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Received 25 Sep 2011; received in revised form 1 Feb 2012; accepted 16 May 2012
*Corresponding author: noparast@ut.ac.ir (M. Noaparast).
Abstract
This study aimed to explore concentration of a low grade sulfide-oxide lead-zinc sample containing 2.3% Pb,
1.91% Zn taken from Changarzeh mine, South Natanz, Iran. The effects of different parameters such as type
and dosage of collector, milling retention time, dosage of sodium sulfur and its preparation time, application
of sodium silicate, pH and solid content were investigated in relation to flotation efficiencies. Optimum
experiment was carried out in cumulative flotation with 200g/t KAX as collector, 2000g/t Na 2S, 500g/t
sodium silicate, 30g/t MIBC and at pH=10. This test yielded 94% of lead recovery under optimum condition
performance, and a concentrate with 70%Pb was produced through cleaning stages. Eighteen minutes was
found to be the optimum time for lead flotation in laboratory scale. Application of gravity method for the
production of a middle product was also considered. For shaking table the effect of table slope and water
flowrate and for jig the effect of water flowrate and frequency were studied. Gravity separation by shaking
table resulted in a concentrate with 46%Pb and 80% recovery, so shaking table could be proposed for
production of pre-concentrate.
1. Introduction
The lead oxide minerals are cerrusite, anglesite treated by sulfidizing agents before being floated
and plambojarusite and the common method for [2, 3, 4]. Adding sulfide salts to the system
the recovery of these minerals is flotation [6]. sulfidizes the oxide mineral surface and makes it
Oxidation degree in lead ores varies from tiny hydrophobic, to be floated easily. As a result,
tarnish to complete oxidation [7]. Nowadays collector consumption decreases [2].
effective beneficiation of the oxide-sulfide ores is When the oxide lead minerals exist in
a great concern for engineers. Low floatability of considerable amounts, first the lead and zinc
these minerals is a result of their high solubility sulfides and then the treated oxide minerals are
[3]. Lead ions solved from the mineral structure floated. The amount of sulfidizing agent for
react with collector and perticipitate as the different ore types is different and normally
insoluble lead xanthate and increase the between 500 to 2500g/t. Precise control is needed
consumption of collector [2]. It was found out that in sulfide addition, because while the shortage of
through cerrusite flotation, collector consumption sulfide ions will cause ineffective sulfidation, over
is much higher than the required amount for consumption of sulfides will depress sulfide and
sulfidized minerals [3]. Aero 404, 407 or 412 in
galena flotation [2, 4]. These researchers declared
combination with isopropyl or amyl xanthate,
that the main reason for high consumption of such as sodium isopropyl xanthate (Z11) and
collector is most probably the reaction between X+ potassium amyl xanthate (KAX), are the preferred
and PbCO3, where X+ could be Pb2+, Cu2+ and/or collectors for flotation of lead minerals. Adding
Zn2+. As a result, the oxide lead minerals are
Atrafi et al./ Journal of Mining & Environment, Vol.3, No.2, 2012
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Aeroflot 65 20 (1 drop)
3.1.2. Collector type
Xanthates are the most common collectors in
pH 8.4-10.4 flotation of oxide and sulfide lead ores [10].
NaSiO3 500 Comparing isopropyle and amyl xanthates, the
undesirable effect of isopropyl xanthate on lead
H2SO4 750 recovery is apparent. Using the same amount of
Sodium Isopropyl Xanthate (Z11) instead of
Potassium Amyl Xanthate (KAX) decreased lead
3. Results and discussion recovery from 96.03% to 92.83% (Figure 3).
3.1. Flotation Isopropyl potassium xanthate is a long chain
Different experiments were performed to collector wile potassium amyl xanthate is a short
determine the optimum amount of parameters. one. The longer the collector chain, the lesser is
Effect of each change of parameter on recovery in the needed collector concentration for its salt
rougher stage was surveyed as follows. precipitation. Along the same lines, the longer the
collector chain, the more hydrophobic is the
3.1.1. Effect of cumulative and sequential mineral surface [9]. With 200g/t collector
flotation concentration, it is predictable that longer chain
To investigate the effect of sequential flotation, collector has better effect on making surface more
lead sulfide minerals were floated first and then, hydrophobic.
