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Minerals liberation management of lead-zinc flotation ore

Conference Paper · January 2013

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Irena Grigorova Ivan Nishkov

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 Proc. of XXIII World Mining Congress, Montreal, Canada, 2013

MINERALS LIBERATION MANAGEMENT OF LEAD-ZINC

FLOTATION ORE

N. Valkanov
Minstroy Holding AD, Bulgaria

I. Grigorova, I. Nishkov*
University of Mining and Geology “St.Ivan Rilski”
Department of Mineral Processing and Recycling
1700 Sofia, Bulgaria
(*Corresponding author: [email protected])

R. Bodurova and M. Damianov

Gorubso-Zlatograd AD, Bulgaria
 Proc. of XXIII World Mining Congress, Montreal, Canada, 2013

ABSTRACT

The paper presents investigation results about the connection between the minerals liberation
management and flotation, responding to lead-zinc concentrator “Erma reka”, Bulgaria. Monitoring of
zinc flotation circuit was carried out. The causes for the high silica content in the final zinc concentrate
were established. It has been found that the quartz is present mainly as liberated particles (>60-80%) in
the fine fractions of the studied products. Regarding the liberated quartz, the selectivity of the flotation
process is not effective. Two approaches were tested to reduce the quartz content of zinc concentrate –
froth washing in zinc cleaner flotation and new gangue depressants in zinc circuit. The experimental
results from bench-scale flotation and industrial tests show that there is possibility to reduce the silica
content of final zinc concentrate more than 2 times without the need for extensive regrinding. The
depression of liberated quartz particles on all operations of zinc circuit using stage depressant addition
is the right solution to produce high-grade zinc concentrate corresponding to the requirements of
metallurgy.

KEYWORDS : Zinc flotation, Liberation, Depressant, Quartz

INTRODUCTION

In the recovery of mineral concentrates from complex sulfide ores by froth

flotation, the ores typically are subjected to a number of operations in interconnected
flotation circuits often including crushing, grinding, and regrinding of intermediate
flotation products. These operations ultimately result in separation of the gangue in
tailing fractions and the formation of concentrates predominant in the desired mineral,
such as lead and zinc sulfides. Regarding to flotation plan practice, metal recovery and
selectivity among the minerals is a strong function of mineral particle size and the
degree of particle liberation in flotation feed. Degree of liberation among valuable
minerals and gangue strongly affect on flotation results.

The flotation circuit typically includes one or more rougher, cleaner, re-cleaner
and scavenger flotation stages with conditioning of the feed thereto by reagents,
selected to effect separations between desired mineral species and undesired gangue.
These reagents comprise collectors, depressants, activators, frothers. The depressants
include a depressant for gangue material, which contains, for example, quartz, lead or
iron silicates or the alike minerals. The gangue depressant is added to feed slurry at
one or more points in the flotation circuit separate from, or along with other reagents.
The amount of depressant employed is dependent on the amount of gangue in the feed
 Proc. of XXIII World Mining Congress, Montreal, Canada, 2013

to the flotation circuit, and to some extent also on the amount of zinc sulfide in the feed.
This gangue, if not removed, would interfere severely with subsequent processing of
the zinc sulfide concentrate, such as in the roasting or electrowinning. Consequently,
the level of the gangue as measured by silica content in the concentrate should be
limited to below about 3 % by weight of the dried solids, with higher levels of gangue
rendering the concentrate unsuitable for efficient recovery of zinc. A quartz problem
exists in thr Erma reka concentrator, Gorubso Zlatograd JSC. The lead-zinc ores are
dressed in Erma reka concentrator. These ores are characterized with variable and
complex mineral and physical composition. Due to this fact, a collective-selective
flotation circuit was established. Two-stage selective flotation is used, where the zinc
and iron minerals are depressed, allowing the galena to float, followed by the activation
of the zinc minerals in the lead tailings to allow a zinc float. The lead circuit includes 2
rougher, scavenger, re-scavenger and 4 cleaner stages. The zinc flotation circuit is
shown in Figure 1. After flotation of galena, the tailings are treated with copper
sulphate, which reactivates the surface of zinc minerals, allowing them to float. Lime is
used to depress pyrite, as has no depressing effect on the activated zinc minerals, and
high pH (10-12) is used in circuit. As, silica depressant water glass is used. The zinc
circuit includes Zn-Py rougher, Zn-Py scavenger and two re-scavenger, Zn-Py cleaner,
Zn rougher, Zn scavenger and re-scavenger, Zn-cleaner and 3 Zn re-cleaner stages.
Finally, the concentrator produces lead and zinc sulfide concentrates. The silica content
in the zinc concentrate is above 3 % and this high level causes a lot of problems in
roasting and electrowinning.
 Proc. of XXIII World Mining Congress, Montreal, Canada, 2013

Figure 1 – Zinc flotation circuit of Erma reka concentrator

The purpose of this research work is to decrease the silica content in zinc
concentrate without the need for extensive regrinding of the rougher concentrate.

