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Practical understanding and application of the effect of dual outlet operation

on industrial flash flotation cell hydrodynamics

Conference Paper · November 2015

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PRACTICAL UNDERSTANDING AND APPLICATION OF
THE EFFECT OF DUAL OUTLET OPERATION ON
INDUSTRIAL FLASH FLOTATION CELL
HYDRODYNAMICS
Dr Bianca Newcombe1; Joe Seppelt2; Brandon Akerstrom3

Abstract
Flash flotation cell surveys have been taken on three separate circuits involving both stream
sampling and axial profiling. All three circuits receive a copper-gold ore feed material. The
objective of the work was to gain an understanding of the role the dual-outlet line plays in flash
flotation cell operation and determine control limits for normal operation of the machine,
targeting an optimised concentrate size distribution and increased unit recovery. Surveys with
the dual outlet open at either 75, 50 or 25 % and with the dual outlet fully closed have been
taken and compared, highlighting the crucial role the dual outlet plays in influencing the
internal hydrodynamics of the industrial machine. When the dual outlet is in operation the
classifier functionality of the machine is clearly evident in axial profile data. When the dual
outlet is too restricted or closed the classifier function is lost in the upper part of cell resulting
in a low per-centage solids region in the top 1 – 1.5 m of cell below the froth interface; and a
lower grade concentrate which contains a higher proportion of very fine (-20 m) material.
Recommendations for operations utilising flash flotation are presented and discussed.

1
Corresponding Author;
Director, OptiFroth Solutions Pty Ltd
biancanewcombe@yahoo.com.au
2
Production & Metallurgy Superintendent, Cadia Valley Operations (Newcrest Mining Ltd)
joe.seppelt@newcrest.com.au
3
Senior Project Metallurgist, Cadia Valley Operations (Newcrest Mining Ltd)
brandon.akerstrom@newcrest.com.au
Introduction
Flash flotation cells are a common means of extracting valuable material from within the grinding
circuit and are designed to process and upgrade cyclone underflow material. Sulphide minerals and
precious metals may accumulate in the circulating load of milling circuits as a function of their
specific gravity and without removal via a process such as flash flotation may be ground to very fine
sizes (slimes) before they can exit via the cyclone overflow stream. The difficulties in recovering
very fine mineral particles via ‘conventional’ flotation routes as well as the reduced capital and
operating costs of a flash flotation machine make it an attractive unit operation in modern
concentrators. (Yoon, 2000; McIvor and Finch, 1991; Sandström and Jönsson, 1988; Trahar, 1981;
Trahar and Warren, 1976). There are several significant differences between this type of flotation
machine and a ‘conventional’ flotation machine, most notably:
 Size distribution of particles in the feed stream is very coarse and may contain small rocks;
 Feed slurry % solids is very high, often over 65 % solids;
 Reagent contact is limited as there are no dedicated conditioning stages prior to flash flotation;
 Residence time is very short, typically between 2 and 3 minutes;
 There is a large amount of material in the feed stream which bypasses the mixing zone of the
cell and goes directly to the bottom tailings discharge (secondary mill feed).

In order to be able to upgrade the feed material into a concentrate stream, the underlying principles
of operation of the machine are significantly different to that of other flotation devices. Flash
flotation machines are required to operate as both a flotation device AND a classification device
(Newcombe, 2014a). In order to achieve good recovery of valuable mineral to the concentrate
launder the internal hydrodynamics of the machine must be such to enable sufficient mixing of slurry
to give all floatable particles the opportunity for flotation recovery; allow heavy particles to settle to
the tailings discharge; whilst concurrently providing a quiescent/settling region where flotation can
be optimized. To achieve this there are several key design elements in place:
 A conical discharge (tailings) outlet, which, in combination with the angle of feed addition,
provide a by-pass mechanism to allow very large particles (small rocks) to go directly to
tails and minimize damage to internal mechanical parts.
 The inner cone is present to drive mineral-rich bubbles up and out into the concentrate
launder.
 A dual outlet line which provides a secondary tailings stream and will be shown in this paper
to influence the internal flow regime of the cell.

These design elements are shown graphically in Figure 1.

P a g e 2 | 29
 Air addition via
impeller shaft

Froth
Zone
Concentrate
Feed Settling
SettlingZone
/ Quiescent Zone
(Cyclone
Underflow)
Middle discharge / Dual outlet
(optional)
Mixing Zone
Very coarse
material by-pass

Tails from
mixing zone

Tailings
(Return to grinding circuit)
NOT TO SCALE

Figure 1 – Schematic of a flash flotation cell (Newcombe, 2014b)

The dual outlet is located in the top region of the cell (inner cone) and due to its location within the
quiescent zone (flotation zone) of the cell provides the operator with valuable information as to the
effectiveness of both the internal classification function of the cell and the characteristics of the
slurry in the flotation region, both of which influence the cells recovery of valuable material.
Managing the slurry per cent solids in this region is key to achieving optimal flotation conditions
and it is always recommended that a density gauge be used on the dual outlet line. Management of
the flow is also important as this stream is required to integrate with other streams returning to the
ball mill, flow meters make control more effective and can often highlight issues occurring within
the cell well before operations staff notice a change in the water balance and hence mill performance.
The efficient classification that occurs within flash flotation machines also means the slurry removed
via the dual outlet line consists of a lower density finer size distribution, which is typically returned
to the mill discharge (cyclone feed) hopper, preventing this material from being unnecessarily
reground and improving overall circuit water efficiency.

The dual outlet line on modern flash flotation cells was originally developed as a means of
providing improved level control for the flash flotation cell. Prior to the development of the
dual discharge system, the pinch sleeve on the tailings discharge line was the sole means of
level control for the cell, which did not provide sufficient stability for good operation where
the feed to the machine was not stable. The dual outlet line, when equipped with a control
valve (usually a pinch valve) was subsequently intended to perform the primary level control
function, with the larger tailings valve taking a secondary role in level control (Bourke and
Kallioinen, 1996). Ongoing issues with stability in flash flotation cells resulted in this
operating philosophy being further refined, with current operating recommendations for flash

P a g e 3 | 29
flotation cells having the dual outlet line being solely responsible for level control, and the
bottom tailings line, equipped with a density gauge, being responsible for density (or water)
management via integration with feed water addition control. The practical reality of operating
industrial flash flotation cells has often resulted in the dual outlet line being either manually
controlled or decommissioned entirely, with a great deal of uncertainty in many operations as
to what its true function is. This paper intends to provide the operator with an insight into the
effect of the dual tailings system on overall machine hydrodynamics and hence metallurgical
performance. The function of the dual outlet line has been tested by firstly operating the flash
flotation cell with this line either fully closed, or at 50 % open, with confirmation work being
performed with the valve at 25, 50 and 75 % open. The results of these surveys are presented
and discussed in subsequent sections. The underlying issue of process control is not considered
in this paper as it warrants its own detailed investigation and is often complicated by the
necessary integration of grinding circuit control systems, which will be unique for each
individual circuit.

Surveys have been conducted at Newcrests Cadia Valley Operation (CVO), which treats a
copper-gold ore. These surveys involved both flash flotation / cyclone sampling as well as
axial profiling of the flash flotation cell. Axial profiling of flash flotation cells (taking samples
with increasing depth into the cell at a single axial location) has been previously shown to be
a highly useful tool in establishing flash flotation cell performance (Newcombe, 2013;
Newcombe et al., 2013a). The recommendation for accurate hydrodynamic characterisation
of a flotation cell is to take measurements at a number of different positions across the cell
and at varying depths incorporating measurements of gas dispersion properties, residence time
distributions and slurry properties such as per cent solids, size distribution and grade
(Newcombe, 2014a; Dahlke et al., 2005; Yianatos et al., 2005; Lelinski et al., 2002; Yianatos
et al., 2001; Mehrotra and Saxena, 1983). However this is not always practically achievable
and in this case, access to the flotation zone is limited by an inner cone, which allows limited
access to the operating cell underneath. The location of the sample point for each of the cells
studied is clearly indicated and discussed in the Axial Profiling section of this paper. These
sample points are generally away from the feed addition point.

A unique method of analysing the data obtained from within operating flash flotation cells has
been previously developed by the lead author (Newcombe, 2014a and 2013) and has been
called ‘profile normalisation’. This method determines the valuable mineral concentration
profile where classification / segregation of particles is occurring within a flotation machine.
Analysis using this method highlights the critical size for flotation recovery under the operating
condition studied and provides a graphical way of quickly comparing size based performance
of valuable minerals under different operating conditions where classification is occurring
counter-current to flotation. An example of this calculation method is presented in Figure 2,

P a g e 4 | 29
this data comes from a refractory gold plant where pyrite is the target mineral for flotation
(Newcombe, 2013). The flash flotation cell contributed approximately half the valuable
material to the final concentrate stream under the conditions represented by Figure 2.

2.50

2.00
S % retained X slurry per cent solids

+850
+600 / -850

1.50 +425 / -600

+300 / -425
+212 / -300
+150 / -212
1.00 +106 / -150
+75 / -106
+53 / -75
+38 / -53
0.50
-38

0.00
30 50 70 90 110 130 150
Cell depth (cm from pulp froth interface)

Figure 2 - Normalised sulphur concentration for each size class with increasing depth into the
flash cell (relative to the mixing zone 150 cm) (Newcombe, 2013)

To perform the data analysis represented by Figure 2, the distribution of the target element (S)
by size at each cell depth measured during axial profiling of the cell is used in conjunction with
the measured slurry % solids at the associated depth. The calculation involves multiplying the
% retained of an element for each size class by the % solids of the slurry at the same depth.
This calculation is repeated for all depths studied down to the ‘mixing zone’ of the cell to
produce a matrix of results. Data is then normalised against the mixing zone data by simply
dividing the results of each size and depth in the matrix by the result for the mixing zone (the
mixing zone is divided by itself and will therefore be 1 for all size classes). The left-hand y-
axis (x = 30 cm) on this graph represents the region just below the pulp-froth interface, whilst
the right-hand y-axis (x = 150 cm) represents the region close to the impeller where good
mixing occurs. As you move along the x-axis from right to left you are moving from the
impeller region, through the quiescent / settling zone towards the froth. This method of analysis
has proven to be successful in understanding how operating changes affect the internal
behaviour of the cell and ultimately its recovery performance. Inspection of Figure 2 highlights
some key information for the system being studied in that case:

P a g e 5 | 29
  Particles in the +150 / -212 m size class are the coarsest particles to maintain a value
around unity and will be termed the ‘critical’ size class for flotation in this system;
 Particles coarser than the critical size class decline in concentration with increasing
coarseness and proximity to the froth interface due to mechanisms causing drop back
or detachment. The concentration of pyrite particles decreases with increasing size as
the froth interface is approached for all size classes coarser than 212 m, demonstrating
the intensifying effect of the ‘downward’ forces as particle size is increased (these
include forces such as gravity and drag and the effect of turbulence) (Crawford and
Ralston, 1988). Particles coarser than 600 m are effectively absent from the pulp at
60 cm below the froth interface;
 Particles finer than the critical size class either approximate unity or increase in value
as the froth is approached. ‘Upward’ forces associated with recovery by true flotation
such as chemical attachment and buoyancy become dominant with particles finer than
212 m.
The method of profile normalisation will be used in this paper to assist in the understanding of
data gathered from within the flash flotation cells at CVO in terms of their internal
hydrodynamic performance.

Experimental

Feed Material
There are two ore sources that feed the concentrator at CVO:
1. the Cadia East mine, which is a panel caving operation, and
2. the Ridgeway mine, which is a block caving operation.

Mineralisation at Cadia East can be divided into two broad overlapping zones; an upper,
copper-rich, disseminated zone and, a deeper gold-rich sheeted vein zone proximal to the
interpreted monzonite. The upper, copper-rich portion of the deposit is stratigraphically
controlled within the upper volcaniclastic unit. Sulphide mineralisation is predominantly
chalcopyrite, with lesser bornite and pyrite. Gold grade increases with depth as disseminated
chalcopyrite levels decrease and disseminated and vein bornite levels increase. The deeper
gold-rich zone is centred on a core of steeply dipping sheeted quartz-calcite-bornite-
chalcopyrite veins. The highest gold grades are associated with bornite-rich
veins. Molybdenite forms a mineralised blanket above and to the east of the higher grade gold
envelope. Cadia East gold ore is primarily in the form of native gold and electrum, in a ratio of
approximately 3.5 : 1.

P a g e 6 | 29
The mineralisation at Ridgeway consists of copper-gold quartz veining zoned about a small
(50-100 metre diameter) composite plug of monzonite to quartz monzonite (termed the
Ridgeway Intrusive Complex; RIC). The plug has intruded relatively flat-lying volcaniclastics
of the mid to late Ordovician Forest Reefs Volcanics (FRV) and the conformably underlying
Weemalla Formation. The identified mineralised system (inside a 0.2g/t Au shell) extends up
to 500 metres E-W, 250 metres N-S and 1100 metres vertically. The most strongly developed
quartz stockwork veining and alteration, and the highest copper and gold grades, occur
immediately adjacent to the monzonite. The intensity of the veining and alteration decreases
both outward and inward from the monzonite porphyry margin. The ore minerals are native
gold, bornite, chalcopyrite and covellite, occurring predominately within veins, but also as
disseminations (Wilson et al., 2003).

Ore Treatment Facility

Cadia Valley Operations consists of two processing plants identified as Concentrator 1 and
Concentrator 2. Concentrator 1 treats mainly Cadia East ore but is currently supplemented by
Ridgeway ore while the Cadia East mine ramps up to full production. A simplified version of
the primary grinding circuit is presented in Figure 3a, to indicate the location and association
of the flash flotation cells with the surrounding classification and comminution equipment.
Trommel undersize from the SAG discharge is split into three separate trains, each with a ball
mill in closed circuit with a dedicated cyclone pack. A portion of the underflow from each
cyclone cluster is split to feed a single flash flotation unit per train (Outotec SK 1200 Skim Air
Flotation Cell). Combined flash flotation concentrate from the Train 1 and Train 2 units feeds
two gravity concentrators which operate in series (Falcon and Knelson). The flash flotation
concentrate produced from the Train 3 unit reports to a dedicated Falcon concentrator. Feed to
each flash flotation cell is roughly controlled by a fixed orifice. Currently only the Train 3 unit
has the capacity to operate the mid-point take off (dual outlet), when in operation this stream
reports back to the cyclone feed hopper.

Concentrator 2 treats ore entirely derived from the Ridgeway underground mine. The primary
grinding circuit is a typical SAG mill and closed circuit ball mill arrangement (Figure 3b).
Cyclone underflow is split between a single flash flotation unit (Outotec SK 1200 Skim Air
Flotation Cell), two pre-screened gravity concentrators and ball mill feed. Feed to the flash
flotation cell is controlled by a static orifice with the head above the orifice dictated by a fixed
weir. Flash flotation concentrate reports to a single Falcon gravity concentrator. Mass-pull rate
of the concentrate of this flash cell can be controlled using an in-situ froth camera which records
real time bubble velocity over the lip. This enables the operator to set the desired froth velocity
which in turn adjusts the air and level set points in the cell to achieve the set velocity.

Flash cells in Figures 3a and 3b have been labelled according to their reference number
throughout this document.

P a g e 7 | 29
 T1 Roughers T2 Roughers T3 Roughers

Flash Cell #2

Flash Cell #1

Gravity
concentrator/s
x1

SAG Mill Gravity

Ball Mills concentrator/s
x1

Gravity
concentrator/s
x2

Figure 3a - Concentrator 1 primary grinding circuit – indicating the location of Flash cells #1
and #2
Tertiary
Grinding

Flash Cell #3

Grav ity Grav ity

concentrator/s concentrator/s
x1 x1

Grav ity
SAG Mill
concentrator/s
Ball Mills
x1

Figure 3b - Concentrator 2 primary grinding circuit – Flash flotation Cell #3

P a g e 8 | 29
Surveys
Data collected for this work involved both conventional style plant sampling of streams
entering and exiting the flash flotation circuit to allow the flows into and out of the flash
flotation cell to be estimated on a size by assay basis; and axial profiling from within the
operating cell to establish the variation of slurry composition with a change in axial height.

Plant survey work

To establish the baseline operating conditions of each flash flotation circuit, surveys have been
taken. These surveys involved taking samples of the CUF, dual outlet line, and flash flotation
cell concentrate (both inner and outer launders). Concentrates were taken as timed lip samples
to determine approximate concentrate tonnages. Surveys were of at least 2 ½ hours duration
with a 10 minute sample time interval. All slurry samples were submitted and analysed for wet
and dry weights for % solids determination, head assay analysis and stream solids SG to allow
volumetric flows to be determined. Samples were then sized and assayed for Au, Cu, Fe, S
and F.

Axial Profiling
Axial profiles have been taken of the operating cell in conjunction with the flash circuit surveys.
Slurry samples were taken at increasing depths within the operating cell using the JK Gas Hold-
Up Probe. This device was selected for use as the sample chamber completely opens at both
ends, allowing slurry to flow freely through the chamber until it is closed. Prior work with
standard spring loaded samplers showed that they often became jammed when very coarse
material was present in the slurry, this issue has been resolved by using a gas hold-up probe.
Further details on this device are available on-line (JKTech, 2011). The increment of sampling
is dictated by the length of the sample pot being used, which in this case was 50 cm. Samples
were taken with the top of the sample chamber at 50, 100, 150 and 200 cm depth below the
froth interface. Taking the highest sample at 50 cm below the froth interface allowed sufficient
depth to ensure that any fluctuations in cells depth caused by the process control system would
not result in froth contamination of the sample. The froth depth during the survey period was
approximately 75 mm, therefore the top of sample pot was approximately 57.5 cm below the
lip of the cell. As samples were taken using the gas hold-up (ɛg) sampler, an average gas hold-
up was also able to be determined at each depth within the cell. The protocol when using this
apparatus was to lower it to the required depth with the sample chamber open at both ends to
allow slurry to flow through for 10 seconds, then close both ends of the sample pot to seal the
slurry sample (and gas) inside. As the sample pot would have to be raised through the layer of
froth to be removed from the cell, the outside was rinsed with process water prior to the sample
being released into a bucket. This process was repeated up to 15 times at each required depth
to produce a single sample of sufficient mass for each depth to allow for all subsequent analysis.
The volumetric difference between the amount of slurry obtained and the total volume of the

P a g e 9 | 29
sample pot allows an estimation of gas-hold-up to be made for each depth in the cell.

As with the majority of industrial flash flotation cells, the inner-cone of the flash cell does not
allow for multiple access sites for axial profiling of the operating cell below, however there is
sufficient space at certain points between the launder lip and inner-cone to manoeuvre the probe
into place for sampling. The location of the sample points relative to the feed inlet for each
cell surveyed are shown on Figure 4, all sample points are located near the cell wall and away
from where the feed is added. Note that flash flotation cells have a centralised tailings outlet
underneath the stator base plate, so proximity to the bottom tailings outlet is equal for the full
circumference of the cell.

Cell #1 sample location

Cell #2 sample location

Cell #3 sample
location

Feed Inlet

Figure 4 – Plan view of the location of sampling

All slurry samples were submitted and analysed for wet and dry weights for % solids
determination, head assay analysis and stream solids SG to allow volumetric flows to be
determined. Samples were then sized and assayed for Au, Cu, Fe, S and F.

Sizing
The procedure for sizing each of the samples involved wet screening at 20 m; drying the
screen products; dry screening the +20 m material from 20 m upwards following the √2
series from 38 m upward to a maximum size of 600 m. The -20 m material from the dry
screening was then combined with that obtained from the wet screening.

P a g e 10 | 29
Results and Discussion
Processing facilities at CVO incorporate 4 separate grinding circuits, each of which has its own
flash flotation circuit. Three of the four flash flotation cells do not use the dual outlet line, in
fact the pipework has been completely removed on two of the four units and the discharge port
from the cell blanked; these cells will be referred to as cells #2 and #3 throughout this report.
The other cell (cell #1), which is also the newest, has an active dual outlet line, and the normal
state of operation of this line has been with the pinch valve closed at 50 %. Prior to this work
the dual outlet line was not incorporated into the process control system and was manually
fixed at 50 %.

Flash Flotation Cell #1

Two profiles were initially taken of flash flotation cell #1:
1. with the dual outlet line open at 50 %, representative of normal operation; and
2. with the dual outlet line closed.
These profiles were conducted to determine how the operation of the dual outlet line affects
the internal hydrodynamics of the machine, with particular focus on the cells classification
function. A second set of confirmation profiles were subsequently taken of this cell with the
dual outlet line at 25, 50 and 75 % open.

Axial Profile Data – Survey 1

Summary data is presented in Table 1 for the dual outlet line open at 50 % (#1) and with the
dual outlet line closed (#2). When the dual outlet is open, segregation of solids is occurring as
expected within the top part of the cell, with both the average % solids and particle size
increasing with increasing cell depth. Gas hold-up values are very low, but in-line with
measurements taken on other operating flash flotation cells (Newcombe et al., 2013a). When
the dual outlet is closed a change appears to happen with the internal flow regime of the cell
and solids segregation is no longer occurring above a depth of 150 cm. The % solids in the
upper region of the cell is also considerably lower when the dual outlet is turned off, which
will hamper the cells ability to recover coarser particles (Newcombe et al., 2012 and 2013b).
The data obtained for survey 1, with the dual outlet open, is similar to what has been previously
observed in other operating flash flotation cells, with a difference of greater than 30 % solids
being observed over the 2 m of cell depth studied.

In both cases the lowest sample has not yet reached the ‘mixing zone’ of the cell. This is
generally determined by the values of % solids and solids size distribution being the same (or
very similar) for 2 consecutive measurements.

P a g e 11 | 29
 50 cm 100 cm 150 cm 200 cm
% Solids #1 32.0 56.0 60.8 62.7
% Solids #2 16.0 16.7 17.0 44.9
Solids P80 #1 197 334 386 419
Solids P80 #2 85 92 94 282
Gas Hold-up % #1 5.5 2.0 2.3 0.3
Gas Hold-up % #2 1.9 2.5 0.7 0.4
Table 1 – Summary Profile Data – Cell #1

The size distribution curves for the total solids are presented in Figure 5 and clearly show the
difference that turning the dual outlet off has made. Similar trends are observed with the target
elements for recovery (Au, Cu and S), as depicted for Cu in Figure 6. The finer size distribution
present in the upper region of the cell when the dual outlet is off results in a lower grade
concentrate, which may be a function of the increased proportion of very fine material being
recovered to the concentrate launder. Table 2 presents the concentrate grades and the % of the
total solids that is finer than 20 m for each case studied.

DO on (50 %) DO off
Au (g/t) 102 88
Cu (%) 8.9 8.3
% passing 20 m 19.0 31.2
Table 2 – Flash Concentrate Data – Cell #1

Total Solids Distribution

100.0%

90.0%

80.0%

70.0%
DO on - 50 cm
60.0% Do on - 100 cm
% Passing

Do on - 150 cm
50.0%
DO On - 200 cm
40.0% Do off - 50 cm
DO off - 100 cm
30.0% Do off - 150 cm
Do off - 200 cm
20.0%

10.0%

0.0%
10 100 1000
Size (m)

Figure 5 – Solids size distribution comparison with increasing depth into cell #1

P a g e 12 | 29
 Distribution of Cu
100.0%

90.0%

80.0%

70.0%
DO on - 50 cm
60.0% Do on - 100 cm
% Passing

Do on - 150 cm
50.0%
DO On - 200 cm
40.0% Do off - 50 cm
DO off - 100 cm
30.0% Do off - 150 cm
Do off - 200 cm
20.0%

10.0%

0.0%
10 100 1000
Size (m)

Figure 6 –Distribution of Cu by size with increasing depth into cell #1

Another phenomenon that has been noted in the profile data is that the +212 and +300 m
fractions have considerably higher grades of Au, Cu and S, with these grades increasing as the
froth is approached. The elevated grades in these two size fractions is consistent throughout
the profile data and are therefore not believed to be attributable to experimental contamination
or assay error. Further to this the grades of these target elements become very high when the
dual outlet is turned off, with 38.3 % of the Au being in the +212 m size classes at 50 cm
depth, however only 11.3 % of the Au in the associated flash concentrate stream is in this size
category. To illustrate the magnitude of these elevated grades the Au data for the 50 cm depth
with the dual outlet turned off is presented in Table 3. A key contributing factor to these coarse
high grade particles not being recovered to the concentrate when the dual outlet is turned off is
the lower slurry density, % solids is halved from 32 % to 16 % by turning the dual outlet off.
Thicker slurries are able to support heavier and denser particles and are known to assist in their
recovery. This issue is possibly being compounded by the frother not having sufficient carrying
capacity for these heavy particles. The combined effect of these factors results in these particles
becoming held-up within the cell and most likely being returned to the mill for further grinding.

P a g e 13 | 29
 Do Off Au
Size Class g/t % Retained % Passing
300 144.1 19% 81%
212 37.5 19% 62%
150 7.2 9% 53%
106 5.3 11% 41%
75 3.6 10% 31%
53 3.3 10% 21%
38 2.5 8% 13%
20 1.8 7% 6%
-20 0.5 6% 0%
Table 3 – Distribution of Au at 50 cm cell depth with the DO off – Cell #1

Axial Profile Data – Survey 2

A confirmation set of axial profiles were taken approximately 2 months after the initial survey
to obtain base-line information with the dual outlet line either 25, 50 or 75 % open. The slurry
samples from these profiles were measured for % solids and grade only. Although both surveys
include a sample taken at 50 % open, the operating conditions of the grinding circuit were
different at the times of each survey and so a direct comparison of these results is not
appropriate. Figure 7 presents the per-centage solids profiles from each survey. What can be
gleaned from these two data sets is the large difference in the solids segregation profile that
occurs when the dual outlet line valve is fully closed or open to 25 %, compared with when it
is 50 % or more open. This data would suggest that there is a minim amount the dual outlet
line must be opened to, to allow the upper part of the cell to act as a classifier. When this
minimum is not exceeded there is a shift in the internal hydrodynamics of the cell.

A change in the distribution of the target elements for flotation is also evident when the grades
at the various depths are considered for each operating condition as presented in Figure 8. The
effect of reducing the dual outlet open position is particularly clear for the Cu data in Figure 8.
The ultimate effect is a lower grade concentrate, as can be seen in the data of Table 4. As the
dual outlet line is opened the concentrate grade of both Au and Cu increase, while that of Fe
and S decreases (pyrite contamination of concentrate is an issue on this particular plant).

Au Cu Fe S
Concentrate Grade (g/t) (%) (%) (%)
Survey 2 – 25 % Open 52.0 5.8 23.8 26.0
Survey 2 – 50 % Open 56.1 6.9 22.1 23.5
Survey 2 – 75 % Open 62.7 7.3 21.2 22.1
Table 4 - Concentrate grades with changing dual outlet position – Cell #1

P a g e 14 | 29
This information can potentially be used to determine control limits for dual outlet operation
so as not to adversely affect concentrate grade and size distribution.

Segregation Profile with Changing Dual Outlet Flow

70

60

50
Slurry % Solids

40

30

20

10

0
0 50 100 150 200 250 300
Depth below froth interface (cm)

Survey 2 - 25 % Open Survey 2 - 50 % Open Survey 2 - 75 % Open

Suvey 1 - 0 % Open Survey 1 - 50 % Open

Figure 7 - Cell #1 segregation profile under each operating condition

Au & Cu Segregation Profile with Changing Dual Outlet Flow

5.0 0.50

4.5 0.45

4.0 0.40

3.5 0.35

3.0 0.30
Au Assay (g/t)

Cu Assay (%)

2.5 0.25

2.0 0.20

1.5 0.15

1.0 0.10

0.5 0.05

0.0 0.00
0 50 100 150 200 250 300
Depth below froth interface (cm)

Au - 75 % Open Au - 50 % Open Au - 25 % Open

Cu - 75 % Open Cu - 50 % Open Cu - 25 % Open

Figure 8 – Cell #1 Au and Cu grades under each operating condition

P a g e 15 | 29
Profile Normalisation
Sized Cu data from survey 1 has been normalised by depth, however as sampling did not extend
deep enough into the cell to reach the ‘mixing zone’, data has been normalised against a depth
of 200 cm (note that the samples for Survey 2 were not sized and could therefore not undergo
this process). Figures 9 and 10 display the results for Cu. The results presented in Figure 9
are typical of normal flash flotation operation, highlighting the 106 m fraction is the critical
size class for flotation recovery of Cu under the operating conditions studied. Particles coarser
than this are observed to decrease in concentration with increasing size as the froth is
approached, demonstrating the intensifying effect of the ‘downward’ forces as particle size is
increased (these include forces such as gravity and drag and the effect of turbulence).
‘Upward’ forces involved in flotation such as chemical attachment and buoyancy become
dominant with particles finer than 106 m, which is clearly illustrated in Figure 9 (coarse
particles being displayed in red and fine particles being displayed in blue). The concentration
of the finer size classes increases relative to the corresponding decrease in slurry per cent solids
as the froth interface is approached.

When the dual outlet is closed the internal flow regime of the cell changes and although the
data has been computed in an identical way the resulting performance curves are vastly
different as can be seen for Cu in Figure 10. The distribution of Cu with size is not changing
as the particles approach the froth, and the % solids is considerably lower and remains constant
over the initial 150 cm measured. There are now no coarse particles being recovered. Some
washing of fines is evident due to the low % solids.

Whilst the data obtained with the dual outlet on showed that at a depth of 50 cm, 15.4 % of the
solids mass was in the +212 m category, when the dual outlet is turned off there are essentially
no coarse particles (+212 m) in the area of the cell approaching the froth. Particles coarser
than 212 m make up only 2.1 % of the solids present at the 50 cm depth.