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89.1 90
89 87.5
88.9
88.8 85
88.7
88.6 82.5
88.5
88.4 80
200 gr/ton 300 gr/ton 3000gr/ton 2000gr/ton 1500gr/ton
Figure 4. Effect of collector dosage on lead Figure 5. Effect of Sodium Sulfur dosage on lead
recovery. recovery
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The effect of adding collector and sulfidizing depression is due to the production of plombit in
agent in stages was studied. Collector and sodium place of lead xanthate on the galena surface [9].
sulfide were added to the pulp in five stages. Also at high pH, iron hydroxide which is probably
Despite what was expected, the results were not entered from steel mill or the pyrite content of the
desirable compared to the base experiment; the ore, to the pulp, will produce the hydrophilic
recovery of staged experiments decreased to metallic oxi-hydroxi and convert the surface to a
77.76% (Figure 6). Since this process was a hydrophilic surface, and floatability will decrease
complex and time-consuming one, it was not [1]. By adjusting pH at 8.5-9 criteria, lead
considered in the following experiments. recovery in concentrate will increase from 88.99
in the base test to 91.28% (Figure 8).
90
80
Recover(%)
85
Recovery(%)
75
80
70
75
65
70
60
Basic Staging
750gr/ton 500gr/ton
Figure 6. Effect of multi stage addition of chemical
on lead recovery. Figure 7. Effect of Sodium Silicate dosage on lead
recovery.
3.1.7. Effect of sodium silicate
Fine particle production during grinding process 3.1.9. Simultaneous effect of low pH and
increases the specific surface of particles and sodium silicate
chemical consumption. These particles cover the To study the simultaneous effect of low pH and
particle surface and lead the valuable minerals to sodium silicate, an experiment was performed.
tail. On the other hand, since a great proportion of The results show that the simultaneous increase of
the valuable minerals exists in the form of fines, these two factors decreased the recovery to
fine removal will not be an effective method to be 74.82%. Since each of these two factors increase
applied. As a result, in another experiment the the recovery, selection of one of them is necessary
effect of sodium silicate addition as dispersant of for attaining optimum pH. The interactive effect
fine particles was studied. In flotation of some of these two factors can be studied through the
minerals, the agglomeration of fine particles will design of experiments.
create problems in flotation control and causes a
decrease in recovery and grade of concentrate.
Thus, when the amount of these coarser particles
is high, the sodium silicate is used as dispersant
[9]. 92
Recovery(%)
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was used. Although a stable and deep froth was 3.1.12. Study of process kinetic
produced, the recovery decreased to 72.23%. To study the floating rate of mineral particles at a
Certainly frother type is different in various time unit through flotation process, froth was
conditions. While the combination of low pH and collected in time intervals. The kinetic diagram
sodium silicate was being studied, it was observed was then drawn as cumulative recoveries versus
that MIBC was not effective in this condition. At time intervals. The cumulative recovery had an
the same condition, adding pine oil improved the upward trend. In the first 6 minutes, the rate of
froth condition. increase was low. After 6 minutes a sudden
increase occured in recovery, and it slowed down
3.1.11. Effect of the number of cleaning stages after 12 minutes, and from 18th minutes onwards
In the final stage, increasing the concentrate grade the recovery was approximately constant (Figure
by employing the minimum cleaning stages (with 10). As a result, 18 minutes was a suitable time
no chemical addition) was studied, when the for froth taking.
