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Flotation machines in brazil - columns versus mechanical cells

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Flotation Machines in Brazil — Columns Versus Mechanical Cells
A C Araújo1, P R M Viana2 and A E C Peres3
ABSTRACT
The role of flotation columns in comparison with conventional
mechanical flotation cells is discussed under the scenario of Brazilian
flotation technology. All iron ore concentrator circuits commissioned
since 1990 incorporated column only flotation technology in rougher,
cleaner, scavenger configuration. Columns were also added to existing
circuits, especially at the cleaner stage. Columns were also incorporated
to phosphate ore flotation circuits operating mechanical cells. In two
phosphate concentrators, columns substituted for all mechanical cells.
Columns perform the cleaning stage in a large sulfide copper
concentrator, following rougher flotation in tank cells. Scavenger of the
cleaner tailings is performed in tank cells at this plant. Other ores that are
concentrated in flotation columns include graphite, talc, lead-zinc sulfide,
and a zinc hydrometallurgical residue for silver recovery.
INTRODUCTION
The first pilot plant scale application of column flotation in
Brazil was performed at the Centre for Development of Nuclear
Technology, aiming at concentrating a phosphoro-uraniferous ore
(Furtado and Peres, 1988). The flotation of this ore in
conventional pilot scale mechanical cells required desliming in
hydrocyclones, the fraction -10 µm being discarded, with P2O5
and U3O8 distributions in the rejected fraction of 10.5 per cent
and 14.0 per cent, respectively. Among other prospective
methods, a flotation column was selected for testwork aiming at
improving the overall process recovery. The key to the success
was a second desliming stage of the slimes from the mechanical
cells circuit, performed in 20 mm ceramic hydrocyclones. The
-2.5 µm fraction was discarded and the -10 µm + 2.5 µm fraction
was the feed to the column. At about the same period, 1986 -
1989, SAMARCO’s iron ore concentrator initiated an intensive
test program with a homemade 1.2 m diameter (48”) column
aiming at a possible column flotation utilisation in an expansion
project (Viana et al, 1991).
The first industrial utilisation of flotation columns in Brazil
took place in a small plant producing gold bearing chalcopyrite
concentrates (Reis Jr and Peres, 1991). Homemade columns
substituted for mechanical cells in rougher-double cleaner
configuration, followed by a scavenger stage in mechanical cells.
Nowadays, column flotation treats 75 million tonnes per year
in terms of flotation feed, only in the iron ore and phosphate
flotation plants. Flotation columns play a prominent role in the
scenario of Brazilian flotation machines. All new iron ore
concentration circuits commissioned since the 1990s consist of
rougher-cleaner-scavenger columns only configuration. Columns
are also utilised in conjunction with mechanical cells in a large
circuit that performs the cleaning stage of rougher concentrates
produced in Jones wet high intensity magnetic separators. The
final concentrate is sized in Derrick screens for further cleaning,
yielding concentrates under 0.8 per cent SiO2.The scavenger
1. Department of Mining Engineering, UFMG, Rua Espirito Santo,
35/702, 30160-030 Belo Horizonte MG, Brazil.
Email: armando@deminufmg.br
2. Department of Mining Engineering, UFMG, Rua Espirito Santo,
35/702, 30160-030 Belo Horizonte MG, Brazil.
Email: pviana@demin.ufmg.br
3. Department of Metallurgical and Materials Engineering, UFMG, Rua
Espirito Santo, 35/206, 30160-030 Belo Horizonte MG, Brazil.
Email: aecperes@demet.ufmg.br
Centenary of Flotation Symposium Brisbane, QLD, 6 - 9 June 2005
HOME
stage is performed in mechanical cells. In another concentrator,
pellet feed produced in mechanical cells is reground to reach the
size distribution required for pipeline transportation and later
pelletising. Quartz particles liberated in this regrinding stage are
floated in a rougher-scavenger columns circuit. In the same
concentrator hematite particles, present in the slimes fraction
previously discarded in the desliming stage preparing the feed
for the mechanical cells circuit, are recovered in columns.
The most outstanding example of columns substituting for
mechanical cells came from the phosphate ore concentration
industry. At an important concentrator, 64 mechanical cells were
replaced by six columns, operating in rougher only
configuration, except for the coarse apatite tailings fraction that
is reground for further liberation prior to a second flotation stage.
Column flotation technology is utilised in other phosphate ore
concentrators, and also in the concentration of graphite, sulfide
lead-zinc ore, talc, and a zinc hydrometallurgical residue.
A large sulfide copper ore concentrator, commissioned in
2004, utilises large size tank cells (20 cells of 160 m3) in the
rougher and scavenger of the cleaner tailings stages and columns
(six cells 4.27 m in diameter and 14 m in height) in the cleaner
stage.
AN OVERVIEW OF FLOTATION PRACTICE IN
BRAZIL
Table 1 presents a summary of the major flotation plants
currently in operation in Brazil. Iron ore and phosphate rock
dominate flotation applications both in terms of tonnage
processed as well as in terms of the number of plants in operation
(also see Figure 1).
Zinc/Lead
5%
Niobium
5%
Other
Coal
5%
17%
Copper
5%
Gold Iron Ore
25%
8%
Graphite
8% Fluorite Phosphate
8% 14%
FIG 1 - Distribution of number of flotation plants (per cent).
Another important feature regarding flotation practice in Brazil
is related to the introduction, firstly of column flotation which
commenced in the late 1980s and, recently, a new trend towards
the use of large mechanical cells (tank type) which are now being
introduced in Brazilian flotation plants. Although not shown on
Table 1, there are examples of projects in the final design phase
and of recent deliveries of large volume tank cells for existing
plants. Flotation columns are also being considered for new
projects as well as for novel applications. Coal preparation plants
are likely to be the next mineral resource where columns will be
applied in combination with mechanical cells.
187
 A C ARAÚJO, P R M VIANA and A E C PERES
188
TABLE 1
Summary of flotation plants currently in operation in Brazil.

