Mineral Processing and Extractive Metallurgy Review

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Application of Knelson concentrator for

beneficiation of copper–cobalt ore tailings

Christian Ndolwa Katwika, Meschac-Bill Kime, Pierre Ngoy Mwana Kalenga,

Bienvenu Ilunga Mbuya & Tony Rukan Mwilen

To cite this article: Christian Ndolwa Katwika, Meschac-Bill Kime, Pierre Ngoy Mwana Kalenga,
Bienvenu Ilunga Mbuya & Tony Rukan Mwilen (2018): Application of Knelson concentrator for
beneficiation of copper–cobalt ore tailings, Mineral Processing and Extractive Metallurgy Review,
DOI: 10.1080/08827508.2018.1481057

To link to this article: https://doi.org/10.1080/08827508.2018.1481057

Published online: 04 Jun 2018.

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MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW
https://doi.org/10.1080/08827508.2018.1481057

Application of Knelson concentrator for beneficiation of copper–cobalt ore tailings

Christian Ndolwa Katwikaa, Meschac-Bill Kime b
, Pierre Ngoy Mwana Kalengaa, Bienvenu Ilunga Mbuya c
,
and Tony Rukan Mwilen a
a
Department of Mines, Universite de Lubumbashi, Lubumbashi, Congo (the Democratic Republic of the); bDepartment of Metallurgy, University of
Johannesburg, Johannesburg, South Africa; cDepartment of Metallurgy, Université de Likasi, Likasi, Congo (the Democratic Republic of the)

ABSTRACT KEYWORDS
The beneficiation of high talc-containing copper–cobalt flotation tailings was studied by centrifugal Gravity separation; Knelson
gravity concentration. It was found that copper and cobalt minerals were finely disseminated in the concentrator; copper–cobalt
gangue matrix so that conventional gravity concentration using spirals and shaking tables would be ore; froth flotation; tailings
ineffective. The actual experimental test work was performed using the Knelson gravity concentrator reprocessing
and the results were transposed to industrial scale by simulating several beneficiation scenarios. The
results indicated that integration of Knelson concentrators in the concentration circuit to treat the
flotation tailings would significantly improve copper and cobalt recoveries from 65.00% to 86.09% and
67.00% to 86.96%, respectively.

