Flotation is the separation process most used to recover valuable minerals from sulphide ores. The design of industrial flotation plants is a complex process involving many stages. Current design practice involves performing laboratory scale grinding and batch flotation tests, followed by a circuit design based on the scale-up of the laboratory kinetics and recovery-grade data. A pilot plant is then operated to evaluate the performance of the circuit based on recovery and grade, usually in the configuration of the intended full-scale plant. The circuit design is refined and economically evaluated after which the design of the full-scale plant is performed. A new approach to full-scale flotation plant design has been proposed by the Julius Kruttschnitt Mineral Research Centre and the Mineral Processing Research Unit of the University of Cape Town, as part of the Australian Minerals Industries Research Association (AMIRA) P9 Project. In this new methodology, the effects of the ore on plant performance are decoupled from the circuit effects. The ore properties are characterised by operating the pilot plant in as simple a configuration as possible. The pilot plant units are configured to perform a similar duty (in terms of mineral content and particle size) to the full-scale operation and their response measured. An important factor in the success of the methodology is having a pilot plant that is capable of accurately characterising the ore properties. For this purpose, the Wemco® Floatability Characterisation Test Rig (FCTR) was built. The FCTR is a self-contained, highly instrumented mobile pilot plant designed to develop and validate the new flotation plant design methodology. The aims of this thesis were to propose, develop and validate a methodology for using the FCTR to design industrial flotation plants. The hypothesis was that full-scale flotation plant design could be accurately performed using the P9 flotation model and modelling and scale-up methodologies, in conjunction with the FCTR. Test work was performed in three main areas: calibration of the ore characteristics and model parameters for the flotation model currently used by the AMIRA P9 Project; validation of the flotation model and modelling methodology; and prediction of full-scale plant performance using parameters determined on the FCTR. The ore floatability characteristics were calibrated using four FCTR circuits of increasing complexity. The ore floatability characteristics were determined for various models derived from data from one, two, three and four calibration circuits. Validation of the flotation model and modelling methodology was performed using three validation methods: internal validity tests, parameter sensitivity tests and predictive validation. From the internal validity tests, some of the models did not meet the validation criteria. The parameter sensitivity tests used Monte Carlo simulations to determine the sensitivity of the regressed model parameters. The tests produced small differences in the values determined from the models and the average values from the Monte Carlo simulations. The floatability characteristics appeared to be stable and unique. Predictive validation was performed using five FCTR circuits, different in configuration to the calibration circuits. The predictive validation was performed using the floatability characteristics determined from each of the calibration models, in conjunction with estimates of the model parameters. Overall, the predictions of the circuit performance were accurate and within experimental standard deviations for most streams in the circuits. The predictions of the key parameters of pentlandite and chalcopyrite recovery were accurate, especially for the final concentrate. The prediction of pyrrhotite recovery produced the largest errors. The prediction of pyrrhotite recovery appeared to be dependent on the addition of depressant to the cleaner and recleaner circuits of the circuit to be predicted. When the depressant addition rates were significantly different from those used in the calibration circuits, the prediction of pyrrhotite recovery was inaccurate. These errors were however reduced when experimental water recovery values were used. The extensive and robust validation of the flotation model and modelling methodology has shown that the flotation model and modelling methodology are valid under certain conditions. This test work represents the first comprehensive validation of the flotation model and modelling methodology incorporating changes in circuit configuration. Using the proposed modelling and scale-up methodology in conjunction with the FCTR, the metallurgical performance of three industrial flotation circuits were predicted. The predicted results were then compared to the experimentally determined results around the industrial circuits. In each case, a scale-up factor between the ore floatability characteristics determined on the FCTR, and the full-scale floatability characteristics, was required to achieve an accurate prediction. The scale-up factor ranged from 0.17 to 0.97 for the case studies investigated. In light of the results from each stage of test work, the proposed flotation plant design methodology was refined. With this methodology and the continual development of techniques for the measurement and prediction of the P9 flotation model parameters, accurate industrial plant design using the FCTR will become possible. With the addition of other unit operations, such as comminution, into the flowsheet, this methodology will eventually lead to the achievement of the ultimate goal of accurate plant design of green-field sites.