optimum conditions of rougher flotation was The remarkable increase in recovery after 6
determined. The results of the experiments are minutes could be the result of sulfur consumption
shown in Figure 9. By increasing the number of by the dissolved lead in the cell; usually a part of
cleaning stages, the lead grade in concentrate will lead preticipate as lead sulfide in pulp. By adding
increase. Finally in the fourth stage (three stage of the sulfidation agent, the sulfide ions were
cleaners on the rougher concentrate), it reached to consumed by the dissolved lead particles. These
about 70% (69.42%), that is desirably more than colloidal particles preticipate on cerrusite surface
60% which is the commercial grade. and interact with collector rapidly. As a result, at
the beginning of froth taking process, a
remarkable increase was observed at the flotation
curve. There existed an assumption which was the
conditioning time of sodium silicate causes a
100
delay in the flotation of lead particles. During the
75 experiments with no dispersant, this delay did not
50 occur.
By passing the curve from the obtained data of
25 kinetic experiment, the kinetic factor of the
0 examined material could be calculated. The
1 stage 2 stage 3 stage 4 stage equation introducing the curve
Grade 12.4 39.39 57.33 69.42
is: y 94.06 1 e
0.206 t
. As a result, the rate
Recovery 94.07 72.97 75 40.03 constant of equation for the Changarzeh lead
sample was estimated k=0.206 min.-1, and
Figure 9. Effect of cleaning stages on lead grade and recovery at the practical infinity was equal to
recovery. 94.06% (Figure 11).
Figure 10. The flotation time versus cumulative lead recovery in kinetic experiment.
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100
80
60
40
20
0
Exp.1 Exp.4
Concentrate 81.06 61.55
Middling 9.92 2.62
Tailing 9.01 35.83
Figure 12. Table slope decrease, and water of feed and table water increase versus lead recovery.
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50
40
30
20
10
0
Exp.1 Exp.4
Concentrate 46.8 31.7
Middling 2.18 4.69
Tailing 1.28 4.94
Figure 13. Table slope decrease, and water of feed and table water increase versus lead grade.
30
20
10
0
Exp.2 Exp.3
Concentrate 8.29 25.9
Middling 2.88 3.12
Tailing 2.37 2.86
Figure 14. Table slope decrease and table water increase on lead grade (coarse particles).
80
60
40
20
0
Exp.2 Exp.3
Concentrate 63.67 54.17
Middling 10.16 5.31
Tailing 26.17 40.52
Figure 15. Table slope decrease and table water increase on lead recovery.
3.2.2. Study of cleaning stages particles. The best concentrate grade was 37.33%
To study the effect of cleaning on rougher which came in the fraction of -2360, water flow of
concentrate obtained from shaking table, the 4 lit/min. and the frequency of 269rpm
second experiment (fine fraction) and the third accompanied balls. This grade was not an
experiment concentrate (coarse fraction) were acceptable grade for jig. Also according to the low
tested. The fine concentrate of the second grade and the fine lead particles existing in feed
experiment underwent a cleaning stage by a table and its loss in jig tail, jig was not recommended
slope of 12%, water of feed of 9 lit/min. and table for pre-concentration production.
water of 10 lit/min. for attaining a higher grade.
Cleaning the coarse concentrate by a table slope
of 12%, water of feed of 10 lit/min. and table 50
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Atrafi et al./ Journal of Mining & Environment, Vol.3, No.2, 2012
- Among frothers, pine oil, MIBC, Aerofloat, [9]. Rezaei, B., (1995). Flotation. in Farsi
(Persianlanguage), University of Hormozgan.
MIBC had the most compatibility with the
optimum test condition. [10]. Seke, M.D., (2005). Optimisation of the selective
flotation of galena and sphalerite at Rosh Pinah
- Adding chemicals in stages for preventing Mine. Ph.D. thesis, University of Pretoria.
sudden increase in pH and galena depression did
not have a remarkable effect on increasing [11]. Weiss, N.L., (1985). SME Mineral Processing
Handbook. Society of Mining Engineers, AIME,
recovery.
New York, Vol. 2.
87