METHODS AND MATERIALS

A number of samplings in the zinc flotation circuit were performed. Sampling

and performance evaluation was applied to three points: cleaner zinc-pyrite
 Proc. of XXIII World Mining Congress, Montreal, Canada, 2013

concentrate, final zinc concentrate and pyrite concentrate (Nishkov et al., 2009). The
samples were collected from each stream every 30 minutes and were combined in a
shift every time. Particle size distribution, content of Zn and SiO2 and quartz
distribution were determined.

Particle size distribution of samples was determined by micro-precision wet

sieving (160 µm and 71 µm) using vibratory sieve shaker Analysete 3, FRITSCH. The
content of Zn was determined by XRF analysis and the content of SiO2 was determined
by AES-ICP. The quartz total, quartz liberated and quartz non liberated distributions
were determined using microscope POLAM-P311.

Froth washing tests were conducted to reduce the silica content in final zinc
concentrate. A potential benefit of froth washing in zinc cleaner stage was studied. The
wash water was added as a light rain, and not a jet (Kaya & Laplante, 1988, 1990). For
all of the tests conducted, wash water rates were only 7 to 12% of the feed water. The
wash boxes were located on racks, just behind the froth overflow lip of each cell. These
wash boxes covered most of the length of the cell lip and provided a steady “rain” of
clarified water to the cells. This arrangement allowed the froth to be rinsed just before
its discharge from the cell. The wash water was distributed across the entire cell and
should be at least added to the cell lip adjacent to the overflow weir.

The effect of chemical reagent addition on minimizing silica contamination in

zinc circuit is investigated using different type depressants. Sodium polyacrylate in
aqueous solution, trade name HYDROPALAT 5040 kindly supplied by COGNIS and
modified polyacrylamide, trade name AERO 7261A; mixture of carbohydrate polymer
and dye, trade name AERO 633 and modified polyacrylamide, trade name AERO
8860GL GCA, kindly supplied by CYTEC respectively, were chosen for this study.
Laboratory and industrial tests using the Erma reka laboratory experimental and
concentrator facilities were conducted.

RESULTS AND DISCUSSION

The data from chemical, particle size distribution and mineralogical analyses of
the studied products are shown in Table 1. The analyses clearly demonstrate the
processes in zinc flotation circuit. The first two stages in zinc circuit – Zn-Py rougher
and Zn-Py cleaner flotation definitely are effective regarding quartz depressing. The
 Proc. of XXIII World Mining Congress, Montreal, Canada, 2013

silica content in cleaner Zn-Py concentrate is 7.40 % (Nishkov et al., 2009). After the
first two stages the silica quantity is decrease more than 7.5 times. The next five stages
of zinc flotation – Zn rougher, Zn cleaner and primary, secondary and tertiary Zn re-
cleaner are not effective regarding gangue separation.
This is marketed in the coarse and middling fractions. The silica content values
in “+0.16 mm” and “-0.16+0.071 mm” fractions in zinc – pyrite concentrate and final
zinc concentrate are practically equal. Regarding the fine fraction “-0.071 mm” the
cleaner stage is relatively effective. The silica content decreases almost 2.5 times. The
data for pyrite concentrate confirm the inefficiency of the process. The silica content in
final zinc concentrate is bigger than in the pyrite concentrate. The results of
mineralogical analyses - quartz distribution (liberated and non-liberated) confirm the
data of chemical analyses. The calculated ratio (R) of liberated quartz (LQ) to non-
liberated quartz (NLQ) demonstrates that the distribution of liberated quartz and
locked quartz in intergrowths in the cleaner zinc – pyrite concentrate, final zinc and
pyrite concentrates is almost equal. Regarding the liberated quartz, the separation
process is not effective. The liberated quartz in final zinc concentrate is 45.2 per cent
from the total quartz. The quartz liberated particles in the fine fraction “-0.071 mm”
are 60-80 % of the studied products. This quantity will be separated in the tailings
under suitable conditions in zinc flotation circuit.