Flotation is the separation process most used to recover valuable minerals from sulphide ores. The design of industrial flotation plants is a complex process involving many stages. Current design practice involves performing laboratory scale grinding and batch flotation tests, followed by a circuit design based on the scale-up of the laboratory kinetics and recovery-grade data. A pilot plant is then operated to evaluate the performance of the circuit based on recovery and grade, usually in the configuration of the intended full-scale plant. The circuit design is refined and economically evaluated after which the design of the full-scale plant is performed. A new approach to full-scale flotation plant design has been proposed by the Julius Kruttschnitt Mineral Research Centre and the Mineral Processing Research Unit of the University of Cape Town, as part of the Australian Minerals Industries Research Association (AMIRA) P9 Project. In this new methodology, the effects of the ore on plant performance are decoupled from the circuit effects. The ore properties are characterised by operating the pilot plant in as simple a configuration as possible. The pilot plant units are configured to perform a similar duty (in terms of mineral content and particle size) to the full-scale operation and their response measured. An important factor in the success of the methodology is having a pilot plant that is capable of accurately characterising the ore properties. For this purpose, the Wemco® Floatability Characterisation Test Rig (FCTR) was built. The FCTR is a self-contained, highly instrumented mobile pilot plant designed to develop and validate the new flotation plant design methodology. The aims of this thesis were to propose, develop and validate a methodology for using the FCTR to design industrial flotation plants. The hypothesis was that full-scale flotation plant design could be accurately performed using the P9 flotation model and modelling and scale-up methodologies, in conjunction with the FCTR. Test work was performed in three main areas: calibration of the ore characteristics and model parameters for the flotation model currently used by the AMIRA P9 Project; validation of the flotation model and modelling methodology; and prediction of full-scale plant performance using parameters determined on the FCTR. The ore floatability characteristics were calibrated using four FCTR circuits of increasing complexity. The ore floatability characteristics were determined for various models derived from data from one, two, three and four calibration circuits. Validation of the flotation model and modelling methodology was performed using three validation methods: internal validity tests, parameter sensitivity tests and predictive validation. From the internal validity tests, some of the models did not meet the validation criteria. The parameter sensitivity tests used Monte Carlo simulations to determine the sensitivity of the regressed model parameters. The tests produced small differences in the values determined from the models and the average values from the Monte Carlo simulations. The floatability characteristics appeared to be stable and unique. Predictive validation was performed using five FCTR circuits, different in configuration to the calibration circuits. The predictive validation was performed using the floatability characteristics determined from each of the calibration models, in conjunction with estimates of the model parameters. Overall, the predictions of the circuit performance were accurate and within experimental standard deviations for most streams in the circuits. The predictions of the key parameters of pentlandite and chalcopyrite recovery were accurate, especially for the final concentrate. The prediction of pyrrhotite recovery produced the largest errors. The prediction of pyrrhotite recovery appeared to be dependent on the addition of depressant to the cleaner and recleaner circuits of the circuit to be predicted. When the depressant addition rates were significantly different from those used in the calibration circuits, the prediction of pyrrhotite recovery was inaccurate. These errors were however reduced when experimental water recovery values were used. The extensive and robust validation of the flotation model and modelling methodology has shown that the flotation model and modelling methodology are valid under certain conditions. This test work represents the first comprehensive validation of the flotation model and modelling methodology incorporating changes in circuit configuration. Using the proposed modelling and scale-up methodology in conjunction with the FCTR, the metallurgical performance of three industrial flotation circuits were predicted. The predicted results were then compared to the experimentally determined results around the industrial circuits. In each case, a scale-up factor between the ore floatability characteristics determined on the FCTR, and the full-scale floatability characteristics, was required to achieve an accurate prediction. The scale-up factor ranged from 0.17 to 0.97 for the case studies investigated. In light of the results from each stage of test work, the proposed flotation plant design methodology was refined. With this methodology and the continual development of techniques for the measurement and prediction of the P9 flotation model parameters, accurate industrial plant design using the FCTR will become possible. With the addition of other unit operations, such as comminution, into the flowsheet, this methodology will eventually lead to the achievement of the ultimate goal of accurate plant design of green-field sites.

