Ubc 2005-0270

CONTINUOUS CENTRIFUGAL CONCENTRATOR
OPERATION AND CONTROL
by
Michael J. McLeavy
B . A . S C . T H E UNIVERSITY OF BRITISH C O L U M B I A , MINING A N D M I N E R A L PROCESS ENGINEERING,
1999
A THESIS S U B M I T T E D IN P A R T I A L F U L F I L M E N T OF T H E R E Q U I R E M E N T S FOR T H E D E G R E E OF
Master of Applied Science
in
THE FACULTY OF GRADUATE STUDIES
MINING AND MINERAL PROCESS ENGINEERING
The University of British Columbia
March 2005
© Michael J. McLeavy, 2005

ABSTRACT
A study was conducted to evaluate the operation and control of a continuous centrifugal gravity
concentrator. The unit that was tested was a pilot scale Knelson Continuous Variable Discharge
(CVD6) Concentrator. The primary objective was to determine the effects of the machine
operating variables on separation performance; concentrate grade and recovery. The secondary
objective was to use the results to develop an operating strategy for the concentrator. Thirdly, in
testing the machine the practical limits of the equipment were determined in order to develop a
basic understanding of where this technology could be applied commercially.
To achieve these objectives four sets of pilot scale experiments were conducted including:
1. Quartz/magnetite statistical experimental design
2. Quartz/magnetite incremental testing
3. Synthetic sphalerite/quartz incremental testing
4. Pb/Zn flotation tailings plant testing at Hudson's Bay Mining and Smelting
Statistical experimental design was used to rank the effects of operating variables on
concentrator grade and recovery. The following table lists the operating variables in order, from
most significant to least significant:
Rank Variable rankings Variable rankings

based on Grade based on Recovery
1 Solid Feed Rate Heavy Particle Size
2 Bowl Speed Pinch Closed
3 Pinch Closed Bowl Speed
4 % Solids %Solids
ii
5 Fluidization Water
Fluidization Flow
6 Feed Grade Pinch Open
7 Pinch Open Feed Grade
8 Heavies Particle Size Solid Feed Rate
The first stage of research in evaluating the operating variables of the CVD was to evaluate the
feed and machine variables using a statistical experimental design approach. This methodology
was selected because of the large number of variables and was the only practical way to evaluate
the individual variables and their interaction effects. A synthetic feed of quartz and magnetite
was tested in a pilot plant that included a Knelson CVD6 concentrator. The result of the
factorial design was a ranking of effects on both grade and recovery for each of the feed and
machine variables.
Testing of both synthetic quartz/magnetite and synthetic quartz/sphalerite resulted in a better
understanding of the trends that result from incremental changes in operating variables.
The plant testing at HBM&S created a large database of information that confirmed the
information from the laboratory scale tests.
Based on the results an operating strategy was developed that includes the following general
strategy:
• Identification of performance expectations
• Testing to produce an array of results that span the spectrum of concentrator abilities
• Identification of a performance boundary layer
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• Qualitative tuning of operating variables to approach boundary layer conditions
• Fine tuning of operating variables using knowledge of the impact of individual operating
variables
Combining information from all of the test programs, the effect of particle specific gravity
differential was investigated. The result was that the CVD was shown to be able to separate
particles down to a specific gravity differential of 0.2. However, the practical limitation where a
reasonable recovery was obtained was a differential of 2.
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TABLE OF CONTENTS
ABSTRACT I
T A B L E O F CONTENTS V
LIST O F FIGURES XI
LIST O F T A B L E S IX
ACKNOWLEDGEMENTS XIII
1 INTRODUCTION 1
2 L I T E R A T U R E REVIEW 2
2.1 HISTORY 2
2.2 B A T C H AND U S E : 2
2.3 EVOLUTION OF CONTINUOUS CENTRIFUGAL CONCENTRATORS FROM B A T C H TECHNOLOGY 4
2.4 FALCON C 5
2.5 KELSEYJIG 7
2.6 KNELSONCVD ". 11
2.6.1 Knelson CVDApplications 14
3 EXPERIMENTAL PROGRAM 14
3.1 TEST PROGRAM 14
3.2 PILOT SCALE CIRCUIT 15
4 Q U A R T Z M A G N E T I T E F A C T O R I A L DESIGN 21
4.1 INTRODUCTION 21
4.2 EXPERIMENTAL 22
4.2.1 Procedure 22
4.2.2 Quartz/Magnetite Assay Procedure 24
4.2.3 Attrition Check 25
4.2.4 Test Program Details 27
V
4.3 RESULTS 31
4.3.1 Introduction 31
4.3.2 Effect of Operating Variables on Grade 33
4.3.3 Effect of Operating Variables on Recovery 35
4.3.4 Conclusion 37
5 QUARTZ/MAGNETITE INCREMENTAL TESTING 40
5.1 INTRODUCTION 40
5.2 EXPERIMENTAL TEST PROGRAM 40
5.3 QUARTZ/MAGNETITE INCREMENTAL TESTING RESULTS 42
5.3.2 Quartz/Magnetite Trends with Changing Bowl Speed. 43
5.3.3 Quartz/Magnetite Trends with Changing Fluidization Water Flowrate 44
5.3.4 Quartz/Magnetite Trends with Changing Percent Solids 47
5.3.5 Conclusion 48
6 L A B TESTING - SYNTHETIC SPHALERITE/QUARTZ 49
6.1 INTRODUCTION 49
6.2 EXPERIMENTAL - SYNTHETIC SPHALERITE/QUARTZ 50
6.2.1 Feed Characterization 50
6.2.2 Test Program 53
6.2.3 Procedures and Sampling 55
6.2.4 Sample Preparation 55
6.3 RESULTS -SYNTHETIC QUARTZ/SPHALERITE 56
6.4 CONCLUSIONS 59
7 HUDSON'S BAY MINING AND SMELTING PLANT TRIALS 60
7.1 INTRODUCTION 60
7.2 EXPERIMENTAL-PLANT TRIALS AT HUDSON'S BAY MINING AND SMELTING 61
7.2.1 Test Program 61
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7.2.2 Procedures and Sampling 63
7.2.3 Sample Preparation 65
13 RESULTS - PLANT TRIALS AT HBM&S 66
7.3.2 Bowl speed 66
7.3.3 Pinch valve open time 67
7.3.4 Pinch valve closed time 70
7.4 CONCLUSIONS 72
8 SPECIFIC G R A V I T Y DIFFERENTIAL 73
8.1 INTRODUCTION 73
8.2 DISCUSSION 73
8.3 CONCLUSIONS 77
9 V A R I A B L E T U N I N G IN A C V D C O N C E N T R A T O R 79
9.1 INTRODUCTION 79
9.2 OPERATING VARIABLE PERFORMANCE RATIO 79
9.3 CONCLUSIONS 84
10 DEVELOPING AN OPERATING STRATEGY FOR A NEW APPLICATION 86
10.1 INTRODUCTION 86
10.2 IDENTIFICATION OF THE OBJECTIVES 86
10.3 C V D BOUNDARY CONDITIONS 87
10.4 QUALITATIVE TUNING 88
10.5 FORMULATION OF A GENERAL TEST PROGRAM 91
10.6 FINE TUNING THE OPERATING VARIABLES 92
10.7 CONCLUSION 93
11 CONCLUSIONS AND RECOMMENDATIONS 94
11.1 FACTORIAL DESIGN 94
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11.2 INCREMENTAL QUARTZ/MAGNETITE 95
11.3 SYNTHETIC SPHALERITE/QUARTZ 96
11.4 H B M & S PLANT TESTING 96
11.5 SPECIFIC GRAVITY DIFFERENTIAL 97
11.6 VARIABLE TUNING IN A C V D CONCENTRATOR 97
11.7 DEVELOPING AND OPERATING STRATEGY FOR A N E W APPLICATION 98
11.8 RECOMMENDATIONS 99
12 REFERENCES 100
13 APPENDIX 1 - QUARTZ/MAGNETITE FRACTIONAL FACTORIAL DESIGN 103
13.1 ALIAS STRUCTURE 104
13.2 FRACTIONAL FACTORIAL DESIGN M A P 105
13.3 FACTORIAL DESIGN TEST RESULTS/ METALLURGICAL B A L A N C E 107
13.4 C A L C U L A T E D FACTORIAL DESIGN RESULTS - EFFECT OF OPERATING PARAMETERS 110
13.5 QUARTZ/MAGNETITE ASSAY PROCEDURE Ill
13.6 ATTRITION CHECK 112
14 APPENDIX 2 - HBM&S GOLD ZINC INCREMENTAL TRIALS 115
viii
LIST OF TABLES
Table 2.3.1 - CVD Commercially available models 5
Table 2.4.1 - Falcon C models and feed capacities 7
Table 2.5.1 - Kelsey Jig models and rated solids feed capacities 9
Table 4.1.1 - Variables impacting product grade and recovery 21
Table 4.2.3.1 - Feed sample standard deviations by size 26
Table 4.2.5.1 - High and low levels for operating variables in factorial design 28
Table 4.2.5.2 - Quartz and magnetite factorial design map 29
Table 4.2.5.3 - Quartz/magnetite factorial design test program 30
Table 4.3.2.1 - Calculated operating variable effects on grade from factorial design results 34
Table 4.3.2.2 - Significant feed variable effects on grade 34
Table 4.3.2.3 - Calculated machine variable effects on grade 35
Table 4.3.3.1 - Calculated operating variable effects on recovery from factorial design results 36
Table 4.3.3.2 - Machine variable effects on recovery 37
Table 4.3.4.1 - Summary of significant variable effects 38
Table 5.2.1 - Synthetic quartz and magnetite incremental test program 41
Table 5.3.2.1 - Results of changing bowl speed with quartz and magnetite 43
Table 5.3.3.1 - Results of changing fluidization water flowrate with quartz and magnetite 46
Table 5.3.4.1 - Results of changing percentage solids with quartz and magnetite 47
Table 6.2.1.1 - Composition of zinc concentrate from HBM&S used in creating the synthetic
feed 51
Table 6.2.1.2 - Composition by size of the zinc concentrate used in the synthetic zinc feed 52
Table 6.2.1.3 - Composition of the blended synthetic quartz/sphalerite feed 52
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Table 6.2.2.1 - Synthetic quartz and sphalerite test program 54
Table 7.2.1.1 - HBM&S incremental testing map of operating variable levels per test 62
Table 8.2.2 - Approximate specific gravity differentials for HBM&S plant trials 76
Table 9.2.1 - General trends for operating variables 82
Table 9.2.2 - Rate of change in grade versus rate of change in recovery 83
Table 11.1 - Summary of significant variable effects 95
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LIST OF FIGURES
Figure 2.4.1 Section view of the Falcon C technology, (www.concentrators.net) 6
Figure 2.1 - Kelsey Jig (www.rochemining.com) 8
Figure 2.5.2 View of the Kelsey Jig showing the slurry flow through the concentrator 9
Figure 2.5.3 - Rotating section of the Kelsey Jig showing the mechanism for pulsing the ragging
bed in the concentrator 10
Figure 2.6.1 Section view of the Knelson CVD concentrator (Knelson Concentrators) 12
Figure 3.2.1 CVD6 pilot plant 17
Figure 3.2.2 - Main level of the CVD6 pilot plant showing the CVD6, feed tank, product
transfer pump and miscellaneous piping 18
Figure 3.2.3 - Sample plant block diagram 20
Figure 4.2.1.1 - CVD6 determination of steady state conditions 23
Figure 4.2.1.2 - Confirmation of steady state conditions for CVD6 24
Figure 5.3.2.1 - Bowl speed relationship with grade, recovery and mass yield with a
quartz/magnetite feed 44
Figure 5.3.3.1 - Fluidization water flowrate relationship with grade, recovery and mass yield
with a quartz/magnetite feed 46
Figure 5.3.4.1 - Feed percent solids relationship with grade, recovery and mass yield with a
quartz/magnetite feed 48
Figure 6.2.1.1 - Size distribution of sphalerite (zinc concentrate from HBM&S) used in
synthetic zinc feed 51
Figure 6.2.1.2 - Size distribution of the synthetic quartz and sphalerite feed 53
Figure 6.3.1 - Bowl speed versus grade at varying pinch valve closed times 57
xi
Figure 6.3.2 - Upper boundary results for synthetic sphalerite/quartz 58
Figure 7.3.2.1 - Grade and recovery versus bowl speed 67
Figure 7.3.3.1 - Grade versus pinch valve open time 68
Figure 7.3.3.2 - Recovery versus pinch valve open time 69
Figure 7.3.4.1 - Grade versus pinch valve closed time 71
Figure 7.3.4.2 - Recovery versus pinch valve closed time 72
Figure 8.2.1 - Separation performance of fully liberated synthetic feeds 74
Figure 8.2.1 - Separation performance of fully liberated synthetic feeds 75
Figure 8.2.2 - Upper boundary lines for recovery and upgrade ratio from the plant trials at
HBM&S 75
Figure 9.2.1 - Recovery versus grade 80
Figure 10.4.1 - Drawing an upper boundary condition on a grade recovery curve 92
xii
ACKNOWLEDGEMENTS
This study was funded by The Science Council of British Columbia and Knelson Concentrators.
The support of these organizations has been greatly appreciated.
The work was supervised by Dr. Bern Klein, Department of Mining and Mineral Process
Engineering, The University of British Columbia
Much of the test work, analysis was performed in collaboration with Michael Lambert. Thank
you for your significant contribution to this work.
Thank you to my parents for their relentless support in this endeavor.
There are many people who have helped along the way, but none more than my loving wife,
Candice. Candice, thank you for your never ending patience and support throughout this
journey.
xiii
1 Introduction
There are currently three commercially available continuous centrifugal gravity concentrators:
the Kelsey Jig, the Falcon C and the Knelson CVD. This thesis is a study into the understanding
of the operation of one continuous centrifugal gravity concentrator, the Knelson Continuous
Variable Discharge (CVD) concentrator. In particular the focus of this thesis is to demonstrate
the impact of operating variables on the separation performance of this continuous centrifugal
gravity concentrator.
This systematic study is aimed at gaining a better understanding of how to operate the
concentrator for a range of applications and to identify the equipment's capabilities and
limitations.
Pilot scale testing was conducted in both controlled laboratory conditions and field testing at an
operating mine. The laboratory work included:
• Testing of a fully liberated synthetic mixture of quartz and magnetite
• Evaluation of a synthetic mixture or sphalerite and quartz.
With the baseline knowledge that was gained in the laboratory, a second phase offield-testing at
an operating Canadian base metal operation was conducted.
The combination of laboratory and field-testing was then evaluated in combination to understand
the effect of operating variables on grade, recovery. Results were analyzed to determine how the
mineral density differential was affected by the same operating variables.
1
2 Literature Review
2.1 History
Gravity concentration is one of the oldest and simplest form of separation of valuable minerals
from gangue material. The first gravity concentrators to be developed exploited the difference in
specific gravity of particles under the force resulting from gravity. Some common devices that
fall into this category are:
• Sluices
• Jigs
• Shaking tables
• Spirals
• Reichert Cones
Many of the gravity separation technologies were developed for the separation of gold. In the
late 1970's Byron Knelson observed that fine gold was being lost in sluice box tails of a placer
operation. Mr. Knelson subsequently set out to develop a machine that could recover this fine
gold. This was the first commercial version of a centrifugal gravity concentrator. The machine
has similarities to a conceptual machine designed, but not commercialized in 1935 by MacNicol
in Australia, (www.concentrators.net). Other batch centrifugal concentrators have been
developed since this time including the Falcon SB.
2.2 Batch and Use
The original Knelson Concentrator is a batch process machine that utilizes a spinning cone to
enhance the force of gravity for improved particle separation. Water is injected into riffles in the
2
cone that creates an enhanced fluidized bed separator in the concentrator to capture gold and/or
platinum group metals. The concentrator accepts feed typically for between 0.5 and 5 hours
depending on the grade and nature of the feed before it is stopped and flushed. Modern versions
of the batch Knelson concentrator are fully automated and flush automatically. In the flush cycle
the feed is stopped, the cone stops spinning and the concentrate is flushed through a multi-port
hub in the bottom of the machine. A typical flush cycle in an automated Knelson concentrator
takes between two and three minutes (www.knelson.com). The mass yield to concentrate of a
batch concentrator is in the order of 0.1% of the feed which is a concentration ratio of
approximately 1000:1.
A typical feed grade for a batch Knelson concentrator can be measured in grams/tonne. There
are two traditional applications for a batch gravity concentrator. One is for hard rock gold mines
where it typically treats the cyclone underflow within a grinding circuit circulating load. The
second application is in alluvial gold applications. Due to the low grade of gold and platinum
group metals in relation to gangue material, a shut-down flush cycle is acceptable as it only
represents between approximately one and eight percent of operating time. In grinding circuit
applications, there is a high probability that free gold in a cyclone feed will report to cyclone
underflow, (S. Banisi, A.R. LaPlante, J. Marois, 1999). Taking the recirculation of gold in
grinding circuits into consideration, it becomes possible to utilize batch gravity concentration
with offline time for flushing. During concentrator flush cycles gold will have a high probability
of remaining in the grinding circuit.
3
2.3 Evolution of Continuous Centrifugal Concentrators from Batch Technology
In applications where the grade of the desired mineral is at percentage levels, the use of a batch
concentrator becomes unfeasible. A batch concentrator would have to be stopped and flushed so
frequently that it would effectively have zero feed availability. In order to address this type of
application with high mass yield requirements, centrifugal gravity concentrators that could
remove concentrate quickly and efficiently were required. This led to the development of the
general class of gravity concentrators commonly known as "continuous centrifugal
concentrators." There are three commercially available machines that qualify as continuous
centrifugal concentrators: Knelson Continuous Variable Discharge (CVD), Falcon C, and Kelsey
Jig.
The Knelson CVD and the Falcon C have the capability of producing a wide range of mass
yields with a practical range from 0 to 65%. The Kelsey Jig is more effective at sharp
separations at relatively low mass yields to concentrate (typically less than 10%> mass yield to
concentrate). In the next sections each of these machines is reviewed in more detail.
4
A list of the commercially available continuous concentrators is shown in Table 2.1.
Table 2.1 The CVD has either one or two concentrating rings as indicated by the model number
(eg. CVD 32-1 has one concentrating ring and CVD32-2 has 2 concentrating rings. The bowl
dimensions range from 6 inches to 42 inches and is indicated by the model number.
Table 2.3.1 CVD Commercially available models
Concentrator Model Feed Tonnage
(tonnes/hour)
Knelson CVD6-1 0.5-2
Knelson CVD20-1 15-35
2.4 Falcon C
The Falcon Model C is the simplest machine as it has only two operating variables; bowl speed
and valve aperture size. It is important to note that the Falcon C has no fluidization water added.
Any water that is required for the operation of the concentrator is added to the Falcon C feed.
The Falcon utilizes a large feed preparation distance in the lower portion of the Falcon C bowl.
The smooth feed preparation section of the concentrator's bowl leads into capture rings in the top
section of the Falcon bowl. At the back of each of the rings is a pneumatically operated annular
discharge valve. The physical features of the Falcon C can be seen in Figure 2.4.1. The valve
5
technology sets the valve to afixedopen aperture size and remains open at all times. The valve
aperture size is adjustable through the automated control on the Falcon C.
Figure 2.4.1 Section view of the Falcon C technology, (www.concentrators.net) { TC "Figure
2.4.1 Section view of the Falcon C technology, (www.concentrators.net)" \f F \1 "1"}
The operating parameters of the Falcon C include:
• Valve aperture size

• G-force
Feed enters the Falcon C through a feed tube in the top of the concentrator and is directed to a
simple feed accelerator that accelerates the slurry to the lower bowl wall. The bottom of the
Falcon C bowl is smooth and acts as a feed preparation area for the capture rings at the top of the
Falcon bowl. The particles travel up the smooth bowl section where heavy particles displace
light particles along the bowl wall. At the top of the bowl is a concentrate collection ring with
6
controllable and remains open to expel concentrate from the capture rings into a dedicated
concentrate launder. The tailing material forms the innermost layer on the bowl wall and
overflows the bowl to a tailings launder.
Table 2.4.1 Falcon C models and feed capacities
Concentrator Rated Feed Capacity
Model (tones solids/hour)
Falcon C400 1-4.5
Falcon CI000 5.5-30
Falcon C2000 22-66
Falcon C4000 45 - 100
The applications for the Falcon C as listed on the Falcon Concentrators Website are Fine coal
cleaning (-1mm coal) and Scavenging of metal values from tailings (www.concentrators.net).
2.5 Kelsey Jig
The Kelsey Jig differs from the Knelson CVD and the Falcon C in that it utilizes a rotating jig
bed. The combination of enhanced g-force and the use of a ragging bed enable the Kelsey Jig to
be used in applications where a narrow specific gravity differential is present. Figure 2.5.1 is a
photograph of a Kelsey Jig and Figure 2.5.2 is a section schematic showing the slurry flow paths
through the concentrator.
7
Figure 2.1 - Kelsey Jig (wvvav.rochemining.com)
The ragging size and density can be altered to affect the crispness of separation in the Kelsey Jig.
Generally the density and size of the ragging in a Kelsey jig is intermediate to the target mineral
and the gangue sg. A ragging recovery circuit is utilized with the Kelsey Jig.
8
Figure 2.5.2 Section view of the Kelsey Jig showing the slurry flow through the concentrator,
(www.rochemining. com)
Table 2.5.1 Kelsey Jig models and rated solids feed capacities.
Concentrator Model Rated Capacity
(tonnes solids/hour)
Kelsey KCJ - Laboratory 15-100 kg/hr
Kelsey J1300 Mk II KCJ 2-30
Kelsey J1800 KCJ 5-60
In the Kelsey Jig, particles are fed into the top and enter the vertical jig bed. The water pulsation
cycles in the hutch behind the bed facilitates particle separation. The centrifugal acceleration
9
imparted on the heavy particles causes them to travel radially outward through ragging and into a
hutch. Low density particles travel upwards across the bed and overflow to a launder. The three
controllable variables in the Kelsey Jig are bowl speed, ragging size/density and jigging
pulsation. Figure 2.5.3 shows a photo of the rotating mechanism in the Kelsey Jig with the
pulsating rubber baffles that provide the movement in the jigging bed. The picture of the
mechanism shows how this concentrator is more mechanically complex than the Knelson CVD
and the Falcon C.
Figure 2.5.3 - Rotating section of the Kelsey Jig showing the mechanism for pulsing the ragging
bed in the concentrator
The Kelsey Jig applications are not well publicized. However the flagship commercial
installation for the Kelsey Jig is in the Australia at the Greenbushes plant, owned by Sons of
Gwalia. In this application the Kelsey jig is being used for the recovery offineTantalum.
10
2.6 Knelson CVD
A section view of the Knelson CVD is shown in Figure 2.6.1. Feed is introduced into the top of
the machine through a feed tube into the center of the bowl section. The feed hits a plate at the
bottom of the bowl section and is dispersed radially to the bowl wall. The particles are
accelerated to a g-force defined by the bowl speed and travel up a short section of smooth wall
towards the ring. The short smooth lower section of the CVD concentrating cone is designed to
smooth the turbulence of the incoming slurry prior to entering the separation ring(s) where
fluidization water, supplied through holes in the ring wall, is added to fluidize the bed of packed
particles. Concentrate is extracted through pinch valves at the back of the ring. The pinch valve
timing (open/closed) can be adjusted. Light particles overflow the bowl into a tailings launder.
11
Feed Tube
Figure 2.6.1 Section view of the Knelson CVD concentrator (Knelson Concentrators)
The Knelson CVD has four main operating variables:
• Bowl Speed (g-force)
• Pinch Valve Open Time
• Pinch Valve Closed Time
• Fluidization Water Flowrate
12
The combination of variables and their associated effects on separation performance produces a
complicated problem of selecting appropriate levels for an effective separation of a mineral
system.
All models of the CVD are fully automated. The machine operating variables listed above can
all be changed via a touch screen user interface connected to PLC control.
The rotating section of the CVD concentrator is driven by a motor on a variable frequency drive.
By entering bowl speed values into the PLC interface the frequency on the drive is altered to the
entered set point. The bowl speed is continually monitored with proximity sensors on the driven
sheave to insure that the set point g-force is maintained.
The feature in the CVD that makes it a continuous concentrator is the ability to remove
concentrate from the separation ring without stopping the feed to the machine. Pneumatically
operated rubber pinch valves that can be opened and closed for specific intervals enable tight
control over the removal of material from the concentrating ring(s). The pinch valve intervals -
open and closed time, are both adjusted by entering set-points into the touch screen interface.
There is an automated piping assembly on the CVD that includes a segmented ball valve in a
feed forward control loop with a digital flowmeter. The water flow to the concentrating ring is
delivered through small straight holes in the back of the concentrating ring. A setpoint for the
water flowrate to the concentrator is set and can be adjusted from the PLC touchscreen interface.
13
2.6.1 Knelson CVD Applications
The CVD has been commercially applied in the following applications (www.knelson.com):
• Separation of iron oxides from talc (Byron, R.O., K. Roberts, 2004)
• Cassiterite
• Chromite
• Gold sulphides (Simpson P., 2003)
Other applications have been or are currently being tested by Knelson Concentrators. These
applications may be in laboratory pilot testing or plant pilot/commercial testing but have not
been accepted as an economic process yet by commercial producers. Some of these applications
include:
• Separation of Tantalite
• Separation of ash and sulphur from coal
• Gold removal from bio-oxidation residues
• Separation of precious metals from used circuit boards
The applications for the CVD are diverse.
3 Experimental Program
3.1 Test Program
The evaluation of the CVD6 concentrator was performed at the laboratory pilot scale and at an
operating mill.
14
The machine was first tested in the laboratory setting with the objective being to develop a
framework understanding of the influence of operating variables on separation performance.
The laboratory testwork was performed with synthetic mixtures in a controlled environment.
The results of the laboratory testing with synthetic mixtures was then verified and expanded on
with field pilot testing at an operating mill. Field-testing enabled the results from the laboratory
testing to be verified and expanded. The field pilot testing enabled large numbers of tests to be
performed in a relatively short period of time.
Field testing was performed on a sulphide stream at Hudson's Bay Mining and Smelting
(HBM&S). The CVD6 was installed with a bleed stream of cleaner flotation feed. The feed,
concentrate and tailings could all be sampled directly at the concentrator.
3.2 Pilot Scale Circuit
A Knelson CVD6 unit was used for pilot scale testing in the UBC Centre for Coal and mineral
Processing (CCMP).
Some of the factors that were considered when designing and constructing the pilot plant were as
follows:
• The feed had to remain consistent for the duration of the testing. The products
(concentrate and tailings) from the CVD could not be recombined with the feed until the
sampling was complete.
• The feed tank had to be agitated in such a way as to produce a homogeneous slurry.
15
• The feed tank needed to be sufficiently sized to accommodate enough feed slurry for a 15
minute feed duration at 1 tonne/hour feed rate to the CVD6.
• The products from the CVD needed to be stored in a separate tank that would
accommodate the slurry plus any water that was added in the CVD6.
• Decant systems were necessary to adjust the feed slurry density prior to each test.
• The feed rate to the CVD6 needed to be consistent, adjustable and reproducible.
• Sample points were required to collect representative samples of feed, concentrate and
tailings.
A pilot scale circuit was designed and constructed. Primary goals of circuit design were to
enable full control of feed rate and enable quality sampling of concentrate, tailings, and feed for
trial runs. Feed is agitated in a 145 x 145cm (57" x 57") flat bottom polyethylene baffled tank by
a 2 V2 hp motor and 38cm (15") axial flow impeller assembly. The feed is pumped through a
side discharge in the feed tank to the CVD by a fixed speed slurry pump. Concentrate and
tailings from the CVD is pumped to a second 145 x 145cm (57" x 57") polyethylene tank where
it is stored until the run is complete. After each run is complete, the feed slurry is transferred
from the holding tank to the feed tank in preparation for the next trial. Figure 3.2.1 shows a
picture of the completed pilot plant
16
17
Figure 3.2.2 - Main level of the CVD6 pilot plant showing the CVD6, feed tank, product
transfer pump and miscellaneous piping.
Much of the equipment used in the construction of the pilot plant was salvaged and assembled
for this duty. Figure 3.2.2 shows the CVD6 in the foreground with water, compressed air and
electricity attached to the equipment. Leading off to the right of the CVD6 are the tails in the top
pipe and concentrate in the lower pipe. Both product pipes are routed to a Sala tank pump that is
used to transfer the combined products to a holding tank on the second level. Sampling was
performed by collecting timed flows of concentrate and multiple cuts of the tails stream.
Figure 3.2.3 shows a conceptual block diagram of the pilot plant. A valved recycle line was used
after the feed pump to adjust the feed rate to the CVD6. An oversized fixed speed pump was
18
used to keep a high line velocity. Tests were performed to ensure that a representative feed
consistently delivered to the unit.
19
Holding Tank
Feed Recycle and

Feed Sample Point Slurry Transfer
(between batches)
Agitated Feed
Excess Water
Feed Pump
Tails Pump
and Sample
Fluidization Point
Tails
Compressed
Concentrate
Concentrate
Pump and
Sample Point
Figure 3.2.3 - Sample plant block diagram
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4 Quartz Magnetite Factorial Design
4.1 Introduction
A factorial design test program was utilized to determine the effects of the CVD operating
variables on product grade and recovery. Originally eight variables were identified as having a
possible effect on the separation performance of the CVD. These operating variables can be
classified as feed and machine variables. The variables are outlined in Table 4.1.1.
Table 4.1.1 - Variables impacting product grade and recovery
Machine Variables Feed Variables
Bowl speed Feed rate
Pinch valve open time % solids
Pinch valve closed time Particle size
Fluidization water flowrate Grade
In order to test one variable at a time at two levels would have required 256 tests and for three
levels would have required 6561 tests. Therefore, a statistical experimental design program was
designed and implemented. A 2 " fractional factorial design was used that required 16 main
8 4
tests and 3 center point runs.
Using a factorial design provided sufficient information to rank the effect of variables on product
grade and recovery. The results of this test program provided an empirical understanding of the
influence of the variables on process performance. The results were used to assist in the
development and implementation of subsequent test programs.
21
4.2 Experimental
4.2.1 Procedure
A mixture of quartz and magnetite was used for the test program. Sized silica sand (quartz) was
obtained and the size distributions were confirmed by sieve analysis. The magnetite was
prepared in two size fractions with P 's of 125 and 425 pm. For testing, the quartz and the
80
appropriate size fraction of magnetite were added to the feed tank. The percent solids were
adjusted to target level and the slurry was agitated.
The preparation procedure for the magnetite involved crushing, grinding and magnetic
separation. The crushing was performed in three stages by jaw crushing and 2 stages of cone
crushing. The magnetite was then cleaned using a lab scale drum magnetic separator. The purity
of the magnetite was checked with a Davis tube and was determined to be 99.99% pure.
Sixteen pilot tests plus four center point tests were conducted. In all tests the same testing and
sampling procedure was employed. Parameter levels including: pinch valve open time, pinch
valve close time, bowl speed, and fluidization water flow rate were set before the feed was
introduced to the concentrator. The feed tank was agitated thoroughly to produce a
homogeneous slurry and then the slurry was pumped through a flow control valve to the
concentrator.
A test was conducted to determine the time required for the CVD6 to reach steady state
operation. Samples of concentrate were taken every 30 seconds and assayed. During the first
several minutes the magnetite grades were erratic but stabilized within 6 minutes. Two
22
additional tests were performed to confirm that grades stabilized with time. Figure 4.2.1.1 shows
the results of the first test. Figure 4.2.1.2 shows the results of the two additional tests that
confirm that steady state is achieved within 8 minutes. Based on the results of this test, the
concentrator was run for 8 minutes prior to sampling in order to ensure steady-state conditions
were achieved. Sampling lasted for 4 minutes during which the concentrate was collected and
composite samples of feed and tailings were collected. Each of the samples was then pressure
filtered, dried and riffled to obtain two representative sub samples. One of the sub-samples was
subjected to assay to determine magnetite grade and the other retained sample was used for size
assay analysis.
Steady State Testing
25%
0% -I , , 1 1
0 100 200 300 400
Time (seconds)
Figure 4.2.1.1 - CVD6 determination of steady state conditions
23
Steady State Determination
50.0% -i , 1 1 : , , , , , , , , r -
Figure 4.2.1.2 - Confirmation of steady state conditions for CVD6
The magnetite grade was determined using a Davis tube. For size assay analysis each sample
was screened into three fractions: +50, -50 +100, and -100 mesh. Each fraction was assayed
with the Davis tube for % magnetics. Sub-samples were retained for assay checks as required to
ensure reconciliation of head assays.
4.2.2 Quartz/Magnetite Assay Procedure
A Davis tube was used to determine magnetite grades by recovering ferromagnetic magnetite
from representative sub-samples. The samples were prepared for assay using the following
procedure:
• Pressure filter
• Dry in oven at 100 degrees Celsius
• Riffle to manageable sample size as follows:
o 100 grams for feed
24
o 100 grams for tails
o 50 grams for concentrate
The riffled samples were weighed and transferred into 500ml glass beakers. Water was run
through the Davis tube and the electro-magnet was started. The water level in the Davis Tube
was kept constant by setting the height of the water discharge tube. The agitation of the Davis
Tube was turned on. A feed funnel assembly was attached to the Davis tube to prevent spillage
of sample. At this point the sample was carefully slurried with a small water jet in the beaker
and washed slowly into the Davis Tube. Care was taken to avoid overfeeding the Davis tube.
Once the entire sample was run through the Davis tube it was allowed to continue agitation for
another 30 seconds. The water and the agitation were then turned off and a beaker placed under
the tube discharge. The magnet was then turned off and the sample was thoroughly washed out
of the tube and into the beaker. After settling for at least 5 minutes the excess water was
decanted from the beaker. The beaker with the magnetite was then dried completely and
weighed. Once weighed, all sample was returned to the feed tank to prevent depletion.
4.2.3 Attrition Check
Many tests were run with the same synthetic quartz/magnetite feed. A test was conducted to
determine if magnetite was being ground during pumping and mixing. Feed samples from all
tests were subjected to size assay analyses using 50 and 100 mesh screens. Table 4.2.3.1
summarizes the standard deviations in feed assays by size over 15 tests. It was determined
from the test that attrition grinding of magnetite was not a factor.
25
Table 4.2.3.1 - Feed sample standard deviations by size
Size Fraction Standard Deviation in Feed
(mesh) Grade from 15 Tests
+50 3%
50 x 100 12%
-100 6%
As an additional precaution, the tests were carried out in a sequence that minimized the number
of feed changes required to complete the program and maintain consistent size distributions and
grades of magnetite.
26
4.2.4 Test Program Details
The 2 " fractional factorial experimental design required 16 main tests plus 3 center point tests.
s 4
Variables tested in this design included:
• Feed Rate (t/h)
• Pulp density of feed
• Magnetite particle size
• Pinch Valve Open Timing (seconds)
• Pinch Valve Closed Timing (seconds)
• Fluidization Flow Rate (gal/min)
• Bowl Speed (RPM)
• Feed Grade (% Magnetite)
For the experimental design, two levels were selected for each variable, a high and a low level.
These levels were selected based on results from preliminary scoping tests. Table 4.2.5.1 shows
the selected high and low levels for each operating and feed variable.
27
Table 4.2.5.1 - High and low levels for operating variables in factorial design
Variable High Low
Heavies (%) 4 1
Fluidization (gpm) 15 5
Pinch Valve Open (s) 0.08 0.03
Pinch Valve Closed (s) 8 2
Bowl Speed (G's) 75 45
Solids Feed Rate (tph) 2 1
% Solids 45 30
Heavies Particle Size (p80)
(microns) 425 125
A fractional factorial map was utilized to determine what the combination of high and low values
for each variable should be used for each test. The map, shown in Table 4.2.5.2, was then
converted into a test program by adding the variable levels into the map. The test program is
shown in Table 4.2.5.3.
28
Table 4.2.5.2 - Quartz and magnetite factorial design
Heavies Solid
Fluidization % Feed Bowl Pinch Pinch
Test Particle Feed
Water Solids Grade Speed Open Closed
Size Rate
1 High High High High High High High High
2 Low High High High High Low Low Low
3 High Low High High Low High Low Low
4 Low Low High High Low Low High High
5 High High Low High Low Low Low High
6 Low High Low High Low High High Low
7 High Low Low High High Low High Low
8 Low Low Low High High High Low High
29
Table 4.2.5.3 - Quartz/magnetite factorial design test program
Heavies Solid
Fluidization Feed Particle Bowl Pinch Pinch Feed
Water % Grade Size (p80 Speed Open Closed Rate
Test (gal/min) Solids (%) microns) (RPM) (s) (s) (t/h)
1 14 45 4 425 925 0.05 8 2
2 5 45 4 425 925 0.03 2 1
3 14 30 4 425 725 0.05 2 1
4 5 30 4 425 725 0.03 8 2
5 14 45 1 425 725 0.03 2 2
6 5 45 1 425 725 0.05 8 1
7 14 30 1 425 925 0.03 8 1
8 5 30 1 425 925 0.05 2 2
9 14 45 4 125 725 0.03 8 1
10 5 45 4 125 725 0.05 2 2
11 14 30 4 125 925 0.03 2 2
12 5 30 4 125 925 0.05 8 1
13 14 45 1 125 925 0.05 2 1
14 5 45 1 125 925 0.03 8 2
15 14 30 1 125 725 0.05 8 2
16 5 30 1 125 725 0.03 2 1
30
4.3 Results
4.3.1 Introduction
The main measured responses from the program were product grade, mass yield and recovery.
Mass balances were generated for each test to obtain mass yields and recoveries. The mass
balance data and operating data was combined into one spreadsheet. Variable effects were
calculated to rank the relative importance of the variables for each of the responses. The effects
of operating variable can be interpreted as the percentage change in the response (grade or
recovery) resulting from the change in that operating variable level.
4.3.1.1 Method of Calculating Operating Variable Effects from Factorial Design Results
For each variable tested in the factorial design an effect was calculated. Two effects were
calculated, one for grade and one for recovery. The effect is a way of quantifying the impact that
individual or interacting variables have on an outcome (grade or recovery).
The design and associated grades and recoveries for each test are presented in Appendix A.
The following methodology outlines the procedure used for calculating the effects for grade and
recovery. For the effect on grade, the following process was used:
• Concentrate grade was recorded for each set of conditions.
• For each operating variable the grades from all of the tests run at high levels for that
specific variable were averaged.
• For each operating variable the grades from all of the tests run at low levels for that
specific variable were averaged.
31
The average grade of the high levels was then subtracted from the average of the low
levels.
The resulting number (in percent) is the effect each variable had on grade when it was
increased from the low to the high level.
32
This procedure can also be summarized by the following equation for calculating effects in a
factorial design:
main effect = y - y_+
The equation above (Box et All., 1978) is used for the calculation of main effects in a factorial
design. As described previously the main effect is the average of the high parameter level results
minus the low parameter level results.
4.3.2 Effect of Operating Variables on Grade
The effects of operating variables on concentrate grade are shown in Table 4.3.2.1. The error
associated with these results is ± 3.4%. The error was calculated by running a series of repeated
tests. The repeat tests were performed at center point levels of variables. The standard
deviations of the duplicate tests are used as the error. Parameters with effects larger than the
error are considered significant.
As shown in Table 4.3.2.1, the parameter that most influenced the grade of the concentrate was
found to be the solid feed rate. As the solid feed rate was increased from 1 tph to 2 tph, the
impact was an 8.2% increase in concentrate grade. Similarly, the effects of other variables are
shown in Table 4.3.2.1. High and low variable levels are summarized in Table 4.2.5.1. Pinch
valve open time, and heavy particle P80 size did not qualify as significant effects because their
effect was less than the standard deviation of +/-3.4%.
33
Table 4.3.2.1 - Calculated operating variable effects on magnetite grade
Rank Variable Effect
1 Solid Feed Rate (t/h) 8.2%

2 Bowl Speed (G's) -7.3%
3 Pinch Closed (s) 6.3%
4 % Solids -6.2%
5 Fluidization (g/min) -4.6%
6 Feed Grade (%) 4.2%
7 Pinch Open (s) -3.1%
8 Heavies Particle Size (p80 microns) 2.0%
In a plant environment, the feed parameters are not easily manipulated. The results have been
split into feed variables and operating variables in Tables 4.3.2.2 and 4.3.2.3. The effect of feed
variables on grade can be used to evaluate the installation location within a plant. However, the
machine operating variables can be used to directly influence the performance of the
concentrator.
Table 4.3.2.2 - Significant feed variable effects on grade
Rank Feed Variable Effect
2 % Solids -6.2%
34
Table 4.3.2.3 - Calculated machine variable effects on grade
Rank Operating Variable Effect
2 Pinch Valve Closed (s) 6.3%
3 Fluidization (gal/min) -4.6%
4.3.3 Effect of Operating Variables on Recovery
The effects that single operating variables had on recovery of magnetite to the concentrate are
shown from most significant to least significant in Table 4.3.3.1. The error associated with these
results is ± 9.0%. The error was calculated using a standard deviation from repeat tests.
35
Table 4.3.3.1 - Calculated operating variable effects on recovery from factorial design results
Rank Variable Recovery Effect
1 Heavy Particle Size (pgo microns) -21.9%
2 Pinch Closed (seconds) -12.5%
3 Bowl Speed (RPM) -12%
4 %Solids -5.9%
5 Fluidization Water Flow (gpm) 4.8%
6 Pinch Open (seconds) 4.0%
7 Feed Grade (%) -3.2%
8 Solid Feed Rate (tons/hour) -1.6%
Considering the results in Table 4.3.3.1, the most influential parameter was found to be the Pgo
size of the heavy particle. It was found that increasing the heavy particle Pgo (magnetite particle
size) in the feed from 125 microns to 425 microns caused the recovery to decrease by 21.9
percent. The decrease in recovery is due to fewer large particles being capable of passing
through the pinch valves in a discrete time. The effects of all parameters tested are summarized
in Table 4.3.3.1.
Table 4.3.3.2 classifies the effects of machine variables on recovery performance. Only
variables that had an effect in excess of +1-9% were considered significant in this test program.
The only feed variable with a significant effect was heavy particle size. This effect was -21.9%.
36
Table 4.3.3.2 - Machine variable effects on recovery
Rank Machine Variable Effect
1 Pinch Closed (seconds) -12.5%
2 Bowl Speed (rpm) -12%
4.3.4 Conclusion
The factorial design testwork with a synthetic feed of quartz and magnetite allowed the effects of
the variables to be ranked. The results can be used to prioritize the impact that variations in the
feed or the machine operating variable levels have on the separation performance. The results
were classified as machine variables and feed variables and rated in order of importance with
respect to both grade and recovery.
Table 4.3.4.1 presents the significant variables in order of significance from the test program.
The table classifies the variables as either feed variables or machine variables. The effects are
measured as either an effect on grade or recovery. Of the 8 variables tested, the only variable
that did not have a significant effect was pinch valve open time. It is possible that the high and
low levels for this variable were set too close together to have a significant effect. Further
incremental testing will determine whether this hypothesis is correct.
37
Table 4.3.4.1 - Summary of significant variable effects
Feed Variables Machine Variables

Grade Recovery Grade Recovery
Solids Feed Pinch Valve Closed
Heavy Particle Size Bowl Speed
Rate Time
Pinch Valve Closed
% Solids Bowl Speed
Time
Feed Grade Fluidization Water
Testing of the impact of feed characteristics is more important for understanding the implications
of different feed types. This section did not reveal a great deal of useful information on the
impact of feed characteristics. The most interesting result was that heavy particle size had a very
significant impact on recovery. This indicates that separation by size is a key parameter to study
when evaluating CVD performance. It is believed that the particle size impacts the rate at which
particles will travel through the pinch valves. Perhaps longer open times would counteract the
recovery drop effect as particle size gets larger. This result demonstrates that it is necessary to
study a more detailed range of parameter levels in order to fully understand the effect of the
operating variables. The next section of this report studies the effect of operating variables over
a broader spectrum than the 3 parameter level factorial design approach.
This test program ranked the operating variables of the CVD based on selected high, low and
midpoint levels for each parameter. During calculation of the effects, interaction effects were
ignored and confounded results were eliminated. In order to better understand the impact of the
variables over a wide range of levels, further incremental testing is recommended. This program
38
was an effective tool in identifying that all variables (other than pinch valve open time)
significant. No variables can be eliminated from further testing.
39
5 Quartz/Magnetite Incremental Testing
5.7 Introduction
Incremental testing is a necessary c o m p a n i o n to a statistical e x p e r i m e n t a l d e s i g n . I n a statistical
e x p e r i m e n t a l d e s i g n a range o f each operating v a r i a b l e is selected. T h e h i g h , l o w and center
p o i n t o f each v a r i a b l e is tested i n the d e s i g n i n order to establish each i n d i v i d u a l parameter's
effect o n the results. T h i s type o f testing is v e r y useful i n e s t a b l i s h i n g w h i c h v a r i a b l e s are
significant i n a s y s t e m o f variables that is v e r y c o m p l e x . H o w e v e r , a factorial d e s i g n does not
s h o w w h a t the grades and recoveries are o v e r the w h o l e range o f l e v e l s for each operating
v a r i a b l e . I n fact, because o n l y three p o i n t s f r o m each operating v a r i a b l e ' s range are tested i n the
d e s i g n , a n i n f l e c t i o n p o i n t i n the results m a y be m i s s e d . I f a range for the v a r i a b l e s is selected
that is too s m a l l then it m a y not encompass the c r i t i c a l m a x i m u m or m i n i m u m p o i n t . I f the range
is too large then the m a x i m u m or m i n i m u m p o i n t m a y be b r i d g e d and not seen. A n i n c r e m e n t a l
test p r o g r a m is r e q u i r e d to s h o w detail o v e r the w h o l e operable range o f the m a c h i n e . It w o u l d
not be feasible to test a l l operating v a r i a b l e s i n an i n c r e m e n t a l d e s i g n so the factorial d e s i g n is
essential i n n a r r o w i n g the focus.
5.2 Experimental Test Program
T h e i n c r e m e n t a l test p r o g r a m for quartz and magnetite tested the effects o f f l u i d i z a t i o n water
flowrate, feed percent s o l i d s , and b o w l speed. P i n c h v a l v e o p e n a n d c l o s e d t i m e w a s not tested
i n this p r o g r a m as it w a s p l a n n e d that they w o u l d be tested i n plant trials. T h i s test p r o g r a m w a s
designed to determine operating parameter trends. T h e test p r o g r a m is s h o w n i n T a b l e 5 . 2 . 1 .
O n l y one v a r i a b l e at a t i m e w a s c h a n g e d i n each subset o f tests i n this i n c r e m e n t a l test p r o g r a m .
40
Table 5.2.1 - Synthetic quartz and magnetite incremental test program
Heavies Lights Solid

Fluidization Feed Particle Particle Bowl Pinch Feed
Water Grade Size (p80 Size (p80 Speed Pinch Closed Rate
Test (g/min) % Solids (%) microns) microns) (G's) Open (s) (s) (t/h)
1 6 25 2 275 425 45 0.03 5 1.5
2 6 30 2 275 425 25 0.05 5 1.5
3 6 30 2 275 425 35 0.05 5 1.5
4 6 30 2 275 425 45 0.05 5 1.5
5 6 30 2 275 425 55 0.05 5 1.5
6 6 30 2 275 425 65 0.05 5 1.5
7 6 30 2 275 425 75 0.05 5 1.5
8 2 30 2 425 425 55 0.05 5 1.5
9 4 30 2 425 425 55 0.05 5 1.5
10 6 30 2 425 425 55' 0.05 5 1.5
11 8 30 2 425 425 55 0.05 5 1.5
12 10 30 2 425 425 55 0.05 5 1.5
13 6 25 2 425 425 55 0.05 5 1.5
14 6 30 2 425 425 55 0.05 5 1.5
15 6 35 2 425 425 55 0.05 5 1.5
16 6 40 2 425 425 55 0.05 5 1.5
41
5.3 Quartz/Magnetite Incremental Testing Results
5.3.1 Introduction
The incremental testing with quartz and magnetite focused on bowl speed, fluidization water
flowrate and feed percent solids. Not all of the operating and feed variables were tested in this
program. The reason for this is that it takes considerable time and effort to run pilot plant
synthetic testing. Therefore the variables that were tested in this program were selected based on
the criteria as described below. Variables that were not tested in this incremental program were
left for testing in subsequent plant testing or eliminated as not significant from the factorial
design.
Bowl speed was investigated because it was identified as having a significant effect on grade and
recovery in the factorial design results. Therefore, analysis of the general trends in grade and
recovery with changing bowl speed was desired.
Fluidization water flowrate was of particular interest as the preliminary testing and the factorial
design did not clearly indicate an appropriate operating range for fluidization water. The
incremental testing allowed this variable to be tested without any other factors impacting the
results.
Feed percent solids was identified as having a significant effect on grade. This variable would
not be easily tested in a plant scenario, as feed parameters cannot easily be manipulated in an
operating mill. Therefore, a controlled lab scale pilot study was considered to be ideal for testing
this parameter.
42
5.3.2 Quartz/Magnetite Trends with Changing Bowl Speed
Incrementally changing the CVD bowl speed between 25 (550rpm) and 75g's (900rpm) resulted
in linear trends in recovery, grade and mass yield as shown in Figure 5.3.2.1.
The bowl speed had the most significant effect on recovery. Increasing bowl speed increased
recovery. The mass yield contributed in part to the increase in recovery with increasing bowl
speed. As the bowl speed increased, the mass yield increased, but at a lesser slope than the
recovery increase. Increasing the bowl speed decreased the grade of the concentrate.
Table 5.3.2.1 - Results of changing bowl speed with quartz and magnetite
Mass
Bowl Con Grade Tails Grade Recovery Yield
Speed (%) (%) (%) (%)
25 29.5 1.35 42.2 3.2

35 22.4 1.16 51.4 5.2
45 20.6 1.11 53.9 5.9
55 19.0 0.86 64.9 7.7
65 18.9 0.77 68.7 8.2
75 16.0 0.67 73.4 10.4
43
Bowl Speed Relationship
20 30 40 50 60 70 80
Bowl Velocity (G's)
• Recovery • Con Grade • Mass Yield
Figure 5.3.2.1 - Bowl speed relationship with grade, recovery and mass yield with a
quartz/magnetite feed
5.3.3 Quartz/Magnetite Trends with Changing Fluidization Water Flowrate
Fluidization water was incrementally changed between 2 and 10 gpm with all other operating
and feed variables constant. The effect on grade, recovery and mass yield are shown in Figure
5.3.3.1.
A small increase in mass yield was observed with increasing mass yield. This increase can be
attributed to lower percentage solids in the concentrate flowing through the pinch valves. The
44
fluidization water acts as a lubricant for the particles and prevents plugging or sticking in the
valves.
The grade of the concentrate was not significantly affected by changing the fluidization water
flowrate. However, the grade decreased slightly over the tested range.
Fluidization water flowrate had a very interesting result on recovery. Between 2 and 6 gpm there
was a sharp increase in recovery. At 6gpm there is a transition point in the recovery trend.
Beyond 6 gpm there was no change in recovery. This result indicates that a minimum amount of
fluidization water is necessary to achieve efficient recovery. Beyond a threshold, 6 gpm,
additional fluidization water only affects grade slightly.
In operating mills water addition is minimized. The result of this test is that fluidization water
should be maintained as close as possible to the threshold of 6gpm. Beyond 6gpm the grade
continues to decrease and needless water is consumed. However, this result also shows that it is
more conservative to run the CVD with more water than the threshold limit as the slope of the
recovery line is very steep before the threshold. The grade and mass yield lines have very small
slopes beyond the threshold. It is conservative to operate the CVD with 7 or 8 gpm.
The result of this test with fluidization water flowrate was informally observed in preliminary
and plant testing. The existence of the transition point was justification to eliminate fluidization
water flowrate from subsequent test programs.
45
Table 5.3.3.1 - Results of changing fluidization water flowrate with quartz and magnetite
Mass
Con Grade Tails Grade Recovery Yield
Fluidization (%) (%) (%) (%)
2 16.6 1.46 30.6 3.7
4 22.0 1.34 35.8 3.2
6 21.6 1.12 47.2 4.4
8 19.3 1.13 47.0 4.9
10 17.6 1.12 47.7 5.5
Fluidization Relationship
60%
50%
40%
• Con Grade
A Recovery
S9 30%
• Mass Pull
20% Poly. (Con Grade)
10%
0%
4 6 8 10 12
Fluidization (gpm)
Figure 5.3.3.1 - Fluidization water flowrate relationship with grade, recovery and mass yield
with a quartz/magnetite feed
46
5.3.4 Quartz/Magnetite Trends with Changing Percent Solids
The percent solids in the feed was changed to determine the effect on separation performance.
As shown in Figure 5.3.4.1, the percentage solids in the feed only affected the recovery. This is
similar to the relationship seen when the fluidization water was changed. The higher the solids
content in the feed, the lower the recovery. This test does not have enough data points to clearly
define an inflection point; it does appear that the optimum feed percent solids was approximately
30%. Mass yield and concentrate grade were not affected by percent solids within experimental
error.
Table 5.3.4.1 - Results of changing percentage solids with quartz and magnetite
Mass
Con Grade Tails Grade Recovery Yield
% Solids (%) (%) (%) (%)
25 22.3 1.2 42.2 3.8
30 20.6 1.1 45.3 4.5
35 20.9 1.2 40.0 3.9
40 22.3 1.5 22.9 2.1
47
% Solids Relationship
10%
• •- • .
0% -I , 1 T
20 25 30 35 40 45
% Solids
• Con Grade A Recovery BMass Pull
Figure 5.3.4.1 - Feed percent solids relationship with grade, recovery and mass yield with a
quartz/magnetite feed
5.3.5 Conclusion
Incremental testing of quartz and magnetite feed tested the effects of bowl speed, fluidization
water flowrate and feed percent solids. Increasing bowl speed was found to increase recovery
and mass yield while decreasing concentrate grade. Fluidization water flowrate was determined
to have the greatest effect on recovery. Threshold minimum fluidization water was found at 6
gpm. Above 6 gpm additional fluidization water did not affect recovery and only slightly
reduced grade. It was determined from this result that fluidization water could be held constant
for all subsequent testing. The C V D was found to perform best with feed percent solids of 30%.
48
6 Lab Testing - Synthetic Sphalerite/Quartz
6.1 Introduction
A synthetic feed of quartz and sphalerite was created to test in the lab. This feed was used
because it models a typical sulfide and silicate ore at a fine size. A test program where one
variable was changed incrementally was used to generate data that could be used for plotting
trends.
Specifically this test program was targeted at testing the capabilities of the CVD concentrator at
separating minerals with a smaller SG differential than was present with the quartz/magnetite
system. This system was fully liberated and particle size distributions were similar for both the
denser sphalerite and the less dense quartz.
The information gathered in this component of the test work can be used to determine the
following:
• Whether the CVD concentrator can make a separation at a specific gravity differential of
1.35 with a fully liberated system. The sphalerite (SG 4.0) and quartz (SG 2.65) system
had a specific gravity differential of 1.35. This is a smaller differential than that of
quartz/magnetite at 2.55. This testing would identify whether the CVD could separate
minerals at a close mineral density.
• If the CVD can make a separation with this material then plant testing at Hudson's Bay
Mining and Smelting (HBM&S) can be pursued to investigate how the CVD will behave
on a non-synthetic feed.
49
6.2 Experimental - Synthetic Sphalerite/Quartz
6.2.1 Feed Characterization
The sphalerite component was a final zinc concentrate obtained from HBM&S. The chemical
composition of the zinc concentrate is summarized in Table 6.2.1.1. The zinc concentrate used in
making the synthetic feed was primarily sphalerite with some pyrite and small amounts of galena
and chalcopyrite. The Pgo of the zinc concentrate was 121pm with a size distribution as shown
in Figure 6.2.1.1. Table 6.2.1.2 is a size-assay of the zinc concentrate that shows the component
grades are evenly distributed over the size distribution.
50
Table 6.2.1.1 - C o m p o s i t i o n o f z i n c concentrate f r o m H B M & S used i n creating the synthetic
feed
Assayed Components % Composition

Zn 53.5
S 31.4
Fe 10.3
Pb 0.8
Cu 0.7
Figure 6.2.1.1 - S i z e d i s t r i b u t i o n o f sphalerite ( z i n c concentrate f r o m H B M & S ) used i n

synthetic z i n c feed
Size Distribution of Zinc Concentrate from HBM&S for Use in

Synthetic Sphalerite Feed
y = 0.0091x-0.3003
R = 0.9806
2
100%
90%
80%
D) 70%
C
"35
(A 60%
ra
a.
9)
> 50%
to
3
C
40%
C
3
o 30%
20%
10%
0%
25 50 75 100 125 150 175
Size (um)
51
Table 6.2.1.2 - Composition by size of the zinc concentrate used in the synthetic zinc feed
Size (um) S (%) Cu Pb (%) Zn Fe (%)
(%) (%)
+150 31.9 0.68 0.84 51.2 9.9
-150+106 30.8 0.84 0.79 52.3 10.0
-106+75 31.4 0.65 0.71 53.7 11.0
-75+53 32.0 0.64 0.87 53.6 10.5
-53+38 29.2 0.68 1.00 52.6 9.6
-38 32.4 0.76 0.76 54.1 8.9
The zinc concentrate was blended withfinequartz with a Pso of approximately 135pm. The
synthetic feed had afinalPgo of 135um and a size distribution that is shown in Figure 6.2.1.2.
Effectively the size distribution of the quartz and the sphalerite concentrate were equal. The
composition of the synthetic feed is shown in Table 6.2.1.3. The zinc grade of the synthetic feed
averaged 8.76%.
Table 6.2.1.3 - Composition of the blended synthetic quartz/sphalerite feed

Assayed % Composition
Components
Zn 8.76
S 5.21
Fe 1.75
Pb 0.13
Cu 0.10
52
Synthetic Quartz/Sphalerite Feed Size Distribution
y = 0.0081x-0.2915
175
Size (microns)
Figure 6.2.1.2 - Size distribution of the synthetic quartz and sphalerite feed
6.2.2 Test Program
The synthetic zinc test program investigated the effects of bowl speed, pinch valve open time and
pinch valve closed time. The experimental program consisted of 31 tests. The feed was changed
completely twice to prevent depletion of sphalerite in discrete size fractions. It was unknown
whether the CVD would preferentially separate certain particle sizes and shapes. If this were to
have happened it could have altered the performance results in tests that were conducted later in
the program. As well, between tests all the sample that was not required for assay purposes was
returned to the feed tank. An outline of the experimental program and the order in which the
tests were run is shown in Table 6.2.2.1. Note that the test order was randomized so minimize
systematic experimental error.
53
Table 6.2.2.1 - Synthetic quartz and sphalerite test program
Bowl Pinch Pinch

Speed Open Closed
5 600 0.07 3
7 800 0.07 3
3 700 0.08 3
9 600 0.07 3
4 700 0.07 3
6 800 0.07 3
8 900 0.07 3
10 1000 0.07 3
1 600 0.05 3
2 700 0.05 3
11 800 0.05 3
12 900 0.05 3
13 1000 0.05 3
14 600 0.04 3
15 700 0.04 3
16 800 0.04 3
17 900 0.04 3
18 1000 0.04 3
19 600 0.05 4
20 700 0.05 4
21 800 0.05 4
22 900 0.05 4
23 1000 0.05 4
24 600 0.05 5
25 700 0.05 5
26 800 0.05 5
27 900 0.05 5
28 1000 0.05 5
29 800 0.05 4
30 800 0.05 4
31 800 0.05 4
54
6.2.3 Procedures and Sampling
Samples of feed, concentrate and tailings were taken for each test. A slightly different procedure
was used in sampling the synthetic quartz/sphalerite feed than was employed for the
quartz/magnetite ore. The reason for this is that the samples for the quartz/sphalerite had to be
chemically assayed which took longer than an assay performed by determining percent
magnetics. As well, the sphalerite had to be dried at a lower temperature to prevent oxidation
that took 24 hours. Any sample that was removed from the circuit was depleting the synthetic
feed for 24 hours. A minimum amount of sample for each test had to be taken while still getting
a representative sample.
The machine was run with feed at the set operating parameters for eight minutes before
sampling. Sampling then took place over the next four minutes. 25 liters of feed were taken for
each run. There was no concern in depletion from feed samples because it was a homogeneous
sample. The tailings were sampled in the same manner as in the quartz/magnetite testing. Four
full pinch valve cycles of tailings were sampled over the four minutes of sampling. The
concentrate was carefully taken to avoid feed depletion effects. Cuts of concentrate were taken
over the four minutes of sampling. Each cut of concentrate included three full pinch valve
cycles. An attempt was made to keep the concentrate samples close to 200 grams each.
6.2.4 Sample Preparation
Slurry samples of feed, tailings and concentrate were all prepared for assay with the same
procedure. The samples were pressure filtered, oven dried at 40°C, cooled, rolled, 10 grams split
55
for assay, and 80-100 grams split for size analysis or duplicate assaying. All remaining sample
was added back to the feed tank.
6.3 Results -Synthetic Quartz/Sphalerite
A wide scatter of results was obtained from the incremental testing of the synthetic
quartz/sphalerite. Some basic trends with mass yield, recovery and grade could be seen when the
results were graphed. However, the results were more qualitative than quantitative due to the
small number of tests in each data set. An example of some trending results is shown in Figure
6.3.1 where the grade is shown to be affected by altering the pinch valve closed times and bowl
speeds. Sulphur grade has been used to track sphalerite grade in these results and a dip is evident
in 4 and 5 second pinch valve closed timings and is not present in the 3 second pinch valve
closed timing at 700 RPM. A more thorough test program is required to determine whether a dip
does in fact exist or whether there was an experimental error at this point. What the graph does
show is that the CVD can clearly upgrade the synthetic feed and that increasing bowl speed and
increasing pinch valve closed time reduces the concentrate grade. More detailed analysis of
operating variable trends will have to be determined in plant testing.
56
Figure 6.3.1 - Bowl speed versus grade at varying pinch valve closed times
B o w l S p e e d versus Grade
(PO 0.05, FW 7)
Pinch Closed = 4 sec

Pinch Closed = 5 sec
• A - Pinch Closed = 3 sec
500 700 900 1100

Bowl Speed (RPM)
All of the results from the sphalerite/quartz synthetic feed testing were plotted as upgrade ratio
versus recovery. The upgrade ratio was defined as the ratio between the CVD concentrate grade
and the CVD feed grade. The Sphalerite grade was calculated based on sulphur and Zn assays.
All the data points that formed an upper boundary condition were plotted independently and a
trend line was drawn using these points. Figure 6.3.2 shows the plotted upper boundary
condition that was derived from this test program. Since a broad combination of parameters was
tested this plot represents the typical separation performance of a CVD6 at 135 micron P80 and a
1.35 SG differential. From the graph it can be seen that upgrade ratios range up to 4.25 and
recoveries range from 10 - 70%.
57
Figure 6.3.2 - Upper boundary results for synthetic sphalerite/quartz
Recovery versus Upgrade Ratio

Synthetic Sphalerite - Quartz Background
80%
Upgrade Ratio
58
6.4 Conclusions
The synthetic sphalerite/quartz testing showed that the CVD is capable of making a separation at
an SG differential of 1.35 with similar particle size distributions of the sphalerite and the quartz
fractions. There was not sufficient data in this program to determine any distinct individual
machine operating parameter trends. A larger data set is required to determine distinct trends.
What was clear was that similar grade and recovery results could be obtained with a variety of
machine operating variable combinations.
The positive results from the lab testing of this synthetic ore indicate that it would be
advantageous to test the CVD in the HBM&S mill. The plant testing will be performed in an
effort to identify CVD machine operating variable trends.
59
7 Hudson's Bay Mining and Smelting Plant Trials
7.1 Introduction
A CVD 6 was installed at HBM&S in Flin Flon Manitoba on a zinc flotation cleaner tails stream.
Incremental plant testing was aimed at thoroughly evaluating the CVD operating variable ranges
using a real feed. The following factors of processing real feed as opposed to synthetic feeds
were present:
• Particles were not always fully liberated
• Size distribution was not as uniform
• Ore consisted of a range of mineral densities
One of the major advantages of plant testing is the speed at which data can be collected. In the
lab each test takes hours to perform due to the amount of preparation required to maintain a
consistent feed for each test. In the plant, a test turnaround is generally half an hour. The ability
to run between 10 and 15 tests per day with relatively consistent feed enables large amounts of
data to be collected for analysis.
This data was generated to provide a large database of grade and recovery information to be used
in the creation of an operating strategy. The incremental nature of the testing provides the ability
to plot trends. These trends can show how three variables at a time interact to produce an overall
impact on separation performance.
60
7.2 Experimental - Plant Trials at Hudson's Bay Mining and Smelting
7.2.1 Test Program
The objective of this test program was to investigate how grade and recovery of gold, copper,
and zinc changed with variations in operating parameter levels. This testing took place in an
operational mill where ore conditions, general mill operating conditions, and maintenance
needed to be factored into the design. Tests were organized into manageable modules that could
be carried out in one day. Ore conditions were assumed to be constant throughout a six-hour
time frame. Feed samples were taken for most tests, or at least one feed sample per hour. Each
module changed only one variable and left the remaining variables fixed.
An incremental test program was performed to determine the individual effects that bowl speed,
pinch valve open time and pinch valve closed time had on the grade (upgrade ration), recovery,
and mass yield. All other operating variables were held fixed. Fluidization water flowrate was
held constant throughout the tests. It has been demonstrated in the laboratory quartz/magnetite
testing that fluidization water has little effect on the grade and recovery if set within the range of
6-12 g/min. The solids feed rate to the machine was maintained throughout each module;
however it varied from module to module with changing percent solids.
The test program was first laid out with approximate ranges of operating variable levels set.
Preliminary testing was performed with the CVD on site to fine-tune the tested ranges. A test
program map is shown in table 7.2.1.1.
61
Table 7.2.1.1 - HBM&S incremental testing map of operating variable levels per test
Bowl Feed
Test Speed Pinch Pinch Rate
Date ID RPM Open (s) Closed (s) % solids (tph)
Oct 04/00 62 500 0.18 4 11.55 0.491
Oct 04/00 63 600 0.18 4 11.55 0.491
Oct 04/00 61 700 0.18 4 11.55 0.491
Oct 04/00 64 800 0.18 4 11.55 0.491
Oct 04/00 65 900 0.18 4 11.55 0.491
Oct 04/00 66 1000 0.18 4 11.55 0.491
Oct 05/00 67 500 0.18 2 21.15 1.01
Oct 05/00 68 625 0.18 2 21.15 1.01
Oct 05/00 82 625 0.18 3 21.15 1.01
Oct 05/00 69 625 0.18 4 21.15 1.01
Oct 05/00 70 625 0.18 6 21.15 1.01
Oct 05/00 71 625 0.18 8 21.15 1.01
Oct 05/00 72 700 0.18 2 21.15 1.01
Oct 05/00 73 700 0.18 3 21.15 1.01
Oct 05/00 74 700 0.18 4 21.15 1.01
Oct 05/00 75 700 0.18 6 21.15 1.01
Oct 05/00 76 700 0.18 8 21.15 1.01
Oct 05/00 77 850 0.18 2 21.15 1.01
Oct 05/00 78 850 0.18 3 21.15 1.01
Oct 05/00 79 850 0.18 4 21.15 1.01
Oct 05/00 80 850 0.18 6 21.15 1.01
Oct 05/00 81 850 0.18 8 21.15 1.01
Oct 06/00 83 700 0.16 4 31.15 1.72
Oct 06/00 84 700 0.17 4 31.15 1.72
Oct 06/00 85 700 0.18 4 31.15 1.72
Oct 06/00 86 700 0.19 4 31.15 1.72
Oct 06/00 87 700 0.2 4 31.15 1.72
Oct 06/00 88 850 0.14 4 " 31.15 1.72
Oct 06/00 89 850 0.15 4 31.15 1.72
Oct 06/00 90 850 0.16 4 31.15 1.72
Oct 06/00 91 850 0.17 4 31.15 1.72
Oct 06/00 92 850 0.18 4 31.15 1.72
Oct 10/00 93 625 0.18 4 38.9 2.04
Oct 10/00 94 625 0.19 4 38.9 2.04
Oct 10/00 95 625 0.2 4 38.9 2.04
Oct 10/00 96 625 0.21 4 38.9 2.04
Oct 10/00 97 625 0.22 4 38.9 2.04
Oct 10/00 98 700 0.18 4 38.9 2.04
62
The tests for this incremental design were run over two weeks. The test program was set-up in a
modular format where each module tested a different variable with all of the other feed and
operating variables held constant. Modules were never interrupted and were always run on the
same day. It was advantageous to be running the concentrator on a cleaner tailings stream
because the effect of changing ore conditions and operational difficulties in the mill were
dampened at that point in the circuit.
7.2.2 Procedures and Sampling
Each day before the CVD was run; a thorough visual inspection was performed. The valves
were set to 5 seconds open time and 2 seconds closed time. When the valves were in the open
position a nylon tie-wrap was inserted in the valve to ensure there was no blockage. The strip
was left in the valve until the valve went into the closed cycle at which time the tie-wrap was
gently pulled to make sure that the valve was actuating properly. This procedure was repeated
for all eight valves. Next Fluidization water was run and a visual inspection was made of the
flow through the fluidization holes. The water was left on for about five minutes to ensure the
machine was flushed. At this point the machine was ready for start-up.
With the water running the machine was started at the testing conditions. The feed rate was
adjusted by using a stopwatch and a bucket. Once the desired feed rate was established the feed
tube was inserted in the top of the machine and the test timer started.
In order to achieve accurate and reproducible results, careful sampling procedures were
established. The two major considerations for obtaining good samples from the CVD were
63
establishing a steady state within the machine and getting a representative cut of feed,
concentrate, and tailings.
When any variable is adjusted in the CVD a certain amount of time is required for the machine to
achieve steady state. In the laboratory with synthetic feeds the steady state time was eight
minutes. In the mill longer stabilization time was allowed. Each test was given a minimum of
15 minutes to stabilize. In tests where the mass yields were exceptionally low the machine was
sometimes left for up to two hours to stabilize. There is no data to justify leaving the machine to
stabilize for that long. The basis for leaving the machine longer to stabilize when very little mass
was being extracted was so that all of the material that may have been resident in the machine or
the sample pipes would be flushed between tests.
Samples were required for feed, concentrate and tailings from each test. The tailings line was
always the highest flowrate and was too high to take the entire stream for any length of time.
Due to the semi-continuous extraction of concentrate, the tailings stream needed to be sampled
over entire pinch valve cycles. If the sample did not accurately represent an entire cycle,
erroneous results may have been created. Therefore, several cuts of the entire tailings stream
over at least two whole pinch valve cycles were taken. Due to the low flowrate of concentrate,
the entire concentrate was collected over varying times between 30 seconds and 6 minutes. At
the end of a test where a feed sample was desired the entire feed stream was collected in a bucket
for ten seconds.
64
7.2.3 Sample Preparation
Slurry samples of feed, concentrate and tailings were all prepared for assay in the same way.
Slurry samples were pressure filtered and transferred to pans and dried overnight in a 60 degree
C oven. Once dry, the samples were screened at 8-mesh to break the dry cake into a powder.
The powder was then mixed on waxed paper and a portion was split out for assay and a second
was retained.
65
7.3 Results - Plant Trials at HBM&S
7.3.1 Introduction
Incremental testing of the CVD 6 in Flin Flon, Manitoba at Hudson's Bay Mining and Smelting
was performed to determine the trends of operating variables on separation performance and to
evaluate the effect of specific gravity differential on particle separation. The results are based on
gold assays as they were the most consistent results out of all the assays.
7.3.2 Bowl speed
Tests were conducted on the zinc cleaner tailings at bowl speeds ranging from 500 to 1000 rpm.
The relationship between gold grade and recovery versus bowl speed is shown in Figure 7.3.2.1.
The slope of the grade versus bowl speed curve shows two distinct zones. Between 500 rpm and
700 rpm, the grade decreased significantly from 35 g/t to 15 g/t gold. However, beyond 700 rpm
the slope flattens; increasing the speed from 700 rpm to 1000 rpm lowers the grade by only 5%.
There is a transition zone for grade between 650 rpm and 750 rpm.
66
Grade and Recovery versus Bowl Speed
500 600 700 800 900 1000
Bowl Speed (rpm)
Figure 7.3.2.1 - Grade and recovery versus bowl speed
The recovery mirrors grade, having two distinct slopes at low and high bowl speeds. Between
500 rpm and 700 rpm there is only a 3% increase in the recovery, but between 700 rpm and 1000
rpm there is a 55% increase. There is clearly a change in separation mechanism that occurs at
the transition speed of about 700 rpm that affects the performance.
7.3.3 Pinch valve open time
Pinch valve open times were varied from 0.14 to 0.22 seconds, while other operating variables
were set (Table 1). The effect of open time was evaluated at three different bowl speeds (625
rpm, 700 rpm and 850 rpm). These test conditions were selected with consideration of the gold
recovery objectives for the mine.
67
Figure 7.3.3.1 shows that the concentrate grade decreased with increasing pinch valve open time.
The trend was the same at all three bowl speeds except that the curves were shifted downwards
with increasing bowl speed.
Grade versus Pinch Valve Open Time
40
35 850 rpm \ 700 rpm \ 625 rpm
30
\v •
S 25
m 20
o
<
10
0.13 0.14 0.15 0.16 0.17 0.18 0.19 0.2 0.21 0.22 0.23
Pinch Valve Open Time (seconds)
Figure 7.3.3.1 - Grade versus pinch valve open time
Figure 7.3.3.2 shows that the recovery increases with increasing pinch valve open time.
Increasing bowl speed shifts the recovery upwards. Recovery increases more rapidly at higher
rpm's per incremental change in pinch valve open time. This trend is more visible beyond the
transition point in the recovery versus pinch valve open time curves. The rate of change in
recovery versus pinch valve open time decreases with decreasing bowl speed. This effect can be
seen in Figure 7.3.3.2 where the linear trend line slopes become flatter when comparing the 850
rpm, 700 rpm, and 625 rpm lines.
68
Recovery versus Pinch Valve Open Time
Pinch Valve Open Time (seconds)
Figure 7.3.3.2 - Recovery versus pinch valve open time
The data trends were drawn as curves in Figures 7.3.3.1 and 7.3.3.2 with straight lines
superimposed. The straight lines indicate two distinct sections for each rpm tested with a
transition zone located around the intersection of the lines (transition point). The trend lines
extend beyond the transition zone to show that the transition is smooth. This suggests that the
mechanism responsible for the change in slope does not occur at a specific point. However, the
transition point is useful to distinguish between zones dominated by different separation
mechanisms.
For pinch valve open times up to the transition point, the steep decrease in grade can be
explained by the dilution of the high-grade material near the pinch valve resulting from the
recovery of lower grade material. Increasing the pinch valve open time further, beyond the
transition point, further increases the proportion of the low-grade material in the ring that is
69
recovered. However, the incrementally increased recovery of low-grade material has a
diminishing effect on dilution. Therefore the grade levels off and eventually approaches the feed
grade.
7.3.4 Pinch valve closed time
Pinch valve closed times were varied from two to eight seconds while hold other operating
variable levels constant (Table 7.2.1.1). As shown in Figure 7.3.4.1, the concentrate grade
increased with increasing pinch valve closed time. A longer pinch valve closed time allows for
more upgrading in the concentrating ring resulting from heavy particles displacing light ones.
Figure 7.3.4.1 also shows that while upgrading took place at a bowl speed of 625 rpm, at higher
bowl speeds (700rpm and 850 rpm) the concentrate grades were not affected significantly.
These results support those described above, which suggested that high bowl speeds inhibit
upgrading in the ring. At high bowl speeds, packing in the ring likely prevents particle
displacement.
Grade versus Pinch Valve Closed Time
18
625 rpm
16
14
5" 12
"©10
•a
re
O
850 rpm
3 4 5 6 7
Pinch Valve Closed Time (seconds)
70
Figure 7.3.4.1 - Grade versus pinch valve closed time
At 625 rpm, the absence of a clear transition point indicates that the grade will continue to
increase with closed time at a uniform rate. Eventually the grade would approach a constant
value that depends on particle specific gravity and size.
As described above, visual observations reveal that cones of coarse high density material radiates
from the pinch valves. The particle size gradation within the cone ranges from coarse near the
pinch valve to fine further away from the valve.
As shown in Figure 7.3.4.2, the recovery decreases significantly for pinch valve closed times up
to about 3 seconds and then decreases at a much slower rate. This transition point represents an
operating limit for pinch valve closed time. Based on operating experience with the CVD, it is
not practical to use pinch valve closed times of less than 3 seconds because the upgrade ratios are
low.
71
Recovery versus Pinch Valve Closed Time
Pinch Valve Closed Time (seconds)
Figure 7.3.4.2 - Recovery versus pinch valve closed time
At 625 rpm, there was almost no recovery over the whole range of pinch valve closed times.
This result was explained by the small pinch valve open time used for these tests, which did not
allow significant mass pull. The recovery curves shift upward with increased bowl speed.
7.4 Conclusions
Plant testing at the HBM&S mill generated significant data that showed the trends formed by
changing operating variables. The one parameter at a time testing methodology showed how the
response curves for grade and recovery formed consistently shaped curves that were shifted with
varying parameter levels. The consistency of the shapes will enable a control strategy to be
developed.
72
8 Specific Gravity Differential
8.1 Introduction
Particle separation in the CVD is based on a combination of specific gravity separation and
particle size classification. The studied mineral systems all have different specific gravity
differentials. The effect of specific gravity differential on separation performance was
investigated in the lab and then verified in the field.
This chapter investigates the upper boundary condition (recovery versus upgrade ratio) results
for quartz/magnetite, quartz/sphalerite, and zinc flotation cleaner tails. Knowing the particle
specific gravity differentials between the target and background minerals the separation
limitations of the CVD are investigated. It is the objective of this chapter to determine the
impact of particle specific gravity on separation in a CVD concentrator.
8.2 Discussion
Figure 8.2.1 shows the upper boundary results for recovery and upgrade ratio for the two studied
synthetic ores; quartz/magnetite and quartz/sphalerite. When plotted on a normal - log plot, two
straight lines are produced. The specific gravity (sg) differential between magnetite and quartz is
2.55 and sphalerite and quartz is 1.35. As expected, Figure 8.2.1 shows that in a fully liberated
system that the higher the specific gravity differential the better the separation performance.
Also note that although the sphalerite system produced lower upgrade ratios, the CVD was still
able to make a separation at a sg differential of 1.35.
73
Recovery versus Upgrade Ratio
Synthetic Ores - Quartz Background
100%
1 10 100
Upgrade Ratio
ure 8.2.1 - Separation performance of fully liberated synthetic feeds
74
Recovery - Upgrade Ratio
HBM&S Plant Trials
100% T - T -
>
0%
1.0 Upgrade Ratio 10.0
• A u • Chalcopyrite * Sphalerite • Galena
Figure 8.2.2 - Upper boundary lines for recovery and upgrade ratio from the plant trials at
HBM&S
Results from the plant trials are analysed separately from the synthetic ores tested in the lab. It is
not clear exactly what the sg differential is as there are 6 components in the natural ore from
HBM&S that are competing. As well, liberation is not 100% as it was in the synthetic systems.
The main composition of the feed to the CVD was pyrite and sphalerite. The feed material in the
HBM&S trials was a flotation cleaner tailings and has a relatively narrow particle size
distribution with a P80 of approximately 100 microns. For this analysis the impact of particle
size has been ignored.
75
Table 8.2.1 - Approximate specific gravity differentials for HBM&S plant trials
% Background Theoretical SG
Composition SG SG Differential
Gold 5.2 X 10"' 19.3 4.53 14.77
Chalcopyrite 5.5 4.2 4.55 -0.35
Sphalerite 21.9 4 4.68 -0.68
Galena 1.7 7.5 4.48 3.02
Pyrite 60.2 5 3.83 1.17
silicates 10.7 2.7 4.75 -2.05
The gold particles were associated with pyrite. The specific gravity of a gold particle is
approximately 19.3. When gold is locked in pyrite the sg becomes a blend between pyrite and
gold. The gold in this ore was not free gold. If approximately 3 0 % of a particle was gold and
70%o were pyrite, then the particle sg would be about 8.5. This is the estimate used for this
analysis as the sg differential becomes 3.94 for a gold/pyrite particle against a background of sg
4.53. Figure 8.2.2 shows that the Au line is just above the galena line. The galena has an sg
differential of 3.02 and is typically well liberated in this concentrate.
Table 8.2.1 shows a theoretical calculation of sg differential. The composition of the
components is based on chemical assay. The background sg differs for each component because
the component in consideration is removed from the calculation in each case. It can be seen that
chalcopyrite, sphalerite and silicates are lower than the background sg in this material. Therefore
it is expected that if these components are present in the CVD concentrate it is only due to mass
yield (feed grade material that reports to concentrate). This can be seen to be true in Figure 8.2.2
where these component lines are all very close to an upgrade ratio of 1.
Figure 8.2.2 shows that Chalcopyrite is slightly upgraded in higher recovery conditions.
Sphalerite is very slightly upgraded when the machine is pulling large mass yields and
76
correspondingly high recoveries. Chalcopyrite is always upgraded more than sphalerite even
though the sg differential between the two minerals is only 0.2. Under no set of operating
conditions did a lower density particle get upgraded more than a higher density particle. There
are clearly four boundary conditions that do not intersect over the entire set of tests that are
defined by the lines drawn for each mineral in Figure 8.2.2.
This testing demonstrates that separation is possible down to an sg differential of 0.2. However,
selectivity would be impossible unless extremely small mass yields were obtained. For small
mass yield applications a batch centrifugal gravity concentrator or other similar technology is
better suited.
In order to get upgrade ratios in excess of 3:1 with recoveries over 50%, a differential between
the target and gangue mineral needs to be 2 or greater. This statement is based on the fully
liberated synthetic systems shown in figure 8.2.1. Also, as seen in the plant trial example, with
multi component feeds the target mineral would need to have a sg differential of 2 or more
between the next highest gangue mineral to achieve selectivity. The CVD cannot be selective at
high mass yields unless there is a sg differential of 2 or more.
8.3 Conclusions
This chapter has shown that the CVD6 concentrator can make separations at a specific gravity
(sg) differential of 0.2 between the target and the background sg. However in order to achieve
good selectivity a practicle sg differential of 2 or more is required.
77
It is recommended that further work be performed on narrower size classes to further understand
the interaction between particle density separation and particle size separation.
78
9 Variable Tuning in a CVD Concentrator
9.1 Introduction
This chapter demonstrates the effects of operating variables on separation performance. The data
was obtained from laboratory and plant testing of a pilot scale Knelson CVD6. By comparing
the rates of change of grade and recovery with incremental changes in the operating variables, a
set of basic guidelines for developing a control strategy is proposed.
9.2 Operating variable performance ratio
As demonstrated by the results of this study, the CVD has the ability to achieve a wide range of
metallurgical results. Figure 9.2.1 shows a plot of recovery versus grade for gold. Each point on
the plot represents a different set of operating conditions. The upper bound on the plot identifies
the maximum performance of a CVD6 for this ore. It is important to know how to manipulate
the operating variables in order to operate a CVD as close to the upper bound as possible.
79
Recovery versus Grade
Au Grade (g/t)
Figure 9.2.1 - Recovery versus grade
Knowing the effect of each variable on both grade and recovery aids in developing an operating
strategy. For all variables tested, changes in the level to increase the concentrate grade resulted
in a decrease in recovery and vice versa. To assist with the development of an operating
strategy, a methodology for comparing the change in grade and recovery at a specified operating
variable range was established.
Each of the operating variables has different ranges and increments (units) of change. Bowl
speed is measured in rpm, pinch valve closed times in seconds, and pinch valve open time in
fractions of a second. The difference in units makes direct comparison of slopes impossible.
Instead, broad operating ranges were selected for the three operating variables. Each operating
range was broken down into equal increments called levels. A midpoint in each operating range
80
was identified for each operating variable. The midpoints were all selected from previous
operating experience as conservative operating levels.
Tests were selected where one variable at a time was changed while the other three variables
were held at midpoint levels. For each operating variable, grade versus parameter level and
recovery versus parameter level plots were generated. Linear trend sections on these plots were
identified and trend lines drawn.
The slopes for grade versus parameter level and recovery versus parameter level were divided to
produce a ratio of the change in grade versus the change in recovery. This ratio of slopes was
used to compare the overall impact of a variable on the separation performance and is referred to
as the operating variable performance ratio (ovp ratio).
Comparing the ovp ratio for each operating variable quantifies the combined grade and recovery
effect of changing each operating variable. Since grade and recovery always have opposing
slopes a net negative ratio results in all cases. For comparison, the absolute value of the ovp
ratio was used. Table 9.2.1 shows the direction of the trends.
The ovp ratio is a semi-quantitative tool for selecting an operating variable to change when
tuning the operation of a CVD. As discussed before, the CVD will have a maximum
performance boundary condition for grade and recovery as demonstrated in figure 9.2.1. The
ovp ratio gives the operator a map of which operating variable to change in order to achieve
boundary condition performance or to move to another point on the boundary line. If the
81
objective is to increase predominantly grade (shift horizontally on Figure 9.2.1), then a high ovp
ratio is desired. However if recovery is the objective a low ovp ratio is desired. The ovp ratio is
a guideline for roughly quantifying an operating variable's overall effect on separation
performance.
Table 9.2.2 summarizes the ovp ratios that were generated at each variable level. Due to
transition points in the trends, the ratios change for bowl speed and pinch valve closed time. In
Table 9.2.2, a high ovp ratio at low bowl speed (403), with all other variables at midpoints
indicates that an increase in bowl speed will influence grade the greatest. Pinch valve open time
had a constant ovp ratio throughout the tested range meaning that it would have the same result
on grade with any incremental change in open time. Other than at low levels, pinch valve closed
time also has a uniform effect on grade. In general, these results indicate that pinch valve open
time generates the greatest change in grade per incremental change in operating variable level.
Table 9.2.1 - General trends for operating variables

Grade Recovery
Increasing Fluidization Decreases Increases (to a limit)
Water Flowrate
Increasing Bowl Speed Decreases Increases
Increasing Pinch Valve Decreases Increases
Open Time
Increasing Pinch Valve Increases Decreases
Closed Time
For the majority of the operating range (levels 3 - 7), pinch valve open time should be used in
making coarse adjustments to concentrate grade. Fine-tuning of the grade should be performed
with bowl speed. If intermediate tuning is needed, the pinch valve closed time can be effective.
82
When considering ovp ratios from a recovery perspective the results mirror those for grade.
Levels 3 through 6 in Table 9.2.2 represent a reasonable operating range. Low ovp ratios in this
range for bowl speed indicate that bowl speed has the greatest effect on recovery per change in
grade. If a significant change in recovery is required with a minimum effect on grade, bowl
speed should be adjusted. A mid-range ovp ratio of 32 for pinch valve closed time classifies this
variable as a mid-range tuning variable for recovery. The ovp ratio of 182 for pinch valve open
time indicates that it is not an effective variable for tuning recovery.
Table 9.2.2 - Rate of change in grade versus rate of change in recovery

Actual Pinch Bowl Pinch Open Pinch Closed
Actual Bowl Actual Pinch
Closed Speed Time Time
Level Speed Setting Open Setting
Setting OVP OVP OVP
(rpm) (seconds)
(seconds) Ratio Ratio Ratio
1 500 0.17 2 403 182 1
2 600 0.18 3 403 182 32
3 700 0.19 4 10 182 32
4 800 0.20 5 10 182 32
5 900 6 10 32
6 1000 7 10 32
7 8 32
For fine-tuning of the machine, the operating variables can be adjusted in smaller increments.
The resolution of control on the operating levels will influence how much fine control a variable
can have. The bowl speed resolution is lrpm, pinch valve open time 0.01 seconds, and the pinch
valve closed time 0.1 seconds. The pinch valve open time is the only operating variable that was
tested in the smallest increment possible.
When testing a new feed in a CVD, a systematic approach for finding the appropriate operating
variable levels should be employed.
• First run the machine at the center-point conditions: 700 rpm bowl speed, mid-range
(0.18 seconds) pinch valve open, 4 seconds pinch valve closed. Pinch valve open time is
83
described as mid-range because all CVD's have unique valve histeresis that changes the
pinch valve open ranges.
• Determine the grade and recovery for the center-point test. The relationships for each
operating variable's effect on grade and recovery can be used to tune the performance. It
is recommended to only change one variable at a time.
9.3 Conclusions
The CVD has four operating variables that affect the metallurgical performance and therefore
levels must be selected to achieve the desired metallurgical results. For all operating variables,
changing the levels to increase grade cause a reduction in recovery and vice versa. A good
understanding of the effects of each variable is important to developing an operating strategy for
optimum performance.
The CVD's operating variables are fluidization water flowrate, bowl speed, pinch valve open
time, and pinch valve closed time. Table 9.2.1 summarizes the general trends observed when
increasing each of the operating variables.
After setting the fluidization water flow rate and selecting an appropriate bowl speed, product
grade and recovery can be optimized by adjust the pinch valve timing. The pinch valve open and
closed times have an interrelated effect for achieving separation performance. Increasing the
closed times allows for more upgrading in the ring. The required open time is the timed need to
drain the upgraded product from each cycle of operation.
84
A ratio of the change in grade versus the change in recovery was defined as the operating
variable performance ratio (ovp ratio). The ovp ratio was used to quantify the operating
variable's overall effect on separation performance. The ovp ratio is considered a useful
parameter to help decide which variable should be changed to cause an improvement in grade
recovery.
85
10 Developing an Operating Strategy for a New Application
10.1 Introduction
The research performed for this project has shown that the CVD can produce a wide range of
mass yield, grade and recovery results. Each CVD application will have a unique set of
objectives depending on the nature of the material, the complimentary processing equipment and
the required product specifications. As shown in the preceding sections of this report,
manipulation of the operating variables and their interaction will affect the final concentrate
outcome.
This section is dedicated to outlining a procedure for tuning the CVD6 concentrator for a new
application. It is assumed that the concentrator is on site and will be tested under constant feed
conditions. This is a critical outcome and is the result of combining the knowledge of operating
parameter ranges and interactions.
10.2 Identification of the Objectives
The CVD concentrator by nature is capable of mass yields to concentrate of 0 - 100% (typically
1 - 60%) of the feed to the unit. By adjustment of all the operating variables in conjunction, one
can produce a random array of results. The ever present trade-off between grade and recovery is
present in the results of a CVD concentrator as they are with any piece of mineral processing
equipment. Therefore it is paramount that the first task in the tuning of a CVD be in the clear
identification of the expectations of the equipment.
86
The first step in making the determination of the objectives is to understand and characterize the
nature of the feed to the concentrator. The target mineral grade should be known. The
association of the target mineral with other species along with the degree of liberation is useful
information. This information can then be used to make a determination of the approximate
mass yield range that will be required to attain the desired recovery.
For example, if an iron oxide material were to be removed from talc and the content of iron
oxide in the material was 0.5% by weight. Then it would be reasonable to assume that in order
to remove the iron oxide from the talc the target mass yield would have to be greater than 0.5%
and likely less than 5% of the feed reporting to concentrate. In this case, the product
specification will require that any content of iron oxide in the talc will render the talc unsaleable.
Therefore the mass yield range will more likely be 3 - 10%.
The more information that is available to narrow the optimization window the faster and more
accurately a solution will be attained. Once a realistic expectation of the result has been
formulated then the "goal posts" have been set and the test program can be organized.
10.3 CVD Boundary Conditions
In order to effectively set out realistic expectations for the CVD6 it is necessary to understand
what its general capabilities are. These capabilities are only semi-quantitative and are limited to
the experience that has been gained in the test programs performed in the production of this
report.
Below is a list of basic rule of thumb expectations for the use of a CVD6 concentrator:
87
• The CVD has been shown to be a very effective "rougher" machine and can generally
produce concentrate grades that are 3 to 6 times as high as the feed grade.
• Recoveries are typically in the range of 70 - 95%
10.4 Qualitative Tuning
When the CVD6 isfirststarted it can be run under any set of conditions. Once running it will be
clear to see approximately how much concentrate is coming out of the concentrator. Since a
basic range of what mass yield is to be targeted has already been established, the operating
parameters can be changed to get within the testing range.
This is where knowledge of the operating variable effects and interactions can be applied. In the
fractional factorial design testing using a feed of quartz and magnetite the effect of both
operating variables and feed variables were investigated to determine the relative effects of the
variables. When a concentrator is tested in the field there is little opportunity to affect the
percentage solids in the feed and the particle size of the target mineral. These results will not be
considered in thefieldtesting and tuning of a CVD as they are not variables that can be
practically changed. For this machine tuning procedure there will be a focus on only the
physical CVD machine variables that include the bowl speed, inch valve open time, pinch valve
closed time, and fluidization water flowrate.
The testing that was performed with the quartz and magnetite material was a useful starting point
for the understanding of the relative importance of the operating variables and their interaction
effects. Unfortunately, the nature of such a test program requires the selection of a low mid and
high value for each of the variables. Because this was the first test program that was used to
88
evaluate the CVD some of the parameter ranges were not selected ideally. The results of the
testing were not incorrect; however in combining the knowledge gained from the incremental
testing, further field testing, and experience the machine variables can be ranked by importance
follows: pinch valve closed time, bowl speed, pinch valve open time, and fluidization water
flowrate. The rankings will help in tuning the approximate range that the operating variables
should be adjusted within. However, what will be demonstrated in the following section is that
although the operating variable adjustments can be ranked the interaction of different
combinations of operating variable levels can produce the identical result. It is because of this
complex and overlapping interaction that necessitates a tuning procedure such as the one that is
outlined in this section. The most valuable outcome of this thesis is the understanding that it is
not the impact of any singular variable on grade and recovery but the achievement of a desired
objective by understanding the capabilities and limitations of the CVD6 and how to tune the
machine to achieve the desired objective.
It is the aim that this procedure can be used to tune all sizes of CVD concentrator and not just the
CVD6. There is a lack of information on the effect of performance scale-up from a CVD6 to
larger CVD models, however it is the opinion of the author that the rankings of operating
variable importance and testing methodology would not change as the size of the machine
increases. It is possible that the performance characteristics would change due to changes in the
geometry and size within the machine, however the fundamentals should remain relatively
constant.
89
It was shown that fluidization water flowrate had no measurable effect on recovery or grade as
long as the CVD6 was operated between 7-10 gpm water addition. Other CVD models would
be similar but the range of fluidization water addition would be different. For this reason the
fluidization water flowrate should be set in the middle of the range at approximately 8.5gpm and
this variable can be eliminated as a variable for the duration of the testing. Once the final
operating variables have been established the fluidization water can be altered slightly in an
attempt to fine tune the results, however it is expected that the impact will be minimal.
The three remaining variables, namely bowl speed, pinch valve open time and pinch valve closed
time, will greatly affect the performance of the concentrator. Bowl speed should be set initially
in the middle of the range at 750 rpm as a starting point. The pinch valves can then be adjusted
to affect the amount of material that is reporting to the concentrate. The exact valve timings
cannot be reported here as each installation will vary depending on the air inlet pressure, length
of air delivery line and size of the concentrator. This is why it is recommended to qualitatively
adjust the valves and take note of the mass yield produced to concentrate. If the nature of the
material is such that any grade determination can be determined by hand panning or observation
of a change in colour, then this is recommended in order to identify a good starting range for the
parameters.
Within an hour, the CVD operator should be able to determine an effective range of pinch valve
timings that will cover the range. If in doubt simply test a very wide range and the results will
drop out. The qualitative portion of this program simply reduces the time and effort that will be
spent on the next stage of the test program.
90
10.5 Formulation of a General Test Program
A wide range of results can be obtained from the manipulation of the CVD operating variables
and the consequential interaction between those variables. In fact, in a test program that covers
the major ranges of all of the operating variables the result will plotted on a grade recovery curve
will yield a very broad spectrum of results. What is possible to determine from any of these sets
of data is that all of the data points will lie beneath a boundary condition line. If sufficient data
points can be generated that suitably span the operating range for the key operating variables
(bowl speed, pinch valve open time, and pinch valve closed time) then an upper boundary line
can be drawn on the plot that defines the optimum operating conditions for the CVD. By moving
along the upper boundary condition line the optimum operating conditions for the desired
objective can be selected. In the case where the optimum condition lies between two or more
points a more focused optimization test program can be run tofinetune the operating variables
and get closer to an optimum condition.
91
Recovery
•
• •
Grade
Figure 10.4.1 - Drawing an upper boundary condition on a grade recovery curve
The results from a very comprehensive test program will yield points on the grade recovery
curve that are equal within error and yet have been derived from different operating variable
combinations. It is this phenomenon that necessitates the use of the boundary condition
evaluation of the results. As long as the operating variable combination that is selected results in
a result that lies on or in close proximity to the upper boundary condition then an acceptable set
of conditions has been selected.
10.6 Fine Tuning the Operating Variables
As demonstrated in the section of this report on the trends in Au recovery and the discussion on
the Operating Variable Performance ratio (OVP), the impact and trends of individual operating
variables can be carefully changed in order to get closer to the desired response. The OVP
methodology should be utilized for the initial fine tuning of the concentrator and also for
92
example when changes in the ore conditions are presented that require a small change in
approach.
10.7 Conclusion
The complexity and interaction effects of the operating variables that exist with a CVD lead to
the possibility of producing the same result with different combinations of operating variables.
As well, if a wide enough spectrum of each operating variable is not tested then a non optimized
result can be attained. It is therefore necessary to have a desired objective and then test the CVD
capabilities for a specific feed material to determine the upper boundary condition that exists for
that application. With the knowledge of what effect individual operating variables have on grade
and recovery as outlined in the Operating Variable Performance Ratio section the results can be
fine tuned to move along the upper boundary condition line.
93
11 Conclusions and Recommendations
This study included fundamental laboratory pilot testing coupled with field pilot work to
evaluate the operation and control of a continuous centrifugal concentrator. Specifically the
Knelson Continuous Variable Discharge (CVD) concentrator was tested. The program included
the following main sections:
• Literature Review
• Experimental Program
• Quartz/Magnetite Factorial Design
• Quartz/Magnetite Incremental Testing
• Synthetic Sphalerite/Quartz
• Hudson's Bay Mining and Smelting Plant Trials
• Specific Gravity Differential
• Variable Tuning in a CVD Concentrator
• Developing an Operating Strategy for a New Application
11.1 Factorial Design
Four feed variables; heavy particle size, feed percent solids, feed rate, and magnetite grade were
identified. Four CVD machine operating variable were identified; bowl speed, pinch valve open
time and pinch valve closed time. With a total of eight variables to investigate a factorial design
was used to rank the relative importance of each of the variables, quantified as the effect on
grade and recovery. The results are summarized in Table 11.1.
94
Table 11.1 - Summary of significant variable effects
Feed Variables Machine Variables

Grade Recovery Grade Recovery
Solids Feed Pinch Valve Closed

Heavy Particle Size Bowl Speed
Rate Time
Pinch Valve Closed
% Solids Bowl Speed
Time
Feed Grade Fluidization Water
11.2 Incremental Quartz/Magnetite
The nature of a statistical experimental design such as the factorial design that was employed in
Chapter 4 sets variable levels at high, low and midpoints. In order to understand the trends that
occur in the grade and recovery results over a full operational range an incremental test program
was employed. A quartz/magnetite feed was used, but only machine variables were tested. One
variable at a time was manipulated and the resulting trends were plotted.
Incremental testing resulted in the following conclusions. Increasing bowl speed was found to
increase recovery and mass yield while decreasing concentrate grade. Fluidization water
flowrate was determined to have the greatest effect on recovery. Threshold minimum
fluidization water was found at 6 gpm. Above 6 gpm additional fluidization water did not affect
recovery and only slightly reduced grade. It was determined from this result that fluidization
water could be held constant for all subsequent testing. Fluidization water is necessary to
enhance separation, but is not a variable that should be manipulated to enhance separation
95
performance. The CVD was found to perform best with feed percent solids of approximately
30%.
11.3 Synthetic Sphalerite/Quartz
In order to evaluate the concentrator's performance on a different feed with a lower specific
gravity differential, but a fully liberated system, a synthetic feed of quartz and sphalerite was
tested. The feed was made in the lab by mixing a sphalerite flotation concentrate from Hudson's
Bay Mining and Smelting (HBM&S) with quartz sand.
The results of the sphalerite/quartz testing satisfied three objectives: contributed separation
performance at a narrow sg differential in a fully liberated system, identified more information
on machine and feed operating parameter ranges, and the successful particle separation justified
further testing of the concentrator at HBM&S on a non-synthetic feed.
The synthetic sphalerite/quartz testing showed that the CVD is capable of making a separation at
an SG differential of 1.35 with similar particle size distributions of the sphalerite and the quartz
fractions.
11.4 HBM&S Plant Testing
Plant testing at the HBM&S mill generated significant data that showed the trends formed by
changing operating variables. The one parameter at a time testing methodology showed how the
response curves for grade and recovery formed consistently shaped curves that were shifted with
varying parameter levels. The consistency of the shapes provided data for use in the
96
development of an operating strategy. Plant testing also provided important information on
selective particle separation by specific gravity.
77.5 Specific Gravity Differential
Information from all of the incremental test programs contributed to this section. It was shown
that the CVD6 concentrator can make separations at a specific gravity (sg) differential of 0.2
between the target and the background sg. However in order to achieve good selectivity a
practical sg differential of 2 or more is required.
It is recommended that further work be performed on narrower size classes to further understand
the interaction between particle density separation and particle size separation.
11.6 Variable Tuning in a CVD Concentrator
Primarily utilizing the information gained from the field testing of the CVD at HBM&S, a tuning
methodology for the machine operating variables; fluidization water, bowl speed, pinch valve
open time and pinch valve closed time, was developed.
After setting the fluidization water flow rate and selecting an appropriate bowl speed, product
grade and recovery can be optimized by adjusting the pinch valve timing. The pinch valve open
and closed times have an interrelated effect for achieving separation performance. Increasing the
closed times allows for more upgrading in the ring. The required open time is the time needed to
drain the upgraded product from each cycle of operation.
97
A ratio of the change in grade versus the change in recovery was defined as the operating
variable performance ratio (ovp ratio). The ovp ratio was used to quantify the operating
variable's overall effect on separation performance. The ovp ratio is considered a useful
parameter to help decide which variable should be changed to cause an improvement in grade or
recovery.
11.7 Developing and Operating Strategy for a New Application
The CVD concentrator has the opportunity to be applied in a wide spectrum of applications.
However, with the complexity and interaction effects of the operating variables a methodology
for testing a new application is beneficial. This section takes the results and experience from all
of the test programs in this study and introduces a methodology that can be employed in testing
any new application for a CVD concentrator.
Fundamentally this methodology includes:
• Identification of performance objectives
• Understanding the CVD's boundary conditions
• Qualitative tuning (preliminary testing)
• Formulation of a general test program
• Fine tuning of the operating variables
98
11.8 Recommendations
This study exclusively used the pilot scale Knelson CVD6 concentrator. It would be useful to
investigate the scale-up effects from pilot scale to production scale.
Finally, the effect of particle size on separation performance was not studied in detail in this
study. Further work to investigate the effect of particle size interactions is recommended.
99
12 References
1. Ancia, Ph., J. Frenay, Ph. Dandois, "Comparison of the Knelson and Falcon Centrifugal
Separators", Mozley International Conference, Falmouth G.B., June 1997.
2. Burt, R.O., 1984, "Gravity Concentration - from Bench Scale to Plant", Annual Meeting
of Canadian Mineral Processors, Ottawa.
3. Byron R., K. Roberts, 2004, "Flotation Improvements in the Luzenac Penhorwood Talc
Concentrator", Proceedings 36 Annual Meeting of the Canadian Mineral Processors,

th
Ottawa, Canada, pp 177-188.
4. Falcon Concentrators http://www.concentrators.net
5. Holland - Batt, A.B. Gravity Separation: A Revitalized Technology - Mining
Engineering. September 1998.
6. Honaker R. Q., B. C. Paul, D. Wang and M Huang, 1995, "The application of Centrifugal
Washing for Fine Coal Cleaning", Minerals and Metallurgical Processing, Vol. 12, pp.
80-84.
7. Knelson Gravity Solutions http://www.knelson.com
100
8. Lambert M., M. McLeavy, B. Klein, I. Grewal, 1999, "Preliminary Studies with a New
Continuous Centrifugal Concentrator", Presentation at BC and Yukon CMP Annual
Meeting.
9. Banisi S., Laplante A.R.; McGill University, Montreal, Marois J.; Hemlo Gold Mines
Ltd., 1991, "The Behaviour of Gold in Hemlo Mines Ltd. Grinding Circuit".
10. McLeavy M., B. Klein and I. Grewal, 2001, "Knelson Continuous Variable Discharge
Concentrator, Analysis of Operating Variables", International Heavy Minerals
Conference, Fremantle, Australia, pp. 119-125
11. Richards R. G. and M. K. Palmer, 1997, "High Capacity Gravity Separators - A Review
of Current Status", Minerals Engineering, Vol. 10, No. 9, pp. 973-982.
12. Roche Mining (MT), 2004, Kelsey Jig http://www.Geologics.com.au
13. Rogan, Chris. Pilot Scale Evaluation of Knelson Variable Discharge Concentrator.
University of New South Wales, School of Chemical Engineering. November 1995.
14. Silva, E.C., N. A. Santos, and V. M. Torres, 1999, "Centrifugal Concentrators, a New Era
in Gravity Concentration, the Experience of CVRD Research Centre", pp. 1-6.
101
15. Simpson P., 2003, "The Knelson Continuous Variable Discharge Concentrator (KC-
CVD) Application on Gold Sulphides", 25 Anniversary of Knelson internal meeting,

th
Vancouver, Canada.
16. Statistics for Experimenters, An Introduction to Design, Data Analysis and Model
Building. George E.P. Box, William G. Hunter, J. Stuart Hunter. John Wiley and Sons
New York, Chichester, Brisbane, Toronto, Singapore. Copyright 1978.
17. Wyslouzil, H.E., 1990, "Evaluation of the Kelsey Centrifugal Jig at Rio Kemptville Tin'
22 Annual Meeting of the Canadian Mineral Processors, Ottawa, Paper No 23, pp. 461
nd
472.
102
13 Appendix 1 - Quartz/Magnetite Fractional Factorial Desig
103
13.1 Alias Structure
A statistical experimental design was used in the quartz/magnetite test program. Below is the
alias structure that was used for this testing.
Alias structure for experimental design showing main, and two factor interaction effects.
Interactions between three or more factors ignored.
h= 1
h= 2
h= 3
1 =
4 4
ls= 5
1 =
6 6
1 =
7 7
1 =
8 8
ll2 = 1-2 + 3-7 + 4-8 + 5-6
ll3 = 1 -3 + 2-7 + 4-6 + 5-8
ll4 = 1-4 + 2-8 + 3-6 + 5-7
lis = 1-5 + 2-6 + 3-8 + 4-7
ll6 = 1-6 + 2-5 + 3-4 + 7-8
ll7 = 1-7 + 2-3 + 6-8 + 4-5
ll8 = 1-8 + 2-4 + 3-5 + 6-7
104
13.2 Fractional Factorial Design Map
Fractional Factorial Map
Heavies Solid
Feed Particle Bowl Pinch Pinch Feed
Test Fluidization % Solids Grade Size Speed Open Closed Rate
1 1 1 1 1 1 1 1 1
2 -1 1 1 1 1 .1 .1 .1
3 1 -1 1 1 -1 1 -1 -1
4 -1 -1 1 1 -1 -1 1 1
5 1 1 -1 1 -1 -1 -1 1
6 -1 1 -1 1 .1 1 1 .1
7 1 -1 -1 1 1 -1 1 -1
8 -1 -1 -1 1 1 1 .1 1
9 1 1 1 .1 -1 .1 1 .1
10 -1 1 1 -1 -1 1 .1 1
11 1 -1 1 -1 1 -1 -1 1
12 -1 -1 1 -1 1 1 1 -1
13 1 1 -1 -1 1 1 -1 -1
14 -1 1 -1 -1 1 -1 1 1
15 1 -1 -1 -1 -1 1 1 1
16 -1 -1 -1 -1 -1 -1 -1 -1
Low variable levels are indicai ed by "-1" in the chart and high values are indicated by "1".
105
Operating Variable Levels for Factorial Design
Variable High Low Center Point

Heavies (%) 4.0 1.0 2.5
Fluidization (gpm) 14 5 10
Pinch Valve Open (s) 0.05 0.03 0.04
Pinch Valve Closed (s) 8 2 5
Bowl Speed (RPM) 925 725 825
Solids Feed Rate (tph) 2 1 1.5
% Solids 45 30 37
Heavies Particle Size (p80) (microns) 425 125 275
106
I
13.3 Factorial Design Test Results/Metallurgical Balance
Factorial Design Test Results

Size Fraction - p80 Pinch Valves Results
Feed
Design Rate Percent Mag Silica Fluidization Feed Grade Con Grade Tails Recovery
Date # RPM (t/h) Solids (microns) (microns) Open (s) Closed (s) (g/min) (%) (%) Grade (%) (%) Mass Pull
11/8/99 1 925 2 45 425 425 0.05 8 14 3.5% 30.9% 2.9% 20.1% 2.3%
11/10/99 2 925 1 45 425 425 0.03 2 5 3.9% 55.0% 3.6% 8.7% 0.6%
11/9/99 3 725 1 30 425 425 0.05 2 14 4.3% 18.1% 0.9% 82.5% 19.3%
11/9/99 4 725 2 30 425 425 0.03 8 5 4.2% 69.9% 4.3% -2.0% -0.1%
11/11/99 5 725 2 45 425 425 0.03 2 14 1.0% 26.4% 0.7% 24.6% 0.9%
11/11/99 6 725 1 45 425 425 0.05 8 5 0.9% 11.4% 0.7% 25.5% 2.1%
11/11/99 7 925 1 30 425 425 0.03 8 14 0.7% 24.2% 0.6% 13.9% 0.4%
11/12/99 8 925 2 30 425 425 0.05 2 5 0.6% 3.7% 0.3% 63.3% 10.8%
11/15/99 9 725 1 45 125 425 0.03 8 14 4.0% 28.0% 3.0% 28.1% 4.0%
11/15/99 10 725 2 45 125 425 0.05 2 5 4.4% 20.5% 1.7% 66.8% 14.4%
11/14/99 11 925 2 30 125 425 0.03 2 14 4.0% 69.0% 2.2% 46.3% 2.7%
11/16/99 12 925 1 30 125 425 0.05 8 5 4.4% 31.4% 1.6% 68.2% 9.6%
11/12/99 13 925 1 45 125 425 0.05 2 14 1.1% 3.5% 0.3% 78.2% 24.4%
11/13/99 14 925 2 45 125 425 0.03 8 5 1.1% 30.9% 0.6% 48.8% 1.8%
11/13/99 15 725 2 30 125 425 0.05 8 14 1.0% 12.9% 0.5% 49.8% 3.9%
11/13/99 16 725 1 30 125 425 0.03 2 5 1.3% 27.1% 1.0% 25.5% 1.2%
107
I
26.4%
69.9%
30.9%
55.0%
18.1%
24.2%
28.0%
20.5%
69.0%
31.4%
11.4%
3.7%
Grade
Pinch Closed Feed Rate _ _

Pinch Open (s) Feed Rate _ _ rt rt
Pinch Open (s) Pinch Closed rt rt _H
Bowl Speed (G's) Feed Rate — rt — —
Bowl Speed (G's) Pinch Closed _ _

Bowl Speed (G's) Pinch Open _ rt — _ 1
Heavies Particle Size (p80 microns) Feed Rate rt rt

Heavies Particle Size (p80 microns) Pinch Closed _ rt rt
Heavies Particle Size (p80 microns) Pinch Open rt rt rt
Heavies Particle Size (p80 microns) Bowl Speed rt rt
Feed Grade (%) Feed Rate _ rt rt —
Feed Grade (%) Pinch Closed rt rt —
Feed Grade (%) Pinch Open rt — _ rt 1
Feed Grade (%) Bowl Speed >—H _ rt

Feed Grade (%) Heavy Particle Size _ rt
% Solids Feed Rate rt _ ^_
% Solids Pinch Closed _ _

% Solids Pinch Open rt rt rt
% Solids Bowl Speed rt rt
% Solids Heavy Particle Size rt _
% Solids Feed Grade rt _ 1 1
00
rt _ rt rt
~zFluidization (g/min) Feed Rate
— —
n Fluidization (g/min) Pinch Closed — —

•
—
NO
Fluidization (g/min) Pinch Open rt rt rt rt
n
"x Fluidization (g/min) Bowl Speed rt rt i rt
Fluidization (g/min) Heavies Particle Size _ _- rt rt
n Fluidization (g/min) Feed Grade — — —
n Fluidization (g/min) % Solids rt rt rt —
00
X Solid Feed Rate (t/h) rt rt rt _
X Pinch Closed (s) _ _

NO
X Pinch Open (s) rt rt
'f,
X Bowl Speed (G's) _ — _ —
X Heavies Particle Size (p80 microns)
C"l
X
Feed Grade (%) • •
(N
X % Solids _ — rt rt _H
Fluidization (g/min) 1
rt rt rt
Factorial Design Test Number <r. r
o
NO 00 ON
— —
— —
*-
— —
— —
*-*
— —
— —
— —
— —
— —
— —
o — — — —
— — —
1
—
— —
•
—
— —
— —
— —
-
— — —
27.1%
30.9%
3.5%
12.9%
13.4 Calculated Factorial Design Results - Effect of Operating Parameters
Calculated Operating Variable Effect on Grade

RANK GRADE EFFECT
3 Pinch Closed (s) 6.3%
4 % Solids -6.2%
5 Fluidization (g/min) -4.6%
7 Pinch Open (s) -3.1%
8 Heavies Particle Size (p80 microns) 2.0%
Calculated Operating Variable Effect on Recovery
RANK RECOVERY EFFECT

1 Heavies Particle Size (p80 microns) -21.9%
2 Pinch Closed (s) -12.5%
3 Bowl SDeed (G's) -12.0%
4 % Solids -5.9%
5 Fluidization (g/min) 4.8%
6 Pinch Open (s) 4.0%
7 Feed Grade (%) -3.2%
8 Solid Feed Rate (t/h) -1.6%
110
13.5 Quartz/Magnetite Assay Procedure
In order to determine the grade of magnetite in samples of feed, concentrate and tailings the
magnetic properties of magnetite were exercised. The procedure for assaying included sample
preparation, assaying and weighing.
During each CVD trial a slurry sample of feed, concentrate and tails was taken. The samples
were prepared for assay by the following process:
• Pressure filtering
• Drying in a 100 degree Celsius sample oven
• Riffling to manageable assay sample size
• Approximate sample sizes were
• 100 grams for feed
• 100 grams for tails
• 50 grams for concentrate
The riffled samples were weighed and transferred into 500ml glass beakers. Water was run
through the Davis tube and the magnet was energized to produce the magnetic field in the middle
section of the Davis Tube. The water level in the Davis Tube was kept constant by setting the
height of the water discharge tube. The agitation of the Davis Tube was turned on. A feed
funnel assembly was attached to the Davis tube to prevent spillage of sample. At this point the
sample was carefully slurried with a small water jet in the beaker and washed slowly into the
Davis Tube. Care was taken in not overfeeding the Davis tube. Once all of the sample was run
through the Davis tube it was allowed to continue agitation for another 30 seconds. The water
and the agitation was then turned off and a beaker placed under the tube discharge. The magnet
111
was then turned off and the sample was thoroughly washed out of the tube and into the beaker.
After settling for at least 5 minutes the excess water was decanted from the beaker. The beaker
with the magnetite was then dried completely and weighed. Once weighed, all sample was
returned to the feed tank to prevent depletion.
13.6 Attrition Check
Many tests were run with the same synthetic quartz/magnetite feed. A concern was whether any
attrition grinding was taking place on magnetite particles. Feed samples from all of the factorial
design tests were size assayed. These size assays included 3 fractions, +50 mesh, 50X100 mesh,
and-100 mesh.
The tests for the factorial design were not run in the order that they are listed in the factorial
design map. The tests were organized in such a way as to minimize the number of feed changes
required to run the research program and to maintain a consistent size distribution and grade of
magnetite.
The table below indicates which batch of magnetite was used for each test and the order in which
the tests were run. After the batch one magnetite at a feed grade of four percent was run for six
tests all of the magnetite was removed from the system and a fresh batch of magnetite was added
to a feed grade of one percent. The magnetite was completely removed and fresh magnetite
added in order to prevent alterations in the size distribution of magnetite caused by the removal
process. After four tests were run with batch two magnetite, at one percent feed grade, the
magnetite was completely removed from the system in order to facilitate adding finer Pso 125um
magnetite. Batch three magnetite was run for four tests. A calculated mass of magnetite was
112
then added to the feed tank to bring the grade from one percent to four percent. The factorial test
program was completed with four tests of batch four magnetite.
Factorial Design Testing Order and Feed Changes

Run# Factorial Design Feed Magnetite Magnetite
Design # Grade (%) P (lim) 80
Batch
1 1 4 425 1
2 1.1 (duplicate) 4 425 1
3 1.2 (duplicate) 4 425 1
4 3 4 425 1
5 4 4 425 1
6 2 4 425 1
7 5 1 425 2
8 6 1 425 2
9 7 1 425 2
10 8 1 425 2
11 13 1 125 3
12 16 1 125 3
13 15 1 125 3
14 14 1 125 3
15 9 4 125 4
16 10 4 125 4
17 11 4 125 4
18 12 4 125 4
The maximum number of tests that any one batch of magnetite was run for was batch one at 6
tests. The feed was screened into three fractions +50 mesh, 50 X 100 mesh and -100 mesh. The
batch one magnetite had a Pgo of 425 um and therefore yielded a very low mass in the -100 mesh
fraction. This low mass produced some erratic feed grade results in this size fraction and does
not give a clear interpretation of attrition. The +50 and the 50 X 100 fractions remain at constant
grades over the course of the 6 tests indicating that attrition was not a factor. If attrition had been
a factor there would be reduced grades in the course size fractions and an increase in grade in the
fine fraction. It should be noted that the plot below shows only the four factorial design tests and
does not include the duplicate runs. Size assay was not performed on the duplicates. However,
113
the duplicates were spanned by the other four tests from the factorial design and therefore are not
significant in this analysis. Attrition was not a factor in the quartz magnetite testing.
Attrition Check - Feed Grade versus Run Order

Batch One Magnetite
9%
~ 8%
T 7%
2 6%
O
• +50
a> 5%
•a
• 50X 1001
i±! 4%
a A-100
S
o
3%
§)
n 2%
S
1%
0%
1 2 3 4 5 6
Run Order
114
14 Appendix 2 - HBM&S Gold, Zinc Incremental Trials
115
I
One Variable at a Time Test Conditions

Bowl Feed
Speed Pinch Pinch Rate
Date Test ID RPM Open (s) Closed (s) % solids (tph)
Oct 04/00 62 500 0.18 4 11.55 0.491
Oct 04/00 63 600 0.18 4 11.55 0.491
Oct 04/00 61 700 0.18 4 11.55 0.491
Oct 04/00 64 800 0.18 4 11.55 0.491
Oct 04/00 65 900 0.18 4 11.55 0.491
Oct 04/00 66 1000 0.18 4 11.55 0.491
Oct 05/00 67 500 0.18 2 21.15 1.01
Oct 05/00 68 625 0.18 2 21.15 1.01
Oct 05/00 82 625 0.18 3 21.15 1.01
Oct 05/00 69 625 0.18 4 21.15 1.01
Oct 05/00 70 625 0.18 6 21.15 1.01
Oct 05/00 71 625 0.18 8 21.15 1.01
Oct 05/00 72 700 0.18 2 21.15 1.01
Oct 05/00 73 700 0.18 3 21.15 1.01
Oct 05/00 74 700 0.18 4 21.15 1.01
Oct 05/00 75 700 0.18 6 21.15 1.01
Oct 05/00 76 700 0.18 8 21.15 1.01
Oct 05/00 77 850 0.18 2 21.15 1.01
Oct 05/00 78 850 0.18 3 21.15 1.01
Oct 05/00 79 850 0.18 4 21.15 1.01
Oct 05/00 80 850 0.18 6 21.15 1.01
Oct 05/00 81 850 0.18 8 21.15 1.01
Oct 06/00 83 700 0.16 4 31.15 1.72
Oct 06/00 84 700 0.17 4 31.15 1.72
Oct 06/00 85 700 0.18 4 31.15 1.72
Oct 06/00 86 700 0.19 4 31.15 1.72
116
i
Bowl Feed
Speed Pinch Pinch Rate
Date Test ID RPM Open (s) Closed (s) % solids (tph)
Oct 06/00 87 700 0.2 4 31.15 1.72
Oct 06/00 88 850 0.14 4 31.15 1.72
Oct 06/00 89 850 0.15 4 31.15 1.72
Oct 06/00 90 850 0.16 4 31.15 1.72
Oct 06/00 91 850 0.17 4 31.15 1.72
Oct 06/00 92 850 0.18 4 31.15 1.72
Oct 10/00 93 625 0.18 4 38.9 2.04
Oct 10/00 94 625 0.19 4 38.9 2.04
Oct 10/00 95 625 0.2 4 38.9 2.04
Oct 10/00 96 625 0.21 4 38.9 2.04
Oct 10/00 97 625 0.22 4 38.9 2.04
Oct 10/00 98 700 0.18 4 38.9 2.04
117

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CONTINUOUS CENTRIFUGAL CONCENTRATOR

OPERATION AND CONTROL

Master of Applied Science

THE FACULTY OF GRADUATE STUDIES

MINING AND MINERAL PROCESS ENGINEERING

The University of British Columbia

© Michael J. McLeavy, 2005

basic understanding of where this technology could be applied commercially.

1. Quartz/magnetite statistical experimental design

2. Quartz/magnetite incremental testing

3. Synthetic sphalerite/quartz incremental testing

most significant to least significant:

Rank Variable rankings Variable rankings

Testing of both synthetic quartz/magnetite and synthetic quartz/sphalerite resulted in a better

information from the laboratory scale tests.

• Identification of performance expectations

• Identification of a performance boundary layer

reasonable recovery was obtained was a differential of 2.

2.3 EVOLUTION OF CONTINUOUS CENTRIFUGAL CONCENTRATORS FROM B A T C H TECHNOLOGY 4

2.6 KNELSONCVD ". 11

2.6.1 Knelson CVDApplications 14

3.1 TEST PROGRAM 14

3.2 PILOT SCALE CIRCUIT 15

4.2.2 Quartz/Magnetite Assay Procedure 24

4.2.3 Attrition Check 25

4.2.4 Test Program Details 27

4.3.2 Effect of Operating Variables on Grade 33

4.3.3 Effect of Operating Variables on Recovery 35

5 QUARTZ/MAGNETITE INCREMENTAL TESTING 40

5.2 EXPERIMENTAL TEST PROGRAM 40

5.3 QUARTZ/MAGNETITE INCREMENTAL TESTING RESULTS 42

5.3.2 Quartz/Magnetite Trends with Changing Bowl Speed. 43

5.3.3 Quartz/Magnetite Trends with Changing Fluidization Water Flowrate 44

5.3.4 Quartz/Magnetite Trends with Changing Percent Solids 47

6 L A B TESTING - SYNTHETIC SPHALERITE/QUARTZ 49

6.2 EXPERIMENTAL - SYNTHETIC SPHALERITE/QUARTZ 50

6.2.1 Feed Characterization 50

6.2.2 Test Program 53

6.2.3 Procedures and Sampling 55

6.2.4 Sample Preparation 55

6.3 RESULTS -SYNTHETIC QUARTZ/SPHALERITE 56

7 HUDSON'S BAY MINING AND SMELTING PLANT TRIALS 60

7.2 EXPERIMENTAL-PLANT TRIALS AT HUDSON'S BAY MINING AND SMELTING 61

7.2.1 Test Program 61

7.2.3 Sample Preparation 65

13 RESULTS - PLANT TRIALS AT HBM&S 66

7.3.2 Bowl speed 66

7.3.3 Pinch valve open time 67

7.3.4 Pinch valve closed time 70

9.2 OPERATING VARIABLE PERFORMANCE RATIO 79

10 DEVELOPING AN OPERATING STRATEGY FOR A NEW APPLICATION 86

10.2 IDENTIFICATION OF THE OBJECTIVES 86

10.3 C V D BOUNDARY CONDITIONS 87

10.4 QUALITATIVE TUNING 88

10.5 FORMULATION OF A GENERAL TEST PROGRAM 91

10.6 FINE TUNING THE OPERATING VARIABLES 92

11 CONCLUSIONS AND RECOMMENDATIONS 94

11.1 FACTORIAL DESIGN 94

11.3 SYNTHETIC SPHALERITE/QUARTZ 96

11.4 H B M & S PLANT TESTING 96

11.5 SPECIFIC GRAVITY DIFFERENTIAL 97

11.6 VARIABLE TUNING IN A C V D CONCENTRATOR 97

11.7 DEVELOPING AND OPERATING STRATEGY FOR A N E W APPLICATION 98