Minerals Engineering 23 (2010) 1198–1206

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Minerals Engineering
journal homepage: www.elsevier.com/locate/mineng

Flotation of copper sulphides assisted by high intensity conditioning (HIC)

and concentrate recirculation
Erico Tabosa, Jorge Rubio *
Laboratório de Tecnologia Mineral e Ambiental (LTM), Departamento de Engenharia de Minas, PPGEM, Universidade Federal do Rio Grande do Sul (UFRGS),
Avenida Bento Gonçalves. 9500, CEP 91501-970, Porto Alegre, RS, Brazil

a r t i c l e i n f o a b s t r a c t

Article history: This paper describes the effect of the partial concentrate (rougher floated product) recirculation to
Received 19 May 2010 rougher flotation feed, here named concentrate recirculation flotation – CRF, at laboratory scale. The main
Accepted 6 August 2010 parameters used to evaluate this alternative approach were flotation rate and recovery of fine (‘‘F” 40–
13 lm) and ultrafine (‘‘UF” <13 lm) copper sulphide particles. Also, the comparative effect of high inten-
sity conditioning (HIC), as a pre-flotation stage for the rougher flotation, was studied alone or combined
Keywords: with CRF. Results were evaluated through separation parameters, grade-recovery and flotation rates,
Flotation
especially in the fine and ultrafine fractions, a very old problem of processing by flotation. Results showed
High intensity conditioning
Concentrate recycling
that the floated concentrate recirculation enhanced the metallurgical recovery, grade and rate flotation of
Copper sulphide fines copper sulphides. The best results were obtained with concentrate recirculation flotation combined with
high intensity conditioning (CRF–HIC). The kinetics rate values doubled, the Cu recovery increased 17%,
the Cu grade increased 3.6% and the flotation rates were 2.4 times faster. These were accompanied by
improving 32% the ‘‘true” flotation values equivalent to 2.4 times lower the amount of entrained copper
particles. These results were explained and proved to proceed by particle aggregation (among others)
occurring after HIC, assisted by the recycled floatable particles. This ‘‘artificial” increase in valuable min-
eral grade (by the CR) resulted in higher collision probability between hydrophobic particles acting as
‘‘seeds” or ‘‘carrier”.
Ó 2010 Elsevier Ltd. All rights reserved.

1. Introduction of selective flocculation with polymers that, despite more than

The poor flotation recoveries of fine (‘‘F” 40–13 lm) and ultra-
fines (‘‘UF” < 13 lm) mineral particles is very well known and
many studies, projects and processes have been proposed, but this
major technical and economic problem still continues (Collins and
Read, 1971; Fuerstenau et al., 1979; Trahar, 1981; Sivamohan,
1990; Song and Lu, 2000; Rubio et al., 2003, 2006). The mineral
fines formation or generation is diverse, from many sources: some
particles are necessarily produced in the grinding process for
adequate liberation of the particles; another fraction comes from
re-grinding and a small quantity from particles shearing and
smearing (in conditioners for example). In some cases, certain min-
eral ores must be ground to very fine particles because of the de-
crease in the grade and the increase of complex ores. Under
actual conditions, a great deal of fine minerals is discarded as
slimes prior to flotation for lack of effective recovery methods.
Many alternatives for solving this problem have been tried, but
unfortunately most of them have not found practical applications
(Rubio, 2002, 2006; Song and Lu, 2000). A good example is the case
* Corresponding author. Tel.: +55 51 3308 9474; fax: +55 51 3308 9477.
E-mail addresses: erico.tabosa@ufrgs.br (E. Tabosa), jrubio@ufrgs.br (J. Rubio).
30 years of extensive studies and a few (mainly iron) plants using
this technique, still remain a ‘‘promising” process (Fuerstenau
et al., 1979; Subrahmanyam and Forssberg, 1990; Sivamohan,
1990; Mathur et al., 2000).
Main problems associated to the fines flotation are caused by
their intrinsic properties, among others, small mass (low momen-
tum), high interfacial free energy. Thus, main flotation drawbacks
are related to the low probability of bubble–particle collision and
adhesion, mechanical entrainment and entrapment, ‘‘slime coat-
ing”, higher flotation reagent adsorption, formation of dense froths
and low process kinetics. It is well known that ultrafine and coarse
particles float more slowly than particles in a mid-size range. The
size limits are not precise but for many mineral systems, the ultra-
fines are those below 5–10 lm, and the coarse sizes are above
100 lm approximately. The flotation rate tends to decrease with
decreasing particle size, because of the increasing importance of
viscous and electrostatic forces, which are less important with lar-
ger particles. The rate of bubble–particle collision is, for the coarser
particles higher than for the ultrafines, but the hydrodynamic
forces associated with turbulence and shear in the pulp, lead to
an increase in the rate of detachment. Thus as the particle size in-
creases, it becomes increasingly difficult to maintain the capillary