Flotation is the separation process most used to recover valuable minerals from sulphide ores. The design of industrial flotation plants is a complex process involving many stages. Current design practice involves performing laboratory scale grinding and batch flotation tests, followed by a circuit design based on the scale-up of the laboratory kinetics and recovery-grade data. A pilot plant is then operated to evaluate the performance of the circuit based on recovery and grade, usually in the configuration of the intended full-scale plant. The circuit design is refined and economically evaluated after which the design of the full-scale plant is performed. A new approach to full-scale flotation plant design has been proposed by the Julius Kruttschnitt Mineral Research Centre and the Mineral Processing Research Unit of the University of Cape Town, as part of the Australian Minerals Industries Research Association (AMIRA) P9 Project. In this new methodology, the effects of the ore on plant performance are decoupled from the circuit effects. The ore properties are characterised by operating the pilot plant in as simple a configuration as possible. The pilot plant units are configured to perform a similar duty (in terms of mineral content and particle size) to the full-scale operation and their response measured. An important factor in the success of the methodology is having a pilot plant that is capable of accurately characterising the ore properties. For this purpose, the Wemco® Floatability Characterisation Test Rig (FCTR) was built. The FCTR is a self-contained, highly instrumented mobile pilot plant designed to develop and validate the new flotation plant design methodology. The aims of this thesis were to propose, develop and validate a methodology for using the FCTR to design industrial flotation plants. The hypothesis was that full-scale flotation plant design could be accurately performed using the P9 flotation model and modelling and scale-up methodologies, in conjunction with the FCTR. Test work was performed in three main areas: calibration of the ore characteristics and model parameters for the flotation model currently used by the AMIRA P9 Project; validation of the flotation model and modelling methodology; and prediction of full-scale plant performance using parameters determined on the FCTR. The ore floatability characteristics were calibrated using four FCTR circuits of increasing complexity. The ore floatability characteristics were determined for various models derived from data from one, two, three and four calibration circuits. Validation of the flotation model and modelling methodology was performed using three validation methods: internal validity tests, parameter sensitivity tests and predictive validation. From the internal validity tests, some of the models did not meet the validation criteria. The parameter sensitivity tests used Monte Carlo simulations to determine the sensitivity of the regressed model parameters. The tests produced small differences in the values determined from the models and the average values from the Monte Carlo simulations. The floatability characteristics appeared to be stable and unique. Predictive validation was performed using five FCTR circuits, different in configuration to the calibration circuits. The predictive validation was performed using the floatability characteristics determined from each of the calibration models, in conjunction with estimates of the model parameters. Overall, the predictions of the circuit performance were accurate and within experimental standard deviations for most streams in the circuits. The predictions of the key parameters of pentlandite and chalcopyrite recovery were accurate, especially for the final concentrate. The prediction of pyrrhotite recovery produced the largest errors. The prediction of pyrrhotite recovery appeared to be dependent on the addition of depressant to the cleaner and recleaner circuits of the circuit to be predicted. When the depressant addition rates were significantly different from those used in the calibration circuits, the prediction of pyrrhotite recovery was inaccurate. These errors were however reduced when experimental water recovery values were used. The extensive and robust validation of the flotation model and modelling methodology has shown that the flotation model and modelling methodology are valid under certain conditions. This test work represents the first comprehensive validation of the flotation model and modelling methodology incorporating changes in circuit configuration. Using the proposed modelling and scale-up methodology in conjunction with the FCTR, the metallurgical performance of three industrial flotation circuits were predicted. The predicted results were then compared to the experimentally determined results around the industrial circuits. In each case, a scale-up factor between the ore floatability characteristics determined on the FCTR, and the full-scale floatability characteristics, was required to achieve an accurate prediction. The scale-up factor ranged from 0.17 to 0.97 for the case studies investigated. In light of the results from each stage of test work, the proposed flotation plant design methodology was refined. With this methodology and the continual development of techniques for the measurement and prediction of the P9 flotation model parameters, accurate industrial plant design using the FCTR will become possible. With the addition of other unit operations, such as comminution, into the flowsheet, this methodology will eventually lead to the achievement of the ultimate goal of accurate plant design of green-field sites.