Mineral Operator Plant/Mine Mechanical cells Column cells Column replaced Collector Modifier pH Flotation feed (tph)
mechanical cells
Phosphate Bunge Cajati Yes Yes No Na sarcosinate Starch Alkaline 1000
Bunge Araxá No Yes Yes Soy bean oil Starch Alkaline 1500
Fosfertil Tapira No Yes Yes Soy bean oil Starch Alkaline 1500
Fosfertil Catalão Yes Yes No Soy bean oil Starch Alkaline 1000
Copebras Catalão Yes No No Soy bean oil Starch Alkaline 800
Graphite Nacional de Grafite Itapecerica Yes No No Pine oil (frother) Na silicate Natural 50
Nacional de Grafite Pedra Azul No Yes No Natural 50
Nacional de Grafite Salto da Divisa No Yes No Natural 50
Zinc Votorantin Metais Vazante Yes Yes No Amine xanthate† Na sulfide Alkaline 80
Votorantin Metais Paracatu Yes No No Na carbonate Alkaline 120
Nickel Votorantin Metais Fortaleza de Minas Yes No No Xanthate CMC Natural 100
Copper Caraíba Min. SA Jaguarari Yes No No Xanthate Lime Natural 200
Min. Serra do Sossego Pará Yes Yes No Xanthate Natural 4000
Brisbane, QLD, 6 - 9 June 2005