0892-6875/$ - see front matter Ó 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mineng.2010.08.004
 E. Tabosa, J. Rubio / Minerals Engineering 23 (2010) 1198–1206 1199

bonds between the particles and the bubbles and to withstand
shearing, while being transported into the froth.
Most selective aggregation using chemicals has not proven to be
a unique and general solution, the conventional or column type flo-
tation machines do not generate the bubbles size distribution re-
quired for an efficient capture of the very fines particles, neither
the actual ‘‘conditioners” (merely pulp distributors) allow aggrega-
tion of the fines particles, F–UF, themselves (Rubio et al., 2003,
2006).
The concept of shear flocculation has been extending to the con-
ditioning stage ahead of flotation (Bulatovic and Salter, 1989; Stas-
sen, 1991). Many authors claim that energy transferred in the
conditioning stage, often expressed as conditioning time, has a pro-
nounced effect on the concentrate recovery, grade and flotation
rate. The high intensity conditioning process (HIC) enhanced the
flotation recovery of the very fine particles of copper sulphides
(Bulatovic and Salter, 1989), gold, uranium oxide and pyrite fines
(Stassen 1991; Valderrama and Rubio, 1998), oxidized copper ores
and copper and molybdenum sulphides (Rubio et al., 2003) and
nickel ore (Chen et al., 1999). It is appear that this process is now
being applied industrial using special designed conditioners.
However, there is a situation, not much explored, viz. staged or
multifeed flotation, whereby differ from conventional flotation in
that two or more feed inputs are used and improvements in both

Table 1
Multifeed circuits reported on the literature.

Author Country/ Comments

Firth et al. (1979)
Firth et al. (1978);
Tsai (1988)
Fuerstenau (1988)
Hosten and Muratoglu (1996)
Fuerstenau et al. (2000)
Rodrigues et al. (2005)
Proyecto Flotación de finos y ultrafinos-
Codelco-Chuquicamata – IM2 (2002),
Tabosa (2007), Tabosa et al. (2009).
Mineral system
Australia/coal Investigation of feed size distribution on the staged flotation of poorly floating coals. These circuits
(staged flotation) were two-stage reagent addition, reflotation of classified tailings and split feed
flotation. The reflotation of classified tailings circuits not only gave the best metallurgical performance,
it also was the least affected by pulp density variations and imperfect size classification
USA/coal Staged froth flotation for deep cleaning of fine coal. In this staged flotation, the slowly flotable, mineral-
rich particles are first rejected, and the resulting overflow is recleaned at lower flotation rates through
careful control of frother concentration. As a result, a clean coal product of lower ash and lower pyritic
sulfur contents has been produced at a higher yield as compared with the single-stage flotation and
other reported multistage flotation circuits. The selectivity of this staged flotation is dictated by the
mineral size and its distribution in the feed coal. The mineral particles that remain in the clean coal
have a volume mean diameter of 6 lm, with 90per cent being smaller than 13 lm
USA/ A brief discussion on the potential of different kind of circuit, namely the multifeed circuits, was
molybdenite presented. Multifeed circuits differ from conventional circuits in that two or more feed inputs are used.
Improvements in both mineral recovery and grade (through autogenous carrier effects) and
conservation of flotation reagents. Multifeed circuits offer potential for large plants processing several
ores of varying composition
Results of an experimental application of this technique to the flotation of a molybdenite ore was
presented to illustrate the potential benefit from multifeed circuit. Molybdenite multifeed circuit
flotation roughers significantly improved the grade of optimized single-stage roughers: from 14 to 34
per cent MoS2 while maintaining comparable molybdenite recovery and reducing Syntex (emulsifying
agent, that is used to enhance molybdenite flotation) and frother consumption by one-half
Turkey/ The possibility of improving the flotation efficiency of Turkish bituminous coal fines by a split feed
bituminous flotation scheme was investigated in comparison with conventional single-stage flotation. Coal samples
coal collected from the <0.6 mm fines treatment circuit of an operating washery were used in laboratory
batch tests simulating single-stage and split feed flotation circuits. Collector (kerosene) and frother (iso-
octanol) additions were used as major test variables. Split feed flotation appeared to be a better
alternative scheme from the metallurgical point of view
USA/coal and Studies of coal and molybdenite flotation circuits were carried out experimentally, using semi-batch
molybdenite flotation methods. Investigation of a new multifeed flotation circuits, in which flotation feed is split into
two fractions with the concentrate from one stage being fed with the other half of the feed into a second
stage. These circuits would permit reduction in reagent additions and higher grade rougher concentrate
was produced with the flotation of a molybdenite ore
Laboratory experimentation showed that multifeed rougher circuits can provides can yield enhanced
results in the flotation of naturally hydrofobic minerals, such as coal and molybdenite
For coal, studies showed that open multifeed rougher circuits can provide wield and product ash
contents comparable to single-stage rougher. Closed multifeed rougher circuits provided much higher
yields than conventional single-stage rougher circuits at lower reagent consumption
For molybdenite flotation, an open two-stage multifeed rougher circuits appears to be far superior to
the single-stage rougher for producing a much higher grade rougher concentrate at lower reagent
consumption. This appear to be due to the effects of conditioning fresh feed with reagent-coated
rougher concentrate
Brazil/copper Investigation of a copper flotation circuit aiming to identify copper losses on fine fraction. Flotation
circuit changes were proposed, namely rougher concentrate recycling on scavenger–cleaner stage (with
and without staged reagent addition)
Best results were obtained when rougher concentrate was recycled on scavenger–cleaner stage,
combined with staged reagent addition (enhancement of 15 per cent copper recovery)
Brazil/chile/ Concentrate recirculation flotation (CRF) was proposed aiming to modify flotation circuits design. CRF
copper includes one conventional flotation stage and a second stage in which its feed is compound of ‘‘first”
(higher flotation kinetics particles) concentrates and fresh feed. On this stage (second stage) occurs an
artificial increase of higher flotation kinetics particles. Those particles are suitable for aggregates
formation, serving as ‘‘seeds” for these aggregates, transporting lower flotation kinetics fine and
ultrafine particles. Besides, aggregates formation can increase using high intensity conditioning (HIC)
combined with this technique
Flotation of sulphide fines results, using CRF technique and HIC combined (CRF–HIC), were compared
with a ‘‘standardized” mill laboratory procedure. Concentrate copper recoveries were of the order of 7–
18 per cent higher and their process kinetics values were higher, 1.5 min 1 for CRF and 2.9 min 1 for
CRF–HIC, compared with 1.2 min 1 for standardized mill laboratory procedure
1200 E. Tabosa, J. Rubio / Minerals Engineering 23 (2010) 1198–1206

mineral recovery and grade (through autogenous carrier effects)
and conservation of flotation reagents were reported. There are
some industrial cases whereby concentrate (a fraction) is, occa-
sionally, being recycled but is not a common practice worldwide.
Several authors (Hu and Huang, 1977; Firth et al., 1978, 1979;
Tsai, 1988; Rubio, 1988; Fuerstenau, 1988 Fuerstenau et al.,
2000; Hosten and Muratoglu, 1996; Rodrigues et al., 2005; Proyec-
to Flotación de finos y ultrafinos – Codelco – Chuquicamata – IM2,
2002; Tabosa, 2007; Tabosa et al., 2009) – see Table 1 – on the
analysis of some coal, copper and molybdenum sulphide flotation
circuits reported the multifeed circuit as a potential alternative cir-
cuit. According to them, several factors may be responsible to these
improvements. Split feed flotation on multifeed circuits, whereby
the concentrate of part of a rougher circuit is mixed with fresh feed
onto another rougher circuit, reducing reagents consumption and
improving fine mineral particles recovery. Also, flotation rate in-

Fig. 1. Schematic representation of the configuration of various conventional and multifeed flotation circuits (after Fuerstenau et al. (2000)).

100 1.20

Cummulative weight, % Copper, %

95 1.15

90 1.10
Cummulative weight, %

85 1.05
Copper, %

80 1.00

75 0.95

70 0.90

65 0.85

60 0.80
>53 35 25 15 <15
Particle size, µm

Fig. 2. Copper and mass size distribution in sample.

 E. Tabosa, J. Rubio / Minerals Engineering 23 (2010) 1198–1206 1201

creases due to an ‘‘artificial” increase of valuable mineral grade
(faster flotation rate), where hydrophobic particles may act as
‘‘seeds” (carrier) to fine particles. Besides this, lower reagents con-
sumption, due to the effects of conditioning fresh feed with re-
agent-coated rougher concentrate.
Fuerstenau et al. (2000) show that multifeed rougher circuits
can provide enhanced results in the flotation of naturally hydro-
phobic minerals, such as coal and molybdenite. For coal, it was
shown that open multifeed rougher circuits (Fig. 1) can provide
yield and product ash contents comparable to single-stage rougher.
Closed multifeed rougher circuits provided much higher yields
than conventional single-stage rougher circuits at lower reagent
consumption. For molybdenite flotation, an open two-stage multi-
feed rougher circuit appears to be far superior to the single-stage
rougher for producing a much higher grade rougher concentrate
at lower reagent consumption.
Firth et al. (1978) suggest a staged (multifeed) flotation circuits
for an Australian poorly floating coal. These circuits were two-
stage reagent addition, reflotation of classified tailings and split
feed flotation. According to them, the key to successful flotation
of poorly floating coals is the equitable distribution of collectors
to all size fractions.
The aim of this work is to compare, at laboratory scale, stan-
dardized rougher flotation tests with partial concentrate (rougher
floated product) recirculation to rougher flotation feed (concen-
trate recirculation flotation – CRF). Also, the comparative effect of
high intensity conditioning (HIC), as a pre-flotation stage for the
rougher flotation, is studied alone or combined with CRF. Compar-

Fig. 3. Schematic representation of the configuration of a standard mill test and details of the flotation cell and froth.

Fig. 4. Schematic representation of the configuration of a concentrate recirculation flotation (CRF) mill test.
1202 E. Tabosa, J. Rubio / Minerals Engineering 23 (2010) 1198–1206

isons were measured through the separation parameters: grade,
recovery (global and true flotation) and flotation rate constants in-
cluded size-by-size results to assess the flotation behaviour of the
fine fractions of copper sulphides.
2. Experimental
2.1. Materials
2.1.1. Ore
Copper porphyry samples, containing 0.98–1.10% Cu were sup-
plied by Codelco – Chile. About 1/4 of the mass and about 40% of
the total copper content is in the fines and ultrafines fractions
(<35 lm). Fig. 2 shows feed size-by-size mass and copper
distribution.
2.1.2. Reagents
Lime, as pH regulator to pH 10.5 was added at the conditioning
stage together with SF-113 (sodium isopropyl xanthate) and SF-
508 (Promoter) at 30 and 8 g t 1 concentration, respectively. The
frother was a propylene glycol, DF-250, at 25 g t 1.
2.2. Methods
2.2.1. Standard mill test
The standard mill tests were carried out in a laboratory D12
Denver flotation machine and in a square flotation cell with 3 L
of capacity, endowed with a manual scrapper to remove the froth.
The pulp with 38% in weight and with pH in 10.5 (monitored with
an AnalionTM pH meter model PM 608), was conditioned with the
collectors SF-113 (25 g t 1), SF 506 (8 g t 1) and the frother
(25 g t 1) for one minute to allow collector and frother adsorption
at 1000 rpm in the cell. After the conditioning time, the flotation
started with the injection of air in the flotation cell, monitored with
a flow meter. Data were obtained from concentrates taken at 1, 2,
3, 5 and 9 min flotation, keeping the volume in the cell constant
with water injection at pH 10.5. Fig. 3 shows a schematic represen-
tation and some pictures of the standard mill test configuration.
2.2.2. Concentrate recirculation flotation (CRF)
The CRF studies were divided into two-stages. The first stage
was carried out a standard mill test, and the first minute concen-
trate (higher flotation probability) was collected. The volume of

Fig. 5. Details of the: (a) 6-blade Rushton impeller and (b) baffles added to the flotation cell at the high intensity conditioning stage.

Fig. 6. Schematic representation of the configuration of a high intensity conditioning (HIC) mill test.
 E. Tabosa, J. Rubio / Minerals Engineering 23 (2010) 1198–1206 1203

this concentrate was measured and added to the second stage feed.
At this second stage, a new standard mill test was carried out,
being its feed composed by a new feed plus the first concentrate
of the STD test (first stage), whilst the pulp volume was kept con-
stant. Fig. 4 shows a schematic representation of the concentrate
recirculation flotation (CRF) tests.
2.2.3. HIC (high intensity conditioning)
The HIC studies were carried out similarly to the standard mill
test, with the exception than the stage of the conditioning of the
pulp with the reagents (collectors and frother), was substituted
for a high turbulent stage, obtained with the introduction of four
baffles in a flotation cell equal to the mill flotation test and a Rush-

80
STD HIC CRF CRF-HIC
CRF HIC

70

60
C pperr reccoveery, %

Cooppeer grradee, %
50

40

30
Cop

20
STD HIC CRF CRF-HIC
10

0
0 2 4 6 8 10
Time, min
Time, min
Fig. 9. Cumulative copper concentrate grades, comparative results (STD, CRF, HIC,
Fig. 7. Flotation kinetic curves of a copper sulphide ore, comparative results (STD, and CRF–HIC). Tests conditions: [SF-113] = 30 g t 1; [SF-506] = 8 g t 1; [DF250] =
CRF, HIC, and CRF–HIC). Tests conditions: [SF-113] = 30 g t 1; [SF-506] = 8 g t 1; 25 g t 1; pH = 10.5; 38% solids by weight; conditioning stage 1000 rpm (HIC and
[DF250] = 25 g t 1; pH = 10.5; 38% solids by weight; conditioning stage 1000 rpm CRF–HIC: 1400 rpm – 3 min).
(HIC and CRF–HIC: 1400 rpm - 3 min).

26
22
STD HIC CRF CRF HIC
CRF-HIC

20 22
m
cle ssize, µm

18
oppeer gradee, %

18
16
Meaan parti
p

14 14
Co

12
10
10
HIC CRF CRF-HIC STD

8 6
20 30 40 50 60 70 80 0 2 4 6 8 10
Copper recovery, % Flotation time, min

Fig. 8. Copper grade-recovery curves, comparative results (STD, CRF, HIC, and CRF– Fig. 10. Mean particle size in the concentrate as a function of time, comparative
HIC). Tests conditions: [SF-113] = 30 g t 1; [SF-506] = 8 g t 1; [DF250] = 25 g t 1; results (STD, CRF, HIC, and CRF–HIC). Tests conditions: [SF-113] = 30 g t 1; [SF-
pH = 10.5; 38% solids by weight; conditioning stage 1000 rpm (HIC and CRF–HIC: 506] = 8 g t 1; [DF250] = 25 g t 1; pH = 10.5; 38% solids by weight; conditioning
1400 rpm – 3 min). stage 1000 rpm (HIC and CRF–HIC: 1400 rpm – 3 min).

Table 2
Flotation of copper sulphides. Comparative separation parameters between STD (mill standard), concentrate recirculation flotation (CRF), high intensity conditioning (HIC), and
combined process (CRF–HIC).
1
Tests Mass 1st minute copper Copper metallurgical Copper grade (%) True flotation Entrainment K (min )
recovery (%) metallurgical recovery (%) recovery (%) grade
Feed calculated (%) Concentrate Tailing
recovery (%)
STD 5.8 60.5 1.1 11.2 0.4 30 1.7 1.2
CRF 9.6 25 67.0 1.3 9.1 0.5 38 1.2 1.5
HIC 6.4 69.0 1.1 12.0 0.4 51 0.9 2.0
CRF–HIC 8.6 43 78.0 1.6 15.0 0.4 62 0.7 2.9
1204 E. Tabosa, J. Rubio / Minerals Engineering 23 (2010) 1198–1206

ton impeller (Fig. 5a). This high-shear radial impeller is excellent
for particle dispersion.
The HIC were carried out in the same D12 Denver flotation ma-
chine, when the stator was taken out, and the rotor was substi-
tuted for a Rushton impeller with 1400 rpm speed (transferring
2 kWh m 3 of pulp), during 3 min, without air injection, and with
50% of solids by weight. After HIC, the solids content was adjusted
to 38% solids by weight, the impeller speed was changed back to
1000 rpm and the flotation started with the injection of air in the
flotation cell, monitored with a flow meter, as in the STD test. Figs.
5 and 6 show some details of the HIC system used.
Herein, the studied variable, conditioning time, was quantified
in terms of energy transferred to pulp. This energy was measured
with a wattmeter, as described by Valderrama (1997).
2.2.4. CRF combined with HIC (CRF–HIC)
The CRF–HIC studies were carried out as a HIC test (stage 1), as
described previously, and the first minute concentrate (higher
flotation probability) was collected. The volume of this concentrate
was measured and added to the second stage feed (new HIC). At
this second stage, a new HIC mill test was carried out, (stage 2)
Yet, best metallurgical and kinetic results were obtained with
concentrate recirculation flotation combined with high intensity
conditioning (CRF–HIC). Results were 17% greater Cu recovery
and 3.6% improved Cu grade at a higher flotation rates (2.4 times
faster). These were accompanied by an enhancement equivalent
to 32.5% in the true flotation values and by a low amount of en-
trained copper particles (2.4 times smaller).
A comparative analysis of copper concentrate grade with flota-
tion time (Fig. 9) shows similar results for both STD and HIC tests.
Concentrate recirculation, however, affected each technique in a
distinct manner. Whilst the concentrate recirculation flotation
(CRF) decreases the copper concentrate grade the CRF assisted by
the high intensity conditioning (CRF–HIC) increases the copper
concentrate grade.
This general behaviour might be the result of an ‘‘artificial” in-
crease in valuable (values) grade followed by an aggregation occur-
ring during the HIC, improving overall flotation performance. The
4.0
STD HIC CRF CRF-HIC

being its feed composed by a new feed plus the first concentrate 3.5
of the HIC test (stage 1), whilst the pulp volume was kept constant.
All concentrates and tailings were filtered, dried, weighed and 3.0
analyzed for copper by atomic adsorption (SpectrAA 110-VarianÒ).
2.5
The process efficiency was measured by evaluating separation
Masss, %

parameter recovery, ‘‘true” recovery and entrainment grade (as de-

2.0
scribed by Warren, 1985, 1991), Cu grade and rate constants. The
M

Rinf (ultimate recovery) and k constants for the Klimpel model (best
1.5
model for the data obtained) were obtained using a nonlinear
regression method (least square fitting). In all the fittings the R2 va- 1.0
lue was about 0.99.
Finally, to assess the performance of flotation in the F and UF 0.5
fractions, size-by-size copper recoveries were measured in the
fractions: >53 lm; 53–35 lm; 35–25 lm; 25–15 lm and <15 lm. 0.0
0.0 0.9 2.4 4.6 9.0 19.0 36.0 66.0 130.0 240.0
Particle size,, µ
µm
3. Results and discussion
Fig. 11. Size distribution of flotation concentrates: comparative results (STD, CRF,
HIC, and CRF–HIC). Tests conditions: [SF-113] = 30 g t 1; [SF-506] = 8 g t 1;
Figs. 7 and 8 and Table 2 show comparative results of flotation [DF250] = 25 g t 1; pH = 10.5; 38% solids by weight; conditioning stage 1000 rpm
of copper sulphides at lab scale. Fig. 7 and Table 2 shows that under (HIC and CRF–HIC: 1400 rpm – 3 min).
standard flotation test conditions, less valuable particle are floated
compared to the other techniques, reaching to recoveries of the or-
der of 60% Cu with rate constants (Klimpel model) of about
60
1.2 min 1 and a true recovery or recovery through bubble–parti-
cles interactions of 30%. STD HIC CRF CRF-HIC
The concentrate recirculation flotation (CRF) test (1st min con- 50
centrate recirculation), compared with the mill standard test, in-
creased the kinetics rate values, enhanced the Cu recovery by
40
6.5% and the recovery by true flotation values by 8%; followed by
Weeightt, %

a decrease in entrainment grade and a slight reduction in copper

final concentrate grade. 30
When the high intensity conditioning (HIC) precedes the STD
flotation test, the kinetics rate values approximately doubled; the
20
Cu recovery increased by 8.5% and the recovery by true flotation
by 21%. Also, the entrainment grade reduced to 0.9 and the copper
final concentrate grade slightly increased. Hence, results show that 10
the high intensity conditioning, as a pre-flotation stage, might in-
crease both copper grade and recovery revealing, like in other stud- 0
ies, high process selectivity. This specificity appear to be >53 35 25 15 <15
demonstrated by the enhanced true flotation values, which can Particle size,, µ
µm
only be explained in terms of the appearance of ‘‘new” valuable
Fig. 12. Particle mass recoveries, in each fraction, compared to the mill standard:
and hydrophobic particles in the concentrate. Thus, either particle comparative results (STD, CRF, HIC, and CRF–HIC). Tests conditions: [SF-113] =
aggregation or surface cleanliness or both, are the mechanisms 30 g t 1; [SF-506] = 8 g t 1; [DF250] = 25 g t 1; pH = 10.5; 38% solids by weight;
involved. conditioning stage 1000 rpm (HIC and CRF–HIC: 1400 rpm – 3 min).
 E. Tabosa, J. Rubio / Minerals Engineering 23 (2010) 1198–1206
100
STD HIC CRF CRF-HIC
90
veryy, %
80
opper rrecov
70
60
Co
50
40
>53 35 25 15
Particle size, µm
Fig. 13. Comparative size-by-size flotation copper recoveries: (STD, CRF, HIC, and
CRF–HIC). Copper recoveries of concentrate products in >53, 35, 25, 15 and <15 lm
fractions. Tests conditions: [SF-113] = 30 g t 1; [SF-506] = 8 g t 1; [DF250] =
25 g t 1; pH = 10.5; 38% solids by weight; conditioning stage 1000 rpm (HIC and
CRF–HIC: 1400 rpm – 3 min).
recycled valuable mineral particles would be acting as ‘‘seeds” or
carriers whereby other particles can be attached.
This combination of methods appears to be similar to the mech-
anisms proposed for the so-called autogenous flotation (Valderra-
ma and Rubio, 1998).
In order to prove the aggregation hypothesis, the mean size of
floatable particles (concentrate) were measured comparatively.
Fig. 10 shows that bigger particles were formed in the very first
minutes of flotation when that is assisted by the high intensity
conditioning. This could therefore suggest the formation of some
kind of particle aggregation.
Moreover, the particle size distribution of concentrate products
for STD, CRF, HIC and CRF–HIC presented in Fig. 11 shows that
when flotation is assisted by the high intensity conditioning (both
HIC and CRF–HIC) coarser particles are recovered; which in turns
could indicate that particles acted as carrier for particle aggrega-
tion of the fines themselves or with coarser particles.
Fig. 12 shows particle mass recoveries, in each fraction, com-
pared to the mill standard. Results show that after HIC and CRF–
HIC the recovery of fine (<15 lm) and intermediate (>53 lm) par-
ticle size was higher when compared to STD. Highest recovery of
fine (<15 lm) particles was obtained with concentrate recircula-
tion flotation, indicating its higher efficiency for the flotation of
the finest particle fraction.
Finally, Fig. 13 shows size-by-size copper recoveries, obtained
in all techniques studied compared to the mill standard. According
to expectations (and mechanisms proposed), this figure shows
clearly higher recoveries in practically all fractions, especially in
the fine and ultrafine fractions (5% higher to CRF) and in the coar-
ser (>35 lm) fraction, 10–15% higher for CRF–HIC. These results
support the aggregation hypothesis of the fines themselves or with
coarser particles (‘‘seeds” or carrier). This may explain the results
obtained, the higher recoveries and concentrate grades at higher
process kinetics.
4. Conclusions
Results found showed that the concentrate recirculation, to a
rougher flotation feed, enhanced the metallurgical recovery, grade
and rate flotation of copper sulphides. The best results were ob-
tained with high intensity conditioning (HIC), as a pre-flotation
stage, combined with concentrate recirculation flotation (CRF),
1205
increasing the kinetics rate values, Cu recovery and concentrate
grade. These results were accompanied by an enhancement in
the ‘‘true” flotation and a low amount of entrained copper parti-
cles. Particle aggregation occurring after HIC, enhanced by the
higher number of recycled floatable particles, might explain these
results. This ‘‘artificial” increase in valuable mineral grade resulted
in higher collision probability between hydrophobic particles act-
ing as ‘‘seeds” or ‘‘carrier”. Size-by-size flotation recoveries appear
to confirm this aggregation mechanism. Hence, it is believed that
these results represent real advances and that this concentrate
recirculation based technique may establish a new basis to im-
prove the potential of HIC, as an efficient pre-flotation stage.
Acknowledgments
<15
The authors are thankful to all institutions supporting research
in Brazil and Chile and all colleagues from the 31-year old LTM
(Environmental and Mineral Technology Laboratory) from our Fed-
eral University in Porto Alegre, South Brazil.
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