 85% - 45mm
Scavenger de-gypsing
Rougher flotation
Leaching
2nd cleaning
C3
T
regrind
De-gypsing flotation
Final tailings
M2C2
T1
M1
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Comparison of industrial process on 1st and 2nd technological line at the Polkowice Concentrator
84
85
86
87
88
89
90
91
92
93
94
95
4 5 6 7 8 9
Co
pp
er
reco
very
, %
Weight percent
Line 2 (standard process)
Line 1 (process with middlings leaching)
concentrate
ΔβCu=+0.6%, ΔεCu=+3.4%
ΔβAg=+150 g/t, ΔεAg=+2.9%
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
The application of non-oxidative leaching
of carbonates from copper concentrate
and middlings with sulfuric acid
in the flotation circuit system enables
a significant increase of recovery and
concentrate grade to the level which can
not be achieved by introduction
of new grinding and flotation equipment
or by modification
of existing flotation circuits.
SUMMARY
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings …. Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
Remarkable increase in flotation recovery and concentrate grade was observed for Cu and Ag,
No need to change the existing flotation circuits,
Effective utilization of H2SO4,
No hazardous effect of leaching products.
SUMMARY
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….
A new hybrid FLF process involving sulphuric acid treatment
of flotation middlings combined with a subsequent flotation in
the commercial scale resulted in a significant increase of
process selectivity.
Originally designed methodology, referred as flotation
analysis, was elaborated for evaluation of sampled material
in laboratory experiments.
A beneficial effect of the chemical pre-treatment of the
flotation middlings on flotation selectivity was shown by
means of floatability curves for unleached and leached
feeds.
It was found that the application of the FLF process on the
industrial scale resulted in an increase of copper recovery by
3.4%.
CONCLUSIONS
Luszczkiewicz A., Chmielewski T., Konieczny A., Leaching and Flotation of Concentrate and Middlings ….