P a g e 16 | 29
 DO on - Cu Normalised against 200 cm data
1.8

1.6
Sieve Size (m)
1.4 850
600
Cu % Retained * % Solids

1.2 425
300
1
212
150
0.8
106

0.6 75
53
0.4 38
20
0.2 10

0
0 50 100 150 200 250
Depth into Cell (cm)

Figure 9 – Normalised profile data for Cu – DO on – Cell #1

Do Off - Cu Normalised against 200 cm data

1.8

1.6

1.4
Sieve Size (m)
300
Cu % Retained * % Solids

1.2
212
1.0 150
106
0.8 75
53
0.6 38
20
0.4
10

0.2

0.0
0 50 100 150 200 250
Depth into Cell (cm)

Figure 10 – Normalised profile data for Cu – DO off – Cell #1

The behaviour of Au is very similar to that of Cu with the critical size for Au in this system
being finer than Cu at 75 m, most likely as a function of the higher SG of gold bearing
minerals. As with the Cu when the dual outlet is turned off the distribution of Au with size is
essentially unchanged as the particles approach the froth. At a depth of 150 cm, 37 % of the
total solids are finer than 20 m. The proportion of fines increases as the froth is approached

P a g e 17 | 29
as the slurry is no longer able to suspend coarse and heavy particles, there are very few coarse
Au particles being recovered.

What can be observed from the data presented throughout this paper is that when the dual outlet
is closed the flow regime within the cell is affected. The cell is no longer functioning as an
effective secondary classifier and recovers the valuable material that is present in the slurry at
a depth of 150 cm, which contains a disproportionately large amount of fine particles. A
balance must be reached that simultaneously optimises the per cent solids through the dual
outlet line; increases the mass pull rate to concentrate; and allows the cell to perform its internal
upgrading of particles to minimise the unwanted entrainment of gangue fines. Optimisation of
both the feed rate and per cent solids will also effect a change in the classification profile within
the machine and these factors must be incorporated into improving the cells overall
performance.

Flash Flotation Cell #2

Axial Profile Data

Summary data is presented in Table 5 and shows that no classification is occurring over the
first 100 cm of depth into the cell, after which classification of solids commences. The mixing
zone of the cell has not been reached over the 2 m of cell depth studied. The per cent solids in
the upper region of this cell is not sufficient to support coarser particles to a distance of 1 m
below the froth; as the froth is approached from this depth the slurry becomes unable to carry
coarser particles and they drop back into the lower regions of the cell. The effect that this has
on the recovery of Au is demonstrated by the data of Table 6, highlighting a concentration layer
of coarse mineral rich material within the machine which is unable to be recovered to the
concentrate launder due to the forces at work within the machine. At a depth between 50 cm
and 1 m below the froth interface there is insufficient buoyancy and chemical attachment to lift
these Au rich particles into the froth layer and they are consequently dropping back into the
mixing zone.
The +212 m material makes up 4.8 % of the total mass present at 100 cm depth with very few
particles coarser than 425 m being present, whilst the CUF (flash feed) stream contains
approximately 36 % of the total solids being coarser than 425 m, and 63 % of the total solids
being coarser than 212 m. Whilst conventional mechanically driven flotation cells are not
expected to recover very coarse particles to the concentrate, it is expected that these particles
would be present in the slurry of a flash flotation cell if it is operating normally, with a well
mixed region around the impeller mechanism. There are no particles reported for the +425 m
fractions of the concentrate, while approximately 43 % of the total solids recovered to
concentrate are in the -20 m size class.
The per cent solids in the upper region of the cell is high enough to provide a good mass pull

P a g e 18 | 29
rate (measured concentrate flow-rate of 20 tph), which could be further improved upon with
the re-instatement of the dual outlet line, complete with a density indicator to allow the per cent
solids in the upper region of the cell to be optimised and controlled for maximum recovery.
This will ensure the cell is able to function correctly as both a classifier and flotation device,
and allow optimisation of the slurry profile in the upper region of the cell to ensure coarse gold
and copper sulphide particles are being recovered before they are returned to the ball mill to be
further ground. Gas hold-up values are very low, but in-line with measurements taken on other
operating flash flotation cells on this plant and elsewhere (Newcombe et al., 2013a).

50 cm 100 cm 150 cm 200 cm

% Solids 20.8% 20.0% 28.1% 39.0%
Solids P80 135 129 195 276
Au P80 191 207 250 273
Cu P80 191 192 224 296
Gas Hold-up % 2.6% 0.7% 1.4% 1.4%
Table 5 – Summary Profile Data – Cell #2

50 cm 100 cm 150 cm
Size Class g/t % Retained g/t % Retained g/t % Retained
300 2.80 3.65% 3.20 4.1% 1.17 8.3%
212 2.21 11.6% 3.72 15.0% 1.39 20.5%
150 1.57 14.3% 1.14 11.2% 0.61 13.8%
106 1.24 15.7% 1.37 19.2% 0.53 12.0%
75 1.21 12.4% 1.09 13.3% 0.70 10.6%
53 1.06 9.4% 0.91 9.5% 0.89 9.8%
38 1.17 8.7% 0.78 7.2% 0.75 6.1%
20 1.11 10.1% 0.67 6.8% 0.88 7.7%
-20 0.46 14.3% 0.35 13.7% 0.36 11.1%
Table 6 - Distribution of Au with increasing depth in an industrial flash flotation cell – Cell #2

The size distribution curves for the total solids are presented in Figure 11 indicating that
classification commences at a depth approaching 1.5 m. Distribution of Cu by size is presented
in Figure 12, similar trends are observed for both Au and S. Particles coarser than 212 m
make up approximately 4.6 % of the total solids recovered to concentrate, and there are
effectively no particles coarser than 425 m in the concentrate stream. Whilst this in itself is
not unusual in a mechanically driven flotation cell, the lack of coarser particles in the 1 m of
cell depth below the froth is unusual for a flash flotation cell. High assay values are consistently
being reported for the +212 m size classes, with the grades increasing as the froth is
approached. This phenomenon was also seen in the data from cell #3 and cell #1 with the dual
outlet on and was made worse when the dual outlet was turned off, it indicates to some extent
that the coarser mineral rich particles are being concentrated within the cell but are unable to

P a g e 19 | 29
be recovered due to their size/weight. If the cell hydrodynamics is improved these particles
could potentially be recovered to concentrate. The use of a stronger frother with greater
carrying capacity for these heavier particles may also assist in improving their recovery.

Total Solids Distribution

100.0%

90.0%

80.0%

70.0%

60.0%
% Passing

Baseline - 50 cm
50.0%
Baseline - 100 cm
40.0% Baseline - 150 cm
Baseline - 200 cm
30.0%

20.0%

10.0%

0.0%
10 100 1000
Size (m)

Figure 11 – Solids size distribution with increasing depth into the cell – Cell #2

Distribution of Cu
100.0%

90.0%

80.0%

70.0%

60.0%
% Passing

Baseline - 50 cm
50.0%
Baseline - 100 cm
40.0% Baseline - 150 cm
Baseline - 200 cm
30.0%

20.0%

10.0%

0.0%
10 100 1000
Size (m)

Figure 12 –Distribution of Cu by size with increasing depth into the cell – Cell #2

P a g e 20 | 29
Profile Normalisation
Both Cu and Au data has been normalised by depth, however as sampling did not extend deep
enough into the cell to reach the ‘mixing zone’, data has been normalised against a depth of
200 cm. Figure 13 presents the results of this analysis on the Cu data obtained for cell #2.
Only particles smaller than 53 m are being efficiently floated by this cell. The distribution of
copper with size is not changing as the particles approach the froth, and the % solids is
considerably lower and remains constant over the initial 1 m measured. There are no coarse
particles being recovered. The higher slurry per cent solids at 1.5 m depth does allow for
continued suspension of coarse particles to this depth however at 1 m depth they have dropped
back and are no longer present. These results are very similar to what was observed to happen
with cell #1 when the dual outlet was closed, showing that there are very few coarse particles
(+212 m) in the area of the cell approaching the froth. Particles coarser than 300 m make
up only 1.4 % of the solids present at the 50 cm depth.

Cu Normalised against 200 cm data

1.8

1.6
Sieve Size ( m)
1.4 850
600
1.2 425
300
1
212
150
0.8
106

0.6 75
Cu % Retaine d * % Soli ds

53
0.4 38
20
0.2 -20

0
0 50 100 150 200 250
Depth into Cell (cm)

Figure 13 – Normalised profile data for Cu – Baseline survey – Cell #2

The behaviour of Au is very similar to that of Cu; the distribution of Au with size is essentially
unchanged as the particles approach the froth. As the froth is approached substantial amounts
of fine material are present in the slurry with 33 % of the total solids at a depth of 50 cm being
in the -20 m size class. The concentrate stream from the flash flotation cell is sent to a gravity
concentrator prior to reporting to the flash cleaner flotation cells. To maximise the amount of
gold extracted by the gravity circuit the flash cell should be producing a concentrate rich in
intermediate sized particles which are amenable to both flotation and efficient gravity recovery.

P a g e 21 | 29
A previous study on a refractory gold concentrator has shown there is a considerable size range
(38 m up to 300 m) that both equipment types are able to recover gold rich particles and
optimisation of the flotation of material within this range should be considered a priority for
maximum profitability on this plant (Newcombe and Semini, 2014).

Flash Flotation Cell #3

Axial Profile Data
Summary data is presented in Table 7 and shows that no classification is occurring over the
first 150 cm of depth into the cell. The P80’s of the target elements are being skewed coarse by
very high assay values reported for the coarse fractions (despite the mass fractions of the coarse
sizes being low). The distribution of solids and target elements by size also remains effectively
unchanged over this distance. The mixing zone of the cell has not been reached over the 2 m
of cell depth studied. It should be noted that the vertical distance between the 2 m sample point
and the top of the stator is approximately 75 cm. Given this close proximity to the mixing
region of the cell, it would have been expected to have slurry with a higher per centage of
solids, however with this machine this was not the case at the time these measurements were
taken. The slurry in the quiescent zone above the stator does not have the carrying capacity to
allow coarse particles to be recovered to the concentrate, which is evident by the very low mass
proportions of the +106 m size classes: 11.1 % of the solids are in the +106 m size classes
at 50 cm depth (similar for 100 and 150 cm depths) and there are effectively no particles present
in the slurry that are coarser than 300 m. Whilst flotation cells are not expected to recover
very coarse particles to concentrate, it is expected that they would be present in the slurry if
the cell is mixing a large proportion of the feed through the impeller. The slurry profile data
for this cell is similar to that of cell #1 with the dual outlet closed. Gas hold-up values are very
low, but in-line with measurements taken on other operating flash flotation cells on this plant
and elsewhere (Newcombe et al., 2013a).

50 cm 100 cm 150 cm 200 cm

% Solids 18.36 18.39 19.54 33.31
Solids P80 75 72 77 227
Au P80 219 240 241 283
Cu P80 210 197 199 273
Gas Hold-up % 5.1 2.0 2.0 1.2
Table 7 – Summary Profile Data – Cell #3

The size distribution curves for the total solids are presented in Figure 14 and clearly show the
lack of classification occurring in the top 150 cm of the cell. Similar trends are observed with
the target elements for recovery (Au, Cu and S), as indicated by the Cu data of Figure 15. The
size distributions of the target elements are being skewed coarse by the consistently higher

P a g e 22 | 29
assays of the coarser fractions. Particles coarser than 212 m make up approximately 4.6 %
of the total solids recovered to concentrate, and there are effectively no particles coarser than
425 m in the concentrate stream. Whilst this in itself is not unusual in a mechanically driven
flotation cell, the lack of coarser particles in the 1.5 m of cell depth below the froth is unusual
for a flash flotation cell. High assay values are consistently being reported for the +150 m
size classes, with the grades increasing as the froth is approached. This indicates to some extent
that these particles are being concentrated within the cell but are unable to be recovered due to
their size/weight. If the cell hydrodynamics is improved these particles could be recovered to
concentrate. This phenomenon was also observed in cell #2 and cell #1 and was made worse
in cell #1 when the dual outlet was turned off.

Total Solids Distribution

100.0%

90.0%

80.0%

70.0%

60.0%
% Passing

Baseline - 50 cm
50.0%
Baseline - 100 cm
40.0% Baseline - 150 cm
Baseline - 200 cm
30.0%

20.0%

10.0%

0.0%
10 100 1000
Size (m)

Figure 14 – Solids size distribution comparison with increasing depth into the cell – Cell #3

P a g e 23 | 29
 Distribution of Cu
100.0%

90.0%

80.0%

70.0%

60.0%
% Passing

Baseline - 50 cm
50.0%
Baseline - 100 cm
40.0% Baseline - 150 cm
Baseline - 200 cm
30.0%

20.0%

10.0%

0.0%
10 100 1000
Size (m)

Figure 15 –Distribution of Cu by size with increasing depth into the cell – Cell #3

Profile Normalisation
Both Cu and Au data has been normalised by depth, however as sampling did not extend deep
enough into the cell to reach the ‘mixing zone’, data has been normalised against a depth of
200 cm. Figure 16 presents the results of this analysis on the Cu data obtained for cell #3. The
distribution of copper with size is not changing as the particles approach the froth, and the %
solids is considerably lower and remains constant over the initial 150 cm measured. There are
no coarse particles being recovered. These results are very similar to what was observed to
happen with cell #1 when the dual outlet was closed, showing that there are essentially no
coarse particles (+212 m) in the area of the cell approaching the froth. Particles coarser than
212 m make up only 1.4 % of the solids present at the 50 cm depth. Please note that
anomalous assays obtained for Cu in the sample taken at a depth of 100 cm are causing large
kinks in the profile for Cu at that depth. Due to this anomaly in the Cu data, the results of Au
normalisation are presented in Figure 17. The behaviour of Au is very similar to that of Cu;
the distribution of Au with size is essentially unchanged as the particles approach the froth.
There is a disproportionately large amount of fine material in the cell; at a depth of 150 cm, 45
% of the total solids are finer than 20 m. The proportion of fines increases as the froth is
approached as the slurry is no longer able to suspend coarse and heavy particles. Again, there
are very few coarse particles being recovered.

What is clearly observed from the data of cell #3 is that the cell is not functioning as an effective
secondary classifier and recovers the valuable material that is present at a depth of at least 150

P a g e 24 | 29
cm, which contains a disproportionately large amount of fine particles. Feed tonnage and
density will have contributed to these findings and these should be optimised to ensure they
are within the design operating specifications of this machine.

Cu Normalised against 200 cm data

4

3.5
Sieve Size ( m)
850
3
600
425
2.5
300
212
2
150
106
1.5
75
Cu % Retaine d * % Soli ds

53
1
38
20
0.5 10

0
0 50 100 150 200 250
Depth into Cell (cm)

Figure 16 – Normalised profile data for Cu – Cell #3

Note that an anomalous assay for Cu in the 100 cm sample is causing a large kink in the profile at that depth, so the data for Au is presented
in Figure 17.

Au Normalised against 200 cm data

1.8

1.6
Sieve Size ( m)
1.4 850
600
1.2 425
300
1
212
150
0.8
106

0.6 75
Au % Retained * % S olids

53
0.4 38
20
0.2 -20

0
0 50 100 150 200 250
Depth into Cell (cm)

Figure 17 - Normalised profile data for Au – Cell #3

P a g e 25 | 29
Conclusions
Axial profiles have been taken on 3 operating flash flotation cells, only one of which has an
active dual outlet line installed. All three cells are 1200 tph units treating a gold-copper ore
feed. Data from these three cells suggests that under the operating conditions studied, when
the dual outlet is closed to 25 % or less there is a shift in the internal classification profile of
the cell, resulting in a region of low density in the upper 1- 1.5 m directly below the froth
interface. This shift appears to cause a reduction in concentrate grade and an increase in the
amount of very fine (-20 m) material recovered to concentrate.

The classification function of a flash flotation machine is a result of the interaction of numerous
processing variables, including feed rate, feed slurry per cent solids, feed size distribution,
mineralogical properties of the ore and valuable mineral liberation characteristics; impeller
type and speed; as well as the usual chemical and physical variables that affect conventional
flotation performance. A change in the internal segregation of solids may be in-sighted by
manipulating these variables in isolation or in combination and further study is required to
determine whether other operational characteristics (such as feed density or rate) have
influenced the results reported here.

A portion of each concentrate stream from the flash flotation cells produced at CVO are treated
through an associated gravity recovery circuit prior to being sent to cleaner flotation cells. The
increased profitability that can be realised from the production of gravity gold provides
motivation to increase the amount of gravity recoverable gold rich material via flash flotation.
Flash flotation provides high levels of recovery for particles up to approximately 150 m in
size, and gravity recovery is suitable for particles between 100 m and 1200 m (Newcombe
and Semini, 2014; Gekko Systems, 2014; Newcombe, Bradshaw and Wightman, 2012;
Dominy, Murphy and Gray, 2011; Marsden and House, 2006; Laplante and Gray, 2005;
Laplante and Spiller, 2002). Furthermore, work by both Newcombe and Semini (2014) and the
AMIRA P420D project (McGrath, Staunton and Eksteen, 2013) have shown that both types of
device are capable of good recovery levels for particles in the +38/-150 μm size range and it is
this region of the size distribution that should be optimised to maximise overall gold
performance. The presence of a concentration layer of coarse gold rich material within the
flash flotation machines (refer to Tables 3 and 6) indicates that gold is being partially
concentrated by true flotation, however conditions within the machine are not currently
amenable to its final recovery over the concentrate launder. The recommendation for the site
in this case is to consider optimising the feed rate and increasing the flash feed slurry percent
solids, whilst simultaneously attuning both froth depth and dual outlet operating range. A
frother with a greater carrying capacity for heavier particles is also worth pursuing, and site
evaluations of alternative frothers in the flash flotation circuit are currently underway.

P a g e 26 | 29
Acknowledgement
The authors wish to thank Newcrest Mining Ltd for granting permission for this paper to be
published. The assistance of the metallurgical team at Cadia Valley is also acknowledged with
thanks, in particular to Joshua Bubnich for his on-going persistence and contribution to taking
the multitude of samples required for this analysis.

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