Iron MBR Vargem Grande No Yes No Amine Starch Alkaline 500

MBR Pico No Yes No Amine Starch Alkaline 700
CSN Casa de Pedra No Yes No Amine Starch Alkaline 800
CVRD Timbopeba Yes No No Amine Starch Alkaline
Timbopeba/ Capanema Yes Yes No Amine Starch Alkaline 600
Alegria Yes Yes No Amine Starch Alkaline 800
Cauê Yes No No Amine Starch Alkaline 1600
Conceição Yes Yes No Amine Starch Alkaline 1800
SAMARCO Germano Yes Yes No Amine Starch Alkaline 3200
Gold Anglo Gold Raposos Yes No No Xanthate Cu sulfate Natural 200
Eldorado Santa Bárbara Yes Yes No Xanthate Natural 200
RPM Paracatu (flash flotation) Yes No No Xanthate Lime Alkaline 1000
Niobium CBMM Araxá Yes Yes No Amine Starch Acid 200
Min. Catalão Catalão Yes No No Amine Starch Acid 50
Fluorite Min. D’El Rey Cerro Azul Yes No No Tall oil Na Silicate Alkaline 100
Min Santa Catarina Morra da Fumaça Yes No No Tall oil Starch Alkaline 120
Min Sartor Itaboraí Yes No No Tall oil 50
Centenary of Flotation Symposium

Feldspar Feldspar Min Ltda Curitiba No Yes No Amine Acid 25

Coal Rio Deserto Siderópolis Yes No No Fuel oil Natural 10
Carboníferra Criciúma Criciúma Yes No No Fuel oil Natural 150
Silver Votorantim Metais Juiz de Fora No Yes Yes Xanthate Acid 20
Magnesite Magnesita SA Brumado Yes No No Amine salt Alkaline 50
Talc Magnesita SA Brumado No Yes No Frother only Natural 5
Potash CVRD Taquari Yes No No Amine Starch Natural 250

† Xanthate: generic term for thio collectors.

Sources: Luz and Almeida, 1989; Luz and Almeida, 2001; Araujo and Viana, 2003; Araujo and Viana, 2001; Chaves, 2002.
 FLOTATION MACHINES IN BRAZIL — COLUMNS VERSUS MECHANICAL CELLS

IRON ORES
Contrary to the vast majority of flotation utilisation worldwide,
iron ores and not copper ores constitute the dominant application
of flotation in Brazil in terms of flotation feed. Over 70 million
tonnes per year are processed by flotation with the production of
approximately 48 million tonnes of concentrates for pellet
production (pellet feed). Table 2 summarises current applications
of flotation in iron ore processing in Brazil. Also shown on the
table are the generic type of equipment used in each case and
approximate dates of the commissioning of the plants. In many
cases there is more than one plant operating at a given mine,
treating different ore lithologies.
of the ores after two to three stages of crushing. Natural size
distribution of Brazilian iron ores normally shows a very clear
peak of concentration of silica bearing minerals (quartz) at the
top size range of the flotation feed (above 75 µm or 200# Tyler).
The uneven distribution of silica presents a challenge to flotation
operations, recoveries at coarser and finer sizes are generally
worse than at the intermediate size range. In at least one plant,
Derrick screens are used as a final upgrading of the flotation
concentrates, removing coarser impurities (above 0.15 mm).
Figure 2 shows the growth of iron ore flotation in Brazil since
the first plant was commissioned in 1977 (SAMARCO’s
Germano Concentrator). It also predicts the growth trend until
2010.

TABLE 2 120

Million tonnes per year (flotation feed)

Iron ore flotation plants in Brazil.
100
Operator Mine/Plant Circuit type Initial
commissioning
MBR Pico Column only 1994 80
Vargem Grande Column only 2001
SAMARCO Germano Combined 1977 60
CSN Casa de Pedra Column only 1991
40
CVRD Cauê Mechanical only 1986
Conceição Combined 1988 (columns
in 1994) 20
Timbopeba Mechanical only 1988
Timbopeba- Combined 1992 (columns 0 1975