No description available.

No description available.

No description available.

A ágata do sul do Brasil apresenta colorações pouco interessantes ou salientes, sendo predominante os tons acinzentados. Tais qualidades foram fatores determinantes para o início do processo de tingimento de ágata do Rio Grande do Sul, no século XVIII. Atualmente, o segmento mineral, apresenta carências relacionadas a tecnologias e processos de produção, além de infraestruturas inadequadas, resultando em prejuízo para as comunidades produtoras. Nesse cenário, a pesquisa se estrutura para avaliar técnicas operacionais viáveis para o setor, objetivando a melhoria do valor agregado às gemas beneficiadas e qualidade na cor. Para o desenvolvimento do tratamento de ágatas, o sistema foi replicado, padronizado e otimizado no Laboratório LAPROM da UFRGS e Centro Tecnológico de Pedras, Gemas e Joias do Rio Grande do Sul. A amostragem foi classificada em quatro padrões e analisada em espectrofotômetro em três etapas distintas. Ao término, se tem a comparação dos resultados do tingimento otimizado e o industrial, com as curvas de distribuição espectral medidas antes e após o tratamento termoquímico da ágata. Com o sistema otimizado, foi possível reduzir custos operacionais, tempo de energia envolvida no sistema, além de manter e elevar a qualidade da cor, sendo possível estabelecer relação com aspectos quanti e qualitativos dos reagentes utilizados. / The agate of the south of Brazil presents not much interesting or salient colorations, being predominant the grayish tones. These qualities were determining factors for the beginning of the agate dyeing process in Rio Grande do Sul, in the 18th century. Currently, the mineral segment presents deficiencies related to technologies and production processes, as well as inadequate infrastructures, resulting in loss to the producing communities. In this scenario, the research is structured to evaluate viable operational techniques for the sector, aiming to improve the value added to the gems benefited and color quality. For the development of the agate treatment, the system was replicated, standardized and optimized in the LAPROM Laboratory of the UFRGS and Centro Tecnológico de Pedras, Gemas e Joias do Rio Grande do Sul. The sampling was classified in four standards and spectrophotometer analyzed in three different phases. In conclusion, is compared the optimized and industrialized dyeing results, with the spectral distribution curves measured before and after the thermochemical treatment of the agate. With the optimized system, it was possible to reduce operating costs, energy time involved in the system, as well as keep and elevate color quality and being possible to establish relationship with quantitative and qualitative aspects of the reagents used.