1. Introduction beneficiation of copper and cobalt ore involves a combination

of concentration by froth flotation and classical gravity separa-
The reduction of talc recovery in copper–cobalt flotation con-
tion by spirals and shaking tables. A crushing–grinding–flota-
centrates is very crucial. In fact, a high talc content into the
tion system is used to produce a 7–8% cobalt and 25–30% copper
concentrate lowers the copper–cobalt grades and causes pro-
bulk concentrate. The flotation reagents regime is based on a
blems in the smelters due to the resulting high MgO content
strengthened dosage of sodium sulphydrate (10,000 g/t) during
(Pugh 1988; Klein et al. 2016; Kime and Kaniki 2017), forcing
the roughing stage for a better sulfidization of malachite and
the smelter operators to impose penalties for the concentrators.
heterogenite minerals. The recovery is based on cobalt, which is
Talc also causes the concentrate froth to be rigid and takes
the highest paying coproduct targeted in the final concentrate.
longer to break down. It also consumes a large amount of
Flotation occurs at temperatures near 35°C in several stages
reagents in flotation. In the processing of high talc-containing
including pre-flotation, roughing, cleaning, and scavenging.
copper–cobalt ore, talc is dealt with by pre-floating it together
The pre-flotation is carried out in two phases; a roughing and
with quartz and other phyllosilicate minerals (muscovite,
a cleaning. Each of the two phases produces a product which is
micas, chlorite, and serpentine) (Kime et al. 2015; Kime and
freed of most talc that is fed to the flotation stage, and a talc
Kaniki 2017). However, the big challenge comes from the fact
concentrate which is the first release of the concentrator. The
that the milling of high talc-containing oxidized copper–cobalt
rougher concentrate produced, combined with the scavenger
ore is done at a coarser size (d80 ≈ 75–150 µm) to avoid
concentrate, is further upgraded to around 31.77% copper and
overmilling the friable talc (Kime and Kaniki 2017). This is
7.44% cobalt through cleaning. This is achieved at recoveries
because talc is fairly hydrophobic; very fine talc (−38 μm) can
about 65.00% copper and 67.00% cobalt. The scavenger tails
adhere to air bubbles to such an extent that talc “crowds out”
constitute the second release of the concentrator. Tails from
the copper–cobalt-bearing minerals on the bubbles and there-
the cleaning stage are sent to a hydrocyclone battery whose
fore reduces copper–cobalt concentrate grades and recoveries.
overflow constitutes the third release of the concentrator. The
The efficient liberation of minerals remains one of the major
hydrocyclone underflow is treated by spirals and shaking tables
challenges in treating high talc-containing copper–cobalt ores.
to produce a copper–cobalt concentrate that is added to the
In addition, it has been observed that most of the recoverable
rougher concentrate; and the tails that are recycled to head of
copper and cobalt are contained in the −106 to + 38 µm range
the scavenger cells. The final tailing is constituted of the pre-
(Kime et al. 2015). Therefore, the trade-off coarse size of the
flotation tails, scavenger tails, and the hydrocyclone overflow.
flotation feed causes a significant amount of valuable minerals
However, due to the initial coarse grinding of the ore and the
to be rejected to pre-flotation of phyllosilicate minerals and
inefficiency of conventional gravity separation, a significant
during the actual flotation.
amount of recoverable copper and cobalt is rejected into the
The New Concentrator of Kipushi (NCK) is a typical example
tailings. This problem could be solved by incorporating centri-
of a plant processing high talc-containing copper-cobalt ore, the
fugal concentrators such as Knelson separators into the
simplified flowsheet is given in Figure 1. At NCK, the

CONTACT Meschac-Bill Kime meschackime@engskillsconsulting.com Department of Metallurgy, University of Johannesburg, Johannesburg, South Africa.
Color versions of one or more of the figures in the article can be found online at www.tandfonline.com/gmpr.
© 2018 Taylor & Francis Group, LLC
2 C. N. KATWIKA ET AL.
Figure 1. Schematic flowsheet of NCK concentrator and metallurgical balances at selected sample points.
concentration circuit to recover copper and cobalt from the
flotation tailings. This beneficiation technique proved to be
cost-effective and environment friendly for low-grade ores and
finely disseminated minerals in complex matrices (Meza et al.
1994; Poulter et al. 1994; Patchejieff et al. 1994; Laplante et al.
1995a, 1995b, 1996; Huang 1996; Ancia et al. 1997; Majumder
and Barnwal 2006; Gupta et al. 2007; Chen et al. 2008; Das et al.
2009; Uslu et al. 2012; Jordens et al. 2013, 2014; Schriner and
Anderson 2015; Angadi et al. 2017; Das and Sarkar, 2018).
Previous studies demonstrated that a Knelson concentrator can
be used effectively to beneficiate low-grade copper–cobalt ores
and tailings (Poulter et al. 1994; Ramakokovhu et al. 2012).
The objective of this work was to investigate the beneficiation
of copper–cobalt flotation tailings by using a Knelson centrifugal
gravity separator. Based on the mineralogical, separation, and
simulation studies, a process flow scheme including froth flota-
tion and Knelson concentrators was proposed.
2. Materials and methods
2.1. Field testing
Two phases of field testing were performed to evaluate the
metallurgical performance of NCK. The first phase of the work
involved a characterization study performed on the feed and
products of the milling circuit of NCK. The first phase of the
work consisted of a characterization study carried out on the
feed and the products of the milling circuit of NCK. The milling
circuit feed sample was collected from Luiswishi mine in the
Democratic Republic of Congo. The second phase of the work
consisted of a characterization study carried out on samples
taken from NCK streams. The samples were taken from the
pulp flows of the feed and selected tails.
2.2. Sampling procedures
All plant samples were collected using a systematic 4-h sam-
pling of pulp flows on selected streams. This sampling mode
was suitable for the flows and was easy to carry out. The
samples were collected across the entire diameters of the
pipes using standard 4 L buckets. After collection, the samples
were homogenized and placed into plastic bags before being
transported to the laboratory for analysis. Out of the 4 L
collected, 1 L was taken for density measurement. The
remaining 3 L was placed in a barrel containing clear water
to dilute the pulp and accelerate the decantation. Each barrel
received all samples of the same product obtained after 24 h.
This was referred to as “sample of the day.” About 18 L of the
pulp of each product could be obtained after 24 h. The sample
of the day was allowed to settle for 12 h. The water phase was
siphoned off and the solid phase was dried at 100°C for 24 h.
After 8–10 days sampling campaign, the dried products
obtained from the same stream were disaggregated, mixed,
and homogenized. Representative subsamples were obtained
for size-assay, mineralogical analysis, and chemical analysis by
riffle splitting the bulk samples. The remaining bulk of the
sample, about 50 kg, was used for the Knelson concentration
testing.
2.3. Mineralogical characterization of ore samples
The mineralogical composition of the ore samples was carried
out with electron microprobe (EMP, CAMECA SX50) and
optical microscope (Leica DMLP, equipped with INFINITY X
camera), both housed at the Mineralogy Laboratory of the
Department of Geology and Applied Geology, Polytechnic
Faculty, The University of Mons.
2.4. Knelson concentration
The Knelson gravity concentration experiments were per-
formed using a laboratory-scale KC-MD3 Knelson™ batch
concentrator (Knelson 2003), hosted in the Minerals
Processing and Valorisation Laboratory at the University
of Mons. The bowl had a capacity of 65 mL of concen-
trate. The optimum operating conditions determined were
a mass load of 1000 g and a centrifugal force of 120g. All