1977

1988

1990

1991

1994

1996

2000

2004

Capanema in 1997)
Alegria (IB 2) Combined 1993
Alegria (IB 3) Column only 1995
Some general considerations should be put forward before
discussing flotation equipment type and iron ore flotation
practices in Brazil. Different approaches are used in each case
with the use of flotation alone as the sole concentration method
in some instances as well as the combination of high intensity
magnetic concentration and flotation in some plants. Generally,
very high-grade products are required, especially for the
production of direct reduction quality pellets that require very
low level of contaminants.
The single largest flotation concentrator is fed at a rate of
approximately 3200 tonnes per hour. Currently only conventional
WEMCO 14 m3 (600 ft3) cells are used. In the near future, they
will be used in combination with Outokumpu 160 m3 tank cells.
A four-line configuration is employed to perform rougher-
cleaner-scavenger duties before regrinding of the concentrate.
The reground concentrate is further processed by column cells in
a two-stage circuit. Final concentrates, with silica grade as low as
0.8 per cent, are obtained from itabiritic ores with over 30 per
cent silica in the feed. As in all flotation applications for iron ore
beneficiation in Brazil, flotation is performed in a reverse
cationic flotation mode. In the same concentrator, slimes are
treated in a separate flotation circuit, in this instance employing
columns only. The slimes are reclassified in small diameter
hydrocyclones ahead of the column circuit. Additional recovery
from the slime circuit increased overall plant recovery by
approximately two per cent in weight.
The concentrator of Germano is unique amongst the iron ore
flotation plants in Brazil because it is only at this concentrator
that grinding operations are used. All other flotation plants are
inside beneficiation circuits in which products with coarser size
distribution are also obtained (lumps and sinter feed, for
instance). Therefore, in these other applications, flotation is
utilised to treat feed that represents the natural size distribution
2010
Year
FIG 2 - Evolution of iron ore flotation in Brazil (2004 onwards is a
trend based on expansion projects already under consideration).
An analysis of Figure 2 clearly shows that the 1990s
represented a period of accelerated growth in flotation
application to Brazilian iron ores. This trend subsided at the
beginning of the 21st century but is expected to experience
another steep growth rate in the next six years.
PHOSPHATE ORES
At the beginning of Bunge’s concentrator operation, only the
coarse fraction of the ore (+44 µm or +325# Tyler) was utilised,
causing significant phosphate losses in the slimes fraction
(natural slimes, produced in the rod mill and slimes from
grinding in the ball mill). These slimes were stored in tailings
ponds from 1977 to 1984. Figure 3 shows the simplified flow
sheet of the concentrator at this stage, including the changes
from the original circuit.
From 1984, the concentration of slimes was performed after
desliming in 40 mm micro-hydrocyclones. Natural slimes (after
grinding in a rod mill) and fines from grinding (produced in a
ball mill) were floated in mechanical cells, as illustrated in
Figure 4. A significant increase of ten per cent phosphorus
recovery was achieved at a phosphate concentrates production
level of 150 kt/year.
From 1992 on, the concentrator attained major changes with
the introduction of flotation columns (CESL, at present CPT),
causing significantly enhanced recovery, reduction in reagents
consumption, resulting in a much simpler flow sheet (Guimarães
and Peres, 2000), illustrated in Figure 5. A supervisory control
system was introduced in 1996. The 40 mm micro-hydrocyclones
were replaced by Mosley 50 mm (2”) hydrocyclones, in 1999.

Centenary of Flotation Symposium Brisbane, QLD, 6 - 9 June 2005 189

A C ARAÚJO, P R M VIANA and A E C PERES

Crushing

Piling and reclaiming

Grinding (rods)

magnetite Low intensity magnetic separation

(tailings pond) ov natural fines
Pre-classification (tailings pond)
ud
Grinding (balls) and classification
ov
Desliming fines from grinding
ud (tailings pond)
barite floated Barite flotation
concentrate (mechanical flotation cells - rougher - scavenger)

(by-product) non floated

Apatite flotation
(mechanical flotaion cells - rougher - 3 cleaners)
floated
non floated
Regrinding (balls) and classification
tailings ov ud
(tailings pond) Desliming
ud
tailings Apatite flotation
(mechanical flotation cells - rougher - 2 cleaners)
(tailings pond)
floated
Filtration

Apatite Concentrate
(coarse)

FIG 3 - Bunge – Araxá concentrator flow sheet (1977 - 1984).