O espessamento é uma operação unitária que tem como finalidade separar, por diferença de massa específica entre o sólido e o líquido, sólidos suspensos em meio fluido, pela ação da gravidade. É bastante empregado industrialmente em processos contínuos no adensamento de polpas e minérios, em unidades com reação de precipitação e no tratamento de efluentes, dentre outros. Os equipamentos que realizam esta operação, chamados espessadores, são, em geral, tanques abertos de formato cilíndrico, instalados no eixo vertical com a entrada da suspensão na parte superior central, de fundo ligeiramente cônico para a retirada da polpa espessada e calha circulando o topo para descarga do líquido clarificado. As várias técnicas de projeto destas unidades contínuas são comumente baseadas em ensaios de bancada com provetas. Não é raro ocorrerem para os mesmos dados experimentais, áreas de projeto com desvios superiores a 50%. O presente trabalho visou verificar a validade das técnicas de seleção de TALMADGE-FITCH, ROBERTS e FLUXO DE SÓLIDOS, para o dimensionamento de espessadores industriais com salmoura e lodo biológico. Foram realizados para este fim, ensaios de espessamento em provetas com as próprias suspensões industriais, calculadas as áreas pelas técnicas supracitadas e comparadas com os resultados das secções dos equipamentos contínuos industriais. Os desvios médios dos diâmetros para cada técnica em relação ao espessadores industriais apresentaram contra a segurança dos equipamentos um valor de 42% para o método de Talmadge-Fitch, 45,5% para Roberts e 43,5% para o método do Fluxo de sólidos. Concluiu-se, para as condições estudadas, que os métodos de provetas utilizados forneceram valores na mesma ordem de grandeza e que requerem um fator de escala para o dimensionamento das unidades industriais contínuas. / Thickening is a unit operation that has the goal of solid-liquid separation. The principle of this separation is the difference of specific weight between solid and liquid. This unit operation is used in mineral industries, to ore concentrate, wastewater, and others. The tanks called thickeners are usually open, with the feed on the top of the equipment. The solids discharge is done trough the bottom in a conical shape. The most techniques of sizing thickeners are based on graduated cylinders, and it is a common get result that has a difference area in about 50%. This happens because security coefficient, difficulties for results interpretation and scales factors. This research has the goal to apply the techniques of selection of Solids Flux, Roberts and Talmadge-Fitch in graduated cylinders. These methods are classical for thickener sizing. A comparison has been made between the results by those methods with the data obtained from continuous industrial units for salt solution and biological brine. The shunting line for the techniques obtained was 42% for Talmadge-Fitch, 45,5% for Roberts and 43,5% for Solid Flux in the relationship with industrial thickeners. In conclusion, for the studied condition, all methods showed values in the same order and requires a scale factors to sizing the continuous thickeners.

No description available.

A ágata do sul do Brasil apresenta colorações pouco interessantes ou salientes, sendo predominante os tons acinzentados. Tais qualidades foram fatores determinantes para o início do processo de tingimento de ágata do Rio Grande do Sul, no século XVIII. Atualmente, o segmento mineral, apresenta carências relacionadas a tecnologias e processos de produção, além de infraestruturas inadequadas, resultando em prejuízo para as comunidades produtoras. Nesse cenário, a pesquisa se estrutura para avaliar técnicas operacionais viáveis para o setor, objetivando a melhoria do valor agregado às gemas beneficiadas e qualidade na cor. Para o desenvolvimento do tratamento de ágatas, o sistema foi replicado, padronizado e otimizado no Laboratório LAPROM da UFRGS e Centro Tecnológico de Pedras, Gemas e Joias do Rio Grande do Sul. A amostragem foi classificada em quatro padrões e analisada em espectrofotômetro em três etapas distintas. Ao término, se tem a comparação dos resultados do tingimento otimizado e o industrial, com as curvas de distribuição espectral medidas antes e após o tratamento termoquímico da ágata. Com o sistema otimizado, foi possível reduzir custos operacionais, tempo de energia envolvida no sistema, além de manter e elevar a qualidade da cor, sendo possível estabelecer relação com aspectos quanti e qualitativos dos reagentes utilizados. / The agate of the south of Brazil presents not much interesting or salient colorations, being predominant the grayish tones. These qualities were determining factors for the beginning of the agate dyeing process in Rio Grande do Sul, in the 18th century. Currently, the mineral segment presents deficiencies related to technologies and production processes, as well as inadequate infrastructures, resulting in loss to the producing communities. In this scenario, the research is structured to evaluate viable operational techniques for the sector, aiming to improve the value added to the gems benefited and color quality. For the development of the agate treatment, the system was replicated, standardized and optimized in the LAPROM Laboratory of the UFRGS and Centro Tecnológico de Pedras, Gemas e Joias do Rio Grande do Sul. The sampling was classified in four standards and spectrophotometer analyzed in three different phases. In conclusion, is compared the optimized and industrialized dyeing results, with the spectral distribution curves measured before and after the thermochemical treatment of the agate. With the optimized system, it was possible to reduce operating costs, energy time involved in the system, as well as keep and elevate color quality and being possible to establish relationship with quantitative and qualitative aspects of the reagents used.