Table 1. Apparent density and d80 of the tailings samples.
Tailings samples d80 (µm)
Pre-float tails 50
Cleaning tails 115
Scavenger tails 106
Final tails 102
the heavy particles (malachite, d ≈ 4.00 and heterogenite,
d ≈ 3.00) sedimented at the bottom of the inter-riffles
spaces of the concentrator as concentrates, while lighter
particles overflowed from the outlet of the gangue. The
actual experimental tests were carried out by varying water
counterpressure in order to optimize the fluidization of
the gangue materials. Determination of Cu and Co was
carried out using an inductively coupled plasma atomic
emission spectrometer (NOVA 400). Data on the apparent
density and d80 of the tailings samples are given in
Table 1.
3. Results and discussions
3.1. Characterization
Samples from different geological units of the Luiswishi
mine were collected and analyzed. Figures 2 and 3 show
the results obtained from the optical microscopy and
microprobe analyses of the ore samples under the study.
As can be seen, the results indicated that the ore was well
oxidized, with predominantly quartz and iron oxides as
gangue materials. Copper and cobalt were much more
localized in the porosity left by the dissolution of the
primary sulfide bodies. Some oxidized sulfide grains were
also observed at the surface. This was the case of the
argillitic sandstone ore sample (RAT, from the French
Roches Argileuses Talqueuses). The RAT sample also con-
tained a significant amount of malachite. The mineralized
black ore zone (BOMZ) sample contained large amounts
Figure 2. Minerals observed at the microprobe on the Luiswishi mine samples. (A) Backscattered-electron image of RAT, (B) siliceous rocks with cavities, (C)
backscattered-electron image of DSTRAT, (D) DSTRAT sp1 (Cu), € DSTRAT sp3 (Co), (F) reflected image of DSTRAT, (G) transmitted image of DSTRAT, (H)
backscattered-electron image of micaceous dolomitic shale (SD1a), (I) backscattered-electron image of carbonaceous dolomitic shale (SD2a), (J) transmitted image
of SD2a.
MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW 3
of iron oxides and quartz and was very porous. In the
Apparent density stratified dolomite (DSTRAT) ore sample, the grains of
2.75 malachite were intimately related to heterogenite. The
2.65
2.65
majority of mineral grains observed were less than
2.65 150 μm in size. The particle size distribution of the pre-
flotation feed and tailings samples is given in Figure 4.
With the exception of the pre-float tails, their d80 lied
between 75 and 150 μm. The fine particle size of the
samples is indicative of the fine dimensional domain of
flotation of oxidized copper–cobalt ores, generally less
than 100 μm. Figure 5 shows the distribution of the metals
in the feed before flotation. Table 2 presents the grades of
metals in the pre-flotation feed, as well as in the tailings
samples. It is observed that the pre-flotation and cleaner
tailings still contain appreciable amounts of copper and
cobalt; 3.63% Cu and 1.08% Co, and 5.16% Cu and 1.01%
Co, respectively. In addition, the mineralogical and che-
mical analysis showed that approximately 80% of recover-
able copper and cobalt metals in the tailings were found in
the size fraction less than 50 μm. Therefore, it would be
inconceivable to treat them by conventional gravity
separation (spirals and shaking tables).
Figure 6 shows the distribution of Cu, Co, Fe, and Mn in
the tailings samples. As can be seen, most of the recoverable
copper and cobalt was contained in the fraction less than
38 μm.
The identification of the major mineral phases was
done with X-ray diffraction (XRD, Siemens D5000) on
disoriented powders of five selected streams: pre-float
feed, pre-flotation tails, cleaning tails, scavenger tails,
and final tails. For the purpose of the analysis, samples
were finely ground (<50 µm), placed on sample holders,
and then crushed using a glass slide so as to have a flat
and smooth surface before being placed in the apparatus
for analysis. The semi-quantification of the weight fraction
of phases was carried out by comparing the integrated
intensities of the diffraction peaks from each of the
4 C. N. KATWIKA ET AL.

Figure 3. Minerals observed under optical microscope on the Luiswishi mine samples: (A) SD1a under polarized reflected light, (B) SD1a under polarized reflected
light + polarized transmitted light, (C) DSTRAT, under polarized transmitted light, (D) DSTRAT, under polarized and analyzed in transmitted light, (E) RAT, under
polarized transmitted light, (F) RAT, under polarized and in analyzed transmitted light, (G) SD2a, under polarized transmitted light, (H) SD2a, under polarized and
analyzed in transmitted light, (I) foliated and silicified rocks under polarized transmitted light, (J) foliated and silicified rocks under polarized and in analyzed
transmitted light.

very fine grains liberated at about a size of less than 75 μm.

Some imbrications of grains of malachite with those of het-
erogenite were also observed. This was the case of some grains
of malachite enveloped by heterogenite.

3.2. Knelson concentration

Figure 4. Particle size distributions of the pre-flotation feed and tailings samples.
determined phases. The XRD pattern of the pre-float feed
is shown in Figure 7. The calculated quantitative XRD
results of the pre-float, as well as all tailings, are listed
in Table 3.
Malachite, cuprite, and chalcopyrite were the major copper
minerals present in the ore sample. Heterogenite, though
present, was not detected due to its amorphous nature.
Besides the valuable minerals, the gangue material was mainly
constituted of quartz, phyllosilicates, goethite, and hematite.
Figure 8 shows the micrographs of the analysis of the pre-
flotation feed by using optical microscopy and microprobe
analysis. It was observed that malachite and heterogenite were
Knelson gravity experiments were conducted to investigate the
effect of counterpressure on copper and cobalt recoveries from the
tailings. Figure 9 shows the effect of the counterpressure on the
recovery of metals from the Knelson concentration of the pre-
flotation tailings. As can be seen, the recovery increased as the
counterpressure increased from 6 to 12 kPa and quickly dropped
for counterpressures beyond. The optimum counterpressure to
fluidize the gangue materials was 12 kPa. The same rationale was
followed to determine the optimal fluidization counterpressures
of the gangue materials of all the other tailings samples. The
results are given in Table 4. As can be seen, the maximum
recoveries occurred at different counterpressures, depending on
the sample treated. This was a clear indication that the concentra-
tion efficiency of the Knelson gravity concentrator strongly
depends on the mineralogy and the valuable metal content in
the ore.
3.3. Search for the optimal circuit configuration
The study of various circuit configurations to extract copper
and cobalt from flotation tailings was performed to improve
the metallurgical performance of NCK. To this end, the NCK
flotation circuit was surveyed. The sampling points and metal-
lurgical balance at the time the survey was taken are indicated
 MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW 5

Figure 5. Distribution of Cu, Co, Fe, and Mn in the pre-flotation feed sample.

Table 2. Grades of metals in the pre-flotation feed and tailings samples. capacity. For the purpose of the simulations, the Knelson
Cu Co Fe Mn models were selected according to the data in Table 5. It
Pre-float feed 4.79 1.09 2.33 0.10 was also hypothesized that the Knelson recovery on an indus-
Pre-flotation tails 3.63 1.08 1.71 0.06 trial scale was 95% of that found in the laboratory. This
Cleaning tails 5.16 1.01 2.88 0.06
Scavenger tails 1.45 0.34 2.23 0.07 hypothesis was justified by the fact that almost all copper–
Final tails 1.88 0.40 2.50 0.09 cobalt minerals in the tailings were well liberated. Therefore,
any further beneficiation process applied to the tailings should
be efficient and cost-effective.
in the processing scheme in Figure 1. Data on the flow rate of The process flowsheet, shown in Figure 10, and which
the pre-flotation were collected at the inlet of the pre-flotation includes a configuration of the flotation circuit and individual
section, that of the tailings was collected at the outlets of their Knelson concentrator for treating each tailing was evaluated.
respective flows. All the samples were dried and characterized The simulation results showed that by using Knelson concen-
with respect to their grade and recovery of copper and cobalt. trators, recoveries about 60.36% Cu, 59.77% Co,; 67.54% Cu,
65.66% Co; 60.41% Cu, 57.05% Co; and 61.11% Cu, 59.52%
3.3.1. Simulation of optimal circuit configuration Co for pre-float tails, cleaning tails, scavenger tails, and final
Simulations were performed in Excel to explore the beneficia- tails, respectively, could be achieved. Similarly, their grades
tion options for the Luiswishi high talc-containing ore. There were 30.36% Cu and 7.96% Co; 37.50% Cu and 8.27% Co;
are several types of Knelson concentrators according to the 9.70% Cu and 2.11% Co; and 14.25% Cu and 3.07% Co for
diameter of the concentration bowl and the processing pre-float tails, cleaning tails, scavenger tails, and final tails,

Figure 6. Distribution of Cu, Co, Fe, and Mn in the tailings samples. PFT: Pre-flotation tails; CT: cleaning tails; ST: scavenger tails; and FT: final tails.
6 C. N. KATWIKA ET AL.

Figure 7. XRD pattern of the pre-flotation feed.

Table 3. Semi-quantitative XRD results of the selected streams. 31.57% Cu and 7.44% Co. This is an indication that the
Concentration (wt%) Knelson concentration process achieved the minimum
Pre-float Pre-flotation Cleaning Scavenger Final requirements of copper–cobalt concentrates for direct smelt-
Mineral feed tails tails tails tails ing or leaching.
Quartz 68.19 4.91 56.83 75.86 77.81 The possibility of mixing different Knelson concentrates
Phyllosilicates 23.82 92.44 21.40 15.85 18.71
Cuprite 5.15 0.40 4.63 6.00 1.56 obtained from the tailings was also explored. This was done to
Malachite 1.50 1.89 10.92 1.24 1.31 see which Knelson concentrate could have a significant
Goethite 0.58 0.23 0.98 0.65 0.23 impact on the global recovery. The simulation results are
Chalcopyrite 0.39 0.00 0.66 0.00 0.20
Hematite 0.36 0.14 2.02 0.40 0.16 presented in Figures 11a and 11b. It appears that only con-
centrates from pre-flotation and cleaning tailings or their
combination had significant values to improve overall recov-
respectively. Using the current configuration (Figure 1), NCK ery. The Knelson concentration of the pre-flotation and clean-
achieves overall recoveries about 65.00% and 67.00% for cop- ing tailings yielded individual concentrates grading 30.36% Cu
per and cobalt, respectively. The concentrates grade about and 7.96% Co; and 5.16% Cu and 1.01% Co, respectively, with