Bunge Cajati operates a flotation circuit consisting of columns
only for the ultrafines and mechanical cells for the coarser sizes,
both in a rougher, cleaner, scavenger configuration. This approach
regarding flotation of phosphates is the most common one, with a
major exception in the Araxá circuit already discussed in detail.
Fosfertil’s concentrator in Catalão operates three circuits, each
one floating a different size range: coarse, fines, and ultrafines.
The coarse apatite circuit consists of four stages, all of them
operating with mechanical cells: barite pre-flotation, rougher,
cleaner, and scavenger. The fines circuit consists of barite
pre-flotation in mechanical cells and rougher apatite column
flotation. The rougher concentrate feeds the coarse apatite
rougher mechanical cell. The ultrafines circuit consists of
rougher and cleaner column flotation stages, and barite
pre-flotation and scavenger stages in mechanical cells.
Fosfertil’s concentrator in Tapira consists of two major
circuits, concentrating two different ore types: grainy (or lumpy)
and friable (Barros and Ferreira, 2004). The friable circuit is
divided in coarse, fine, and ultrafine stages. The grainy ore,
coarse and fine friable ores circuits consist of mechanical cells in
rougher, cleaner, recleaner, and scavenger configurations. The
ultrafine friable circuit consists of rougher and cleaner flotation
columns and mechanical cells scavenger stage. Flotation
columns were utilised in the past in the grainy ore circuit and in
the friable circuit treating fractions other than ultrafines. The
operation of these columns is predicted to resume after the 2005
expansion of the concentrator.
OTHER ORES
A graphite ore concentrator operates a sequence of intercalated
grinding and flotation stages. Originally, flotation was performed
in mechanical cells in all stages. Recently a flotation column
substituted for mechanical cells in the first cleaner stage resulting
in enhanced carbon grade in the concentrate. The same company
operates two other concentrators in circuits consisting of
mechanical cells only.
A mine producing magnesite also yields talc as a by-product.
The magnesite ore is concentrated in mechanical cells, operated
as a single reverse cationic flotation circuit. The talc ore is
purified in a flotation column for the removal of quartz and other
minor impurities.
A large sulfide copper ore concentrator operates a rougher
circuit consisting of two lines with seven tank cells each
(160 m3), producing final tailings. The cleaner circuit consists of
six columns (14 m height; 4.27 m diameter) that produce final
concentrate. The cleaner tailings are submitted to a scavenger
operation in one bench of six tank cells (160 m3) producing final
tailings, the concentrate being combined with the rougher
concentrate.

190 Brisbane, QLD, 6 - 9 June 2005 Centenary of Flotation Symposium

 FLOTATION MACHINES IN BRAZIL — COLUMNS VERSUS MECHANICAL CELLS

Crushing

Piling and reclaiming

Grinding (rods)

magnetite Low intensity magnetite separation

(tailings pond) ov
Desliming
Pre-classification (2 stages)
ud ov
Grinding (balls) and classification tailings pond
Slimes pond
ov ov
Desliming Desliming
(2 stages)
ud
barite floated Barite flotation
Apatite flotation
concentrate (mechanical flotation cells - rougher - scavenger)
(mechanical flotation cells - rougher - 3 cleaners)
(by-product) non floated
Apatite flotation
(mechanical flotation cells - rougher - 3 cleaners) floated
non floated
Regrinding (balls) and classification
tailings ov ud
(tailings pond) Desliming
ud
tailings Apatite flotation
(tailings pond) (mechanical flotation cells - rougher - 2 cleaners)
floated
High intensity magnetic separation

Filtration Filtration

Apatite Concentrate Apatite Concentrate

(coarse) (ultrafine)

FIG 4 - Bunge – Araxá concentrator flow sheet (1984 - 1991).

A lead-zinc sulfides concentrator utilises columns in the CONCLUDING REMARKS

rougher and cleaner circuits and mechanical machines in both
scavenger circuits.
Two oxidised zinc flotation plants are operated with a
combined circuit including both mechanical and column cells.
The two plants treat zinc silicate and carbonate ores on an
alkaline circuit that includes sulfidisation of the zinc bearing
minerals before flotation. Columns were added to these plants
not as replacement but for grade improvement.
Two niobium flotation plants treat pyrochlore using
conventional mechanical flotation circuits. These plants use acidic
circuits to treat by cationic flotation the niobium ores. In one of
the two plants, an early trial with a column cell was not successful.
Three concentrators perform the flotation of gold associated
with sulfide minerals in circuits consisting of conventional
mechanical cells. One operation utilises a flash flotation machine
treating the hydrocyclone underflow in the grinding circuit. Only
one plant utilises column flotation.
A sulfide nickel ore concentrator operates a circuit consisting
of conventional mechanical cells in a standard rougher-cleaner-
scavenger.
With flotation responding for the processing of over 170 million
tonnes of run-of-mine ores per year in Brazil, the current
scenario, in relation to the type of equipment employed, reveals a
return of mechanical cells in newly erected plants and for plants
undergoing revamping or in a design phase. The return of
mechanical cells has not, however, significantly affected the
introduction of column cells that are still being considered as the
best choice for cleaning circuits as well as for column-only
circuits in plants where this selection has been working well in
previous plants.
In the last 15 years, approximately 60 per cent of all plants that
revamped their circuits employed columns, clearly demonstrating
that column flotation since its implementation in the mid 1980s
in Brazil has made an important advance in the minerals
processing sector. In most cases nowadays columns employ
either air-only or water/air spargers. External high efficiency
air/slurry mixers are still being used only on a trial basis, with
successful application in a few plants.
New copper ore plants, that should be in operation in the next
five years, will most likely operate with combined circuits, as is
the one recently commissioned in 2004 by Mineração Serra do

Centenary of Flotation Symposium Brisbane, QLD, 6 - 9 June 2005 191

A C ARAÚJO, P R M VIANA and A E C PERES

Crushing

Piling and reclaiming

Grinding (rods)

magnetite Low intensity magnetic separation

(tailings pond) ov
Desliming
Pre-classification (2 stages)
ud ov
Grinding (balls) and tailings pond
Slimes pond
classification ov ov
Desliming Desliming
(2 stages)
ud
barite floated Barite flotation
Apatite flotation
concentrate (rougher flotation column)
(rougher flotation column)
(by-product) non floated
Apatite flotation
(rougher flotation column) floated
non floated
Regrinding (balls) and classification
tailings ov ud
(tailings pond) Desliming
ud
tailings Apatite flotation
(tailings pond) (rougher flotation column)

High intensity magnetic

Filtration Filtration

Apatite Concentrate Apatite Concentrate

(coarse) (ultrafine)

FIG 5 - Bunge – Araxá concentrator flow sheet (1992 - 2004).

Sossego SA. Some of the new iron ore plants under consideration
are also likely to implement combined circuits. Large volume
tank cells are indeed making an important footprint in the
Brazilian flotation scenario.
ACKNOWLEDGEMENTS
The authors would like to thank CNPq (National Research
Council of Brazil) and several people from different companies for
sharing information and data, namely CPT Brasil, Outokumpu,
Bunge Fertilizantes, Fosfertil, MBR, CVRD, Feldspar Mineração
Ltda, Votorantin Metais and Magnesita. The authors are also
indebted to Professors Jorge Rubio (UFGRS) and Paulo Roberto
Gomes Brandão (UFMG).
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192 Brisbane, QLD, 6 - 9 June 2005 Centenary of Flotation Symposium

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