Table 1 – Particle size distribution, chemical and mineralogical analyses

Particle size Yield SiO2 Zn Quartz Quartz Quartz R = LQ/NLQ
fraction, (wt %) (wt %) (wt %) Total, Liberated, Non
mm % % Liberated,
%
Cleaner zinc – pyrite concentrate
+0.16 26.79 10.5 25.12 10 25 75 0.33
-0.16+0.071 31.97 6.89 28.39 7 25 75 0.33
-0.071 41.24 5.79 36.80 5-6 80-82 18-20 4.0-4.5
Total 100 7.40 30.98 7.2 48.1 51.9 0.93
Final zinc concentrate
+0.16 21.30 10.32 43.39 8 20-25 75-80 0.25-0.33
-0.16+0.071 30.93 6.69 49.83 4-5 40 60 0.66
-0.071 47.77 2.38 55.68 2 60 40 1.5
Total 100 5.62 51.25 4.2 45.2 54.2 0.83
Pyrite concentrate
+0.16 42.85 5.39 0.84 5 42 58 0.72
-0.16+0.071 36.28 2.98 0.37 2-3 50-54 46-50 1.0-1.17
 Proc. of XXIII World Mining Congress, Montreal, Canada, 2013

-0.071 20.87 4.27 0.43 4 79-80 20-21 3.76-4.0

Total 100 4.80 0.58 3.9 53.5 46.5 1.15

Two different approaches were used to minimize silica contamination in zinc

concentrate without the need for extensive regrinding of the rougher concentrate:
froth washing in zinc cleaner flotation and new gangue depressants in zinc circuit.

The wash water system was tested in zinc cleaner stage. Adding wash water
above the froth decreases gangue entrainment at higher water recovery and also
increases the chance of water short-circuiting to the concentrate. It was established
that the height of the wash water addition above the froth should be minimized to
increase froth stability. The results illustrate the effectiveness of froth washing method.
The silica content of final zinc concentrate was reduced to 2.8 %. It appears that the
froth washing decreases gangue entrainment, especially the liberated quartz particles.

Bench-scale flotation tests using the Erma reka laboratory experimental

facilities were conducted. The re-cleaner flotation experiments with fresh samples of
zinc cleaner concentrate were performed. The depressant dose was 30 g/t. The
experimental results from laboratory flotation tests are presented in Table 2.

Table 2 - Silica content in final zinc concentrate

Depressant SiO2,
(wt %)
HYDROPALAT 5040 2.24
AERO 633 2.03
AERO 8860GL GCA 2.30
AERO 7261 A 4.95

The data illustrate the effect of addition of selected depressants. The silica
content decreases more than 2.5 times. These results indicate that the used reagents
are powerful depressants and suggest that the liberated quartz particles are depressed.
It appears that the powerful depressant can be an approach to minimizing silica
contamination in final zinc concentrate without the need for extensive regrinding of the
rougher concentrate.
 Proc. of XXIII World Mining Congress, Montreal, Canada, 2013

The industrial tests in Erma reka concentrator were conducted. The effect of
stage depressant addition using two reagents on minimizing silica contamination in
zinc circuit is investigated. The conditions of Test 1 and Test 2 (depressant addition
points and depressant type) are presented in Table 3. The total depressant dosage rate
was 40 g/t.

Table 3 - Addition points and type of depressant

Depressant addition Depressant type
points Test 1 Test 2
Zn-Py Cleaner Hydropalat 5040 Hydropalat
5040
Zn Rougher Hydropalat 5040 Aero 633
Zn Cleaner Hydropalat 5040 Hydropalat
5040
Zn Recleaner Hydropalat 5040 Hydropalat
5040
Third Zn Recleaner Hydropalat 5040 Aero 633

Sampling and performance evaluation was applied to five points: rougher zinc-
pyrite concentrate; cleaner zinc-pyrite concentrate; cleaner zinc concentrate; final zinc
concentrate and pyrite concentrate. The following characteristics of the sampling
products were determined: - content of Zn, Fe and SiO2 and quartz distribution.

Figure 2 shows the results from Test 1. The data illustrate the effect of
HYDROPALAT 5040 addition on zinc, iron and silica content of zinc circuit products.
The stage reagent addition leads to decreasing of silica content more than 4.5 times –
from 10.75 % in rougher Zn-Py concentrate to 2.3 % in final Zn concentrate. In the
same time the zinc content increases from 27.14 % to 55.25 %.
 Proc. of XXIII World Mining Congress, Montreal, Canada, 2013

Figure 2 – Effect of Hydropalat 5040 addition on Zn, Fe and SiO2 content of zinc
flotation circuit products: 1 - Rougher Zn-Py concentrate; 2 - Cleaner Zn- Py
concentrate; 3 - Cleaner Zn concentrate; 4 - Final Zn concentrate; 5 - Py concentrate

Figure 3 shows the results from Test 2. The data demonstrate the strong effect
of HYDROPALAT 5040 and AERO 633 addition on zinc, iron and silica content of zinc
circuit products. The stage addition of both reagents decreases the silica content
considerably (8.5 times) - from 11.1 % in rougher Zn-Py concentrate to 1.3 % in final
Zn concentrate. The zinc content of final Zn concentrate reaches to 56.3%.
 Proc. of XXIII World Mining Congress, Montreal, Canada, 2013

Figure 3 – Effect of Hydropalat 5040 and Aero 633 addition on Zn, Fe and SiO2 content
of zinc flotation circuit products: 1 - Rougher Zn-Py concentrate; 2 - Cleaner Zn- Py
concentrate; 3 - Cleaner Zn concentrate; 4 - Final Zn concentrate; 5 - Py concentrate

Tables 4 presents the quartz distribution as liberated particles and locked as

intergrowths in the products of zinc flotation cycle without depressant and after one or
two depressants addition, respectively. The data clearly demonstrate the strong effect
of depressants on liberated quartz particles.

Table 4 - Quartz distribution as liberated particles and locked as intergrowths

Without depressant Hydropalat 5040 addition Hydropalat 5040 & Aero 633
Product addition
Quartz Quartz Quartz Quartz Quartz Quartz Quartz Quartz Quartz
Total, Liberated, Non Total, Liberated, Non Total, Liberated, Non
% % Liberated, % % Liberated, % % Liberated,
% % %
Rougher Zn- 10.0 49 51 9.8 49 51 10.1 49 51
Py
concentrate
Cleaner Zn-Py 7.2 48 53 7.3 46 54 7.5 46 54
concentrate
Cleaner Zn 6.1 46 52 3.6 34 66 3.2 30 70
concentrate
Final Zn 4.2 45.2 54.2 2.2 16 84 1.2 11 89
concentrate

The ratio (R) of liberated quartz (LQ) to non-liberated quartz (NLQ) of zinc
flotation circuit products is presented in Figure 4.
 Proc. of XXIII World Mining Congress, Montreal, Canada, 2013

Figure 4 - Calculated ratio of liberated quartz (LQ) to non liberated quartz (NLQ)
versus zinc flotation circuit products: 1 - Rougher Zn-Py concentrate; 2 - Cleaner Zn-Py
concentrate; 3 - Cleaner Zn concentrate; 4 - Final Zn concentrate

The ratio (R) of liberated quartz (LQ) to non-liberated quartz (NLQ) decreases 8
times - from 0.96 in rougher Zn-Py concentrate to 0.12 in final Zn concentrate. The
combination of two depressants is more effective than one depressant addition. One
year industrial experience has shown the way of minimizing the silica contamination in
final zinc concentrate without the need for extensive regrinding of the rougher
concentrate. The depression of liberated quartz particles on all operations of zinc
flotation circuit using stage depressants addition is the right solution to produce high-
grade zinc concentrate and to be up to the requirements of metallurgy.

CONCLUSIONS

The causes for the high silica content in the final zinc concentrate of Erma reka
lead-zinc concentrator were established. The process of gangue separation in zinc
cleaner stages is not effective. It was found that the quartz is present mainly as
liberated particles (>60-80 per cent) in the fine fractions of the studied products.
Regarding the liberated quartz, the selectivity of the process is not effective.

The laboratory and industrial tests have demonstrated that there are
possibilities to minimize the silica content up to 1.5 – 2.0 per cent in final zinc
 Proc. of XXIII World Mining Congress, Montreal, Canada, 2013

concentrate without the need for extensive regrinding. The depression of liberated
quartz particles on all operations of zinc circuit using stage addition of HYDROPALAT
5040 and AERO 633 is the right solution to produce high-grade zinc concentrate
corresponding to the requirements of metallurgy.

ACKNOWLEDGEMENTS

Financial support for this studies and permission to publish this paper from
GORUBSO ZLATOGRAD JSC is gratefully acknowledged.

REFERENCES

Kaya, M., Laplante, A. (1988). Evaluation of the potential of wash water addition and froth vibration on
gangue entrainment in mechanical flotation cells. In Y. Aytekin (Ed). Second International
Mineral Processing Symposium, (pp. 175-184). Izmir, Turkey.
Kaya, M., Laplante, A. (1990). Froth washing and froth vibration in mechanical flotation machines, SME
Annual Meeting and Exhibit, (p. 11), Preprint No. 90-30, Salt Lake City, USA.
Nishkov, I., Grigorova, I., Valkanov, N., Bodurova, R., & Damianov, M. (2009). On the possibility of
reducing the silica content of zinc sulphide concentrates. In S. Krausz (Ed.), Thirteen Balkan
Mineral Processing Congress, (pp. 234-239). Romania, Focus: Petrosani.

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