Figure 8. Minerals observed in the pre-flotation feed. Optical microscopy – (A) observed under polarized transmitted light, (B) under polarized and analyzed in
transmitted light, (D) observed under polarized reflected light. Microprobe analysis – (C): observed under polarized transmitted light, (E): BSE, (F) observed under
polarized transmitted light.
 MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW 7

Figure 9. Effect of counterpressure on the recovery. Constant variables: mass load: 1000 g and centrifugal acceleration: 120g.

Table 4. Recovery of copper and cobalt from the tailings samples as a function recoveries about 68.36% Cu and 59.77% Co, 67.54% Cu and
of optimum counterpressures. 65.66% Co, respectively. This means, they would individually
Cu Co contribute to the overall concentrate at 0.23 and 0.40 t/h, or a
Samples Recovery Grade Recovery Grade global contribution of 0.63 t/h.
Pre-float tails (12 kPa) 71.96 32.55 62.92 8.40 Two configurations were then selected and evaluated to
Cleaning tails (48 kPa) 71.09 42.67 69.12 8.26 optimize the overall recovery. The first one, shown in
Scavenger tails (43 kPa) 63.59 10.15 60.05 2.41
Final tails (42 kPa) 64.33 15.46 62.65 3.22 Figure 12, included the flotation circuit and a single Knelson
Constant variables: mass load: 1000 g and centrifugal acceleration: 120g. concentrator to treat the pre-flotation tails. The simulation
results showed that the overall copper recovery would result
in an additional recovery of 0.06 tCu/h and that of cobalt by
0.02 tCo/h. However, the contribution of a concentrate less
Table 5. Considerations on the choice of Knelson models.
rich in copper (30.36% Cu) obtained from the centrifugal
Bowl
d80 Apparent Flow rate Bowl capacity
treatment of the pre-float tails would lead to a slight decrease
Tails (µm) density (t/h) diameter (″) (t/h) in the overall content of the global concentrate (31.46% Cu
Pre-float tails 50 2.75 2.78 10 8 instead of 31.57% Cu). The cobalt content of the overall
Cleaning tails 115 2.65 4.67 10 8 concentrate would remain unchanged at around 7.44%. The
Scavenger tails 106 2.65 52.66 20 80
Final tails 102 2.65 56.75 20 80 low contribution can be explained by the low mass contribu-
tion (0.23 t/h) of the pre-float tails concentrate to the overall

Figure 10. Schematic for separate treatment of tailings. PFT: Pre-float tails; CT: cleaning tails; ST: scavenger tails; and FT: final tails.
8 C. N. KATWIKA ET AL.

concentrate (6.42 t/h). The contribution of the treatment of

Figure 11a. Recovery in the case of joint treatment of tailings. PFT: Pre-float tails;
CT: cleaning tails; ST: scavenger tails; and FT: final tails.
each tailing to the total concentrate can also be obtained. The
results are presented in Figures 13a and 13b. As can be seen,
the treatment of final tails would greatly improve the overall
results. Another configuration that was evaluated included the
flotation circuit and two Knelson concentrators to treat the
pre-float tails and cleaning tails. The simulation results are
presented in Figure 14. The data indicate that by mixing the
Knelson concentrates to the current overall concentrate, about
4.21% Cu and 2.57% Cu could be further recovered.
Simulations were also performed to see the contribution of
the concentrates obtained from the separate or joint treatment
of tailings on the final concentrate. The results are given in
Figures 15a and 15b.
The simulation results of analyses of four industrial-scale
scenarios evaluated to improve NCK’s metallurgical perfor-
mance can be summarized as follows:

(1) The Knelson concentration of pre-float tails could

Figure 11b. Grade of the final concentrate in the case of joint treatment of the
tailings. PFT: Pre-float tails; CT: cleaning tails; ST: scavenger tails; and FT: final
tails.
produce a 42.67% Cu and 8.26% Co concentrate, at
71.09% Cu and 69.12% Co recoveries. However, with
the very low flow rate of pre-float tails (4.67 t/h), the
quantities of metals resulting from this treatment are
also low (0.15 tCu/h and 0.03 tCo/h); this would be

Figure 12. Contribution of pre-float tails concentrates to the overall concentrate. PFT: Pre-float tails; CT: cleaning tails; ST: scavenger tails; and FT: final tails.

Figure 13. Contribution of separate tailings concentrates to the overall concentrate. (A) Current final concentrate, (B) contribution of pre-float tails (PFT) concentrates
to the overall concentrate, (C) contribution of cleaning tails (CT) concentrates to the overall concentrate, (D) contribution of scavenger tails (ST) concentrates to the
overall concentrate, and (E): contribution of final tails (FT) concentrates to the overall concentrate.

Figure 14. Contribution of joint PFT–CT concentrates to the overall concentrate. PFT: Pre-float tails and CT: cleaning tails.
Figure 15a. Contribution of combined tailings concentrates to the overall con-
centrate. (A) Current final concentrate, (F) contribution of joint PFT–CT concen-
trates to the overall concentrate, (G) contribution of joint PFT–ST concentrates to
the overall concentrate, (H) contribution of CT–ST concentrates to the overall
concentrate, and (I) contribution of joint PFT–CT-ST concentrates to the overall
concentrate. PFT: Pre-float tails; CT: cleaning tails; and ST: scavenger tails.
Figure 15b. Contribution of combined tailings concentrates to the overall con-
centrate. (A) Current final concentrate, (F) contribution of joint PFT–CT concen-
trates to the overall concentrate, (G) contribution of PFT–ST concentrates to the
overall concentrate, (H) contribution of joint CT–ST concentrates to the overall
concentrate, and (I) contribution of PFT-CT–ST concentrates to the overall con-
centrate. PFT: Pre-float tails; CT: cleaning tails; and ST: scavenger tails.
an insignificant contribution to the NCK overall
concentrate.
(2) The joint treatment of pre-float tails and cleaning
tails could produce a 34.92% Cu and 7.94% Co con-
centrate, at 68.75% Cu and 62.50% Co recoveries.
Since the joint pre-float tails–cleaning tails flow rate
is 2.78 t/h, the quantities of the metals resulting from
this joint treatment would also lead to a small con-
tribution to the total concentrate (0.22 tCu/h and
0.05 tCo/h).
MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW 9
(3) The Knelson concentration of the final tailings would
produce a 24.19% Cu and 5.58% Co concentrate, at
86.09% Cu and 86.96% Co recoveries. Given the high
flow rate of final tails (56.95 t/h) and its metal grades
(1.88% Cu and 0.40% Co), the quantities of metals
produced would be 0.65 tCu/h and 0.14 tCo/h. This
would represent a significant improvement in recov-
ery efficiencies compared to the current situation.
However, it should be noted that the grades would
decrease (24.19% Cu and 5.58% Co) compared to the
current situation. This can be explained by the dilu-
tion of the actual concentrate by the concentrate
obtained from the final tails (FT) treatment.
(4) The joint treatment of pre-float tails, cleaning tails,
and scavenger tails could produce a 22.89% Cu and
2.21% Co concentrate, at 84.44% Cu and 84.06% Co
recoveries. Given the flow rate of the joint pre-float
tails–cleaning tails–scavenger tails of 52.66 t/h, the
increase in metal recoveries in the overall concentrate
is evident.
Table 6 shows how the different simulated circuit config-
urations would affect the overall outputs. Using recovery
efficiencies, the simulation results showed that the concen-
trate obtained from the processing of the final plant tailings,
to be blended with the overall concentrate obtained under
current plant conditions, would significantly improve the
overall recovery efficiencies at 86.09% Cu and 86.96% Co.
4. Conclusion
The following conclusions can be drawn from this work.
(1) Mineralogical and chemical characterization of the
high talc-containing copper–cobalt flotation tailings
under the study showed that about 80% of the reco-
verable copper and cobalt metals were in the size
fraction less than 50 μm.
(2) The batch concentration test work indicated that
Knelson gravity concentrator was cost-effective at
recovering copper and cobalt from high talc-
10 C. N. KATWIKA ET AL.

Table 6. Summarized results of the simulated circuit configurations compared to the actual NCK circuit configuration.
Recovery Concentrate Concentration
(%) grade (%) ratio
Circuit configuration Cu Co Cu Co Cu Co Concentrate weight yield (%)
Current NCK circuit 65.00 67.00 32.10 7.52 6.60 6.80 9.80
Addition of pre-float tails concentrate 66.89 69.57 31.46 7.44 6.60 6.80 10.20
Addition of concentrate obtained from the joint processing of PFT and CT 69.21 69.57 32.66 7.50 6.80 6.90 10.10
Addition of concentrate obtained from the joint processing of PFT, CT, and ST 84.44 84.06 22.89 5.21 4.78 4.78 15.83
Addition of final tailings concentrate 86.09 86.96 24.19 5.58 5.10 5.10 17.00
PFT: Pre-float tails; CT: cleaning tails; ST: scavenger tails.

containing copper–cobalt flotation tailings. Under the Funding

optimal conditions, overall recoveries of approxi-
mately 64.36% Cu and 60.50% Co were obtained.
(3) The proposed flowsheet for treating the high
talc-containing copper–cobalt ore included a flotation
section and gravity separation section using Knelson
concentrators. Using such a flowsheet, the simulation
results showed that it would be possible to produce a
concentrate of 24.19% Cu and 5.58% Co with recoveries
of 86.09% Cu and 86.96% Co. This would represent an
increase of about 0.65 t/h Cu and 0.14 t/h Co of NCK’s
current capacity. Considering that the concentrator pro-
duces approximately 53,481.00 t/year of concentrate, the
6825.60 t/year of the surplus recovered would represent
an annual profit of $6825,000.00 using a price of $1000/t
of copper–cobalt concentrate.
5. Highlights
● Oxidized copper–cobalt ore samples and flotation resi-
dues are characterized to evaluate losses in copper and
cobalt metals in the flotation circuit.
● The flotation tailings are treated with the Knelson cen-
trifugal gravity separator for the recovery of copper–
cobalt-bearing minerals.
● High centrifugal acceleration (120g) was used for opti-
mal separation.
● The advantage of centrifugal gravity separation is shown
as well as the superiority of centrifugal gravity separation
on conventional gravity separation (spirals and shaking
tables) for copper–cobalt-bearing minerals of the tailings.
● Several industrial beneficiation scenarios are simulated;
the optimum flowsheet is proposed.
● Centrifugal gravity concentration of the flotation tails
would significantly improve copper and cobalt recoveries
from 65% to 86.09% and 67% to 86.96%, respectively.
Acknowledgments
The authors gratefully acknowledge the support of NCK in providing
them with the opportunity to complete this work and allowing it to be
published.
Disclosure statement
The authors report no conflicts of interest. The authors alone are
responsible for the content and writing of the article.
This work was supported by The University of Mons, The Belgian
Technical Cooperation, and The University Cooperation for Development.
ORCID
Meschac-Bill Kime http://orcid.org/0000-0003-4380-807X
Bienvenu Ilunga Mbuya http://orcid.org/0000-0002-3850-9051
Tony Rukan Mwilen http://orcid.org/0000-0003-3569-3233
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