FLOTATION ARRANGEMENT AND METHOD RELATED THERETO

Abstract

A flotation arrangement, a flotation plant and a method related thereto are disclosed. The flotation arrangement includes a first flotation section and a second flotation section. The arrangement further includes a dewatering system for separating solid material and liquid to obtain a dewatered solid material stream and a separated liquid stream, and the dewatering system is arranged before the second flotation section and connected thereto for leading said dewatered solid material stream to the second flotation section and the arrangement includes recovery means for recovering the separated liquid stream.

Claims

1. A flotation arrangement comprising: a first flotation section including a first flotation unit comprising a mechanical agitator, and a second flotation section including a second flotation unit, which comprises i) a fluid bed device comprising devices for creating a fluid bed, and/or ii) a froth device comprising devices for creating a froth layer, wherein particles are fed for interaction with froth layer in the froth layer, under the froth layer close proximity thereof, or above the froth layer, or any combinations thereof, wherein the arrangement further comprises a dewatering system for separating solid material and liquid to obtain a dewatered solid material stream and a separated liquid stream, and said dewatering system is arranged before the second flotation unit and connected thereto for leading said dewatered solid material stream to the second flotation unit and the arrangement comprises recovery means for recovering the separated liquid stream.

2. The flotation arrangement according to claim 1, wherein the recovery means are arranged to lead at least part of the separated liquid stream to the second flotation unit.

3. The flotation arrangement according to claim 1, wherein the second floatation unit comprises a fluid bed device comprising devices for creating a fluid bed.

4. The flotation arrangement according to claim 1, wherein the second flotation unit comprises i) a fluid bed device comprising devices for creating a fluid bed, and ii) a froth device comprising devices for creating a froth layer, wherein particles are fed for interaction with froth layer in the froth layer, under the froth layer close proximity thereof, or above the froth layer, or any combinations thereof.

5. The flotation arrangement according to claim 1, wherein the first flotation unit is i) at least one device comprising a closed vessel for a pressurized flotation, wherein flotation concentrate is removed by pressure from the vessel, and/or ii) at least one device comprising a flotation vessel and: an inlet connected for receiving feed to be handled in said flotation vessel and arranged to a lower part of the flotation vessel, an overflow means for removing flotation concentrate, arranged to an upper part of the flotation vessel, and an outlet for removing underflow, arranged to a lower part of the flotation vessel.

6. The flotation arrangement according to claim 1, wherein the dewatering system is a dewatering cyclone.

7. The flotation arrangement according to claim 1, wherein the dewatering system is arranged to provide a solid material stream with a solids content of above 50 weight-%, preferably 60 to 80 weight-%, of the total weight of the stream.

8. The flotation arrangement according to claim 1, wherein the mechanical agitator comprises means for mixing a slurry and creating bubbles therein.

9. The flotation arrangement according to claim 1, wherein the first flotation unit comprises at least three flotation vessels arranged in series such that the outlet for removing underflow of a preceding flotation vessel is connected to the inlet of a following flotation vessel.

10. The flotation arrangement according to claim 1, wherein the first flotation unit comprises a flotation vessel and the flotation vessel comprises devices for creating a froth layer.

11. The flotation arrangement according to claim 1, wherein the mechanical agitator comprises means for mixing a slurry and creating bubbles therein.

12. The flotation arrangement according to claim 1, wherein the first flotation unit comprises at least one flotation vessel and the flotation vessel comprises a device comprising an inlet connected for receiving feed to be handled in said flotation vessel and arranged to a lower part of the flotation vessel, an overflow means for removing flotation concentrate, arranged to an upper part of the flotation vessel, and an outlet for removing underflow, arranged to a lower part of the flotation vessel.

13. The flotation arrangement according to claim 1, wherein the first flotation unit comprises a flotation vessel and the flotation vessel comprises a closed vessel for a pressurized flotation, wherein flotation concentrate is removed by pressure from the vessel.

14. The arrangement according to claim 1, wherein the arrangement further comprises a third flotation unit comprising a flotation vessel that comprises devices for pneumatical gas addition.

15. The arrangement as claimed in claim 14, wherein the flotation vessel comprises a froth separation device comprising devices for creating a froth layer, comprising an inlet connected for receiving feed to be handled in said flotation vessel and arranged to an upper part of the flotation vessel, and an overflow means for removing flotation concentrate, arranged to an upper part of the flotation vessel.

16. The flotation arrangement as claimed in claim 14, wherein the flotation vessel comprises a downcomer for slurry infeed, the downcomer equipped with a nozzle for feeding pressurized flotation gas in slurry therein.

17. The flotation arrangement as claimed in claim 16, wherein the downcomer comprises an outlet nozzle configured to induce a supersonic shockwave into the slurry as it exits the downcomer.

18. The flotation arrangement as claimed in claim 16, comprising a separation unit arranged for preventing large particles entering in the third flotation unit.

19. The arrangement as claimed in claim 18, wherein the separation unit comprises a grizzly or a grating.

20. A flotation plant comprising the flotation arrangement according to claim 1.

21. The flotation plant according to claim 20, wherein the plant comprises a pre-milling section comprising a mill selected from the group consisting of an autogenous grinding mill, a semi-autogenous grinding mill, and a high-pressure grinding roll or any combination thereof.

22. A flotation method for separating valuable minerals from a slurry, wherein the method comprises the steps of: treating the slurry in a first flotation section including a first flotation unit comprising a mechanical agitator, subsequently, treating the slurry in a second flotation section including a second flotation unit, which comprises i) a fluid bed device comprising devices for creating a fluid bed, and/or ii) a froth device comprising devices for creating a froth layer, wherein particles are fed for interaction with froth layer in the froth layer, under the froth layer close proximity thereof, or above the froth layer, or any combinations thereof, wherein the method further comprises the step of treating the slurry in a dewatering system for separating solid material and liquid to obtain a de-watered solid material stream and a separated liquid stream, and said dewatering system is arranged before the second flotation unit and said dewatered solid material stream is led to said second flotation unit and the separated liquid stream is recovered.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The present disclosure will be better understood from the following detailed description read in light of the accompanying drawings, wherein:

[0026] FIG. 1 shows a schematic view of the flotation arrangement of this disclosure.

[0027] FIG. 2 shows a schematic view of the flotation arrangement of this disclosure.

[0028] FIG. 3 shows a schematic view of the flotation arrangement of this disclosure.

[0029] Unless specifically stated to the contrary, any drawing of the aforementioned drawings may be not drawn to scale such that any element in said drawing may be drawn with inaccurate proportions with respect to other elements in said drawing in order to emphasize certain structural aspects of the embodiment of said drawing.

[0030] Moreover, corresponding elements in the embodiments of any two drawings of the aforementioned drawings may be disproportionate to each other in said two drawings in order to emphasize certain structural aspects of the embodiments of said two drawings.

DETAILED DESCRIPTION

[0031] Generally, in standard flotation such as standard mechanically agitated flotation cells, underflow from a first primary flotation unit may comprise considerable amounts of coarser particles of valuable mineral(s) mixed with finer gangue particles. Standard mechanical flotation cells only separate effectively within a narrow size range of approximately 20 microns to 150 microns depending on the ore type and the liberation of the ore, and may vary. Thus, coarser particles are not fully recovered by these standard flotation units. This can result in a substantial loss of valuable coarse minerals. One application of so called “coarse flotation” is treatment of the tailings or an underflow stream to increase the overall recovery of valuable material. This may be fresh tailings from the ongoing current process or from reclaimed tailings ponds. Any captured minerals from the tailings stream may then be reground and subjected to further standard flotation to improve product grade. However, this is energy consuming. Excessive classification devices can be utilized, which also are energy consuming.

[0032] The current disclosure describes an arrangement, which provides an improvement by treating all solids within the underflow stream from a first flotation section within a second flotation section, such as a coarse flotation unit. The stream may have relatively high percentage solids by weight before entering the second flotation unit. This is typically above 50 or 55 weight %, or above 65 weight-% solids. A higher solids content may enable improved efficiency of the second flotation section. In addition, the separated water can be utilized enabling savings in process water usage. Typically, the fresh tailings i.e. underflow from standard flotation contains rather high amounts of water, so parts of it can be separated. Thus, a dewatering stage and a dewatering system in combination with the first flotation unit (such as standard mechanically agitated flotation cells) and the second flotation unit (for coarser particles) provides an advantage. By optimizing the use of water, a cost-effective process for an industrial scale application may be achieved.

[0033] The dewatering system is not a classification system. The separated water may immediately be returned to the process water system, but could be needed further in the coarse flotation process.

[0034] Coarse flotation processes that can handle high percentages of solids in the feed are preferred. One such process is separation-in-froth or other froth interaction processes, or fluidized-bed flotation technology. The second flotation unit may require water to maintain its operations, and thus at least part of the water separated and recovered using the dewatering system may be utilized.

[0035] The benefits of the arrangement, plant and method of this disclosure include providing: [0036] immediate recyclability and utilization of process water. The aim is to allow only minor amounts of solids is within the separated liquid/water stream. [0037] Smaller unit size of the second flotation unit may be achieved by first using a robust first standard flotation system for removing a large mass of valuable material. Thus, the underflow from the first flotation system is significantly smaller than the feed to the first flotation system. In addition, water may be removed. Thus, a second so-called coarse flotation unit does not need to account for the high volume of water in typical flotation tailings. By utilizing the described combination of systems, the overall size of the equipment after the first flotation unit may be reduced. [0038] No pre-classification units are typically needed. This reduces the upstream equipment requirements.

[0039] The arrangement, plant and method of this disclosure provides a way to control the water balance of the flotation process. Flotation uses large amounts of water, so water balance control is important. Robust standard flotation uses less water, so placing such a flotation section first optimizes the consumption and evens the stream. Separating and recovering the water before the second flotation unit (coarse flotation) gives an added effect. There is overall less material to be treated in the more water consuming second (coarse) flotation unit.

[0040] The separated and recovered water may be led to a process water system. I may also be recovered in a process water tank and/or tailings pond. Further, it may be recirculated directly to a specific unit, such as a flotation unit. Preferably, the second flotation unit comprising a fluid bed. The advantage is that the fluid bed can handle the coarse material well.

[0041] Thus, described is a flotation arrangement comprising: [0042] a first flotation section including a first flotation unit (1) comprising a mechanical agitator, and [0043] a second flotation section including a second flotation unit (2), which comprises
i) a fluid bed device comprising devices for creating a fluid bed, and/or
ii) a froth device comprising devices for creating a froth layer, wherein particles are fed for interaction with froth layer in the froth layer, under the froth layer close proximity thereof, or above the froth layer, or any combinations thereof,
wherein the arrangement further comprises a dewatering system (3) for separating solid material and liquid to obtain a dewatered solid material stream (31) and a separated liquid stream (32), and said dewatering system is arranged before the second flotation unit (2) and connected thereto for leading said dewatered solid material stream (31) to the second flotation unit (2) and the arrangement comprises recovery means (33) for recovering the separated liquid stream (32).

[0044] According to one embodiment, the recovery means are arranged to lead at least part of the separated liquid stream (32) to the second flotation unit (2). Optionally, all or nearly all of the separated liquid stream may be led to the second flotation unit. The second flotation unit may be a so-called coarse flotation unit, which typically can require water. Thus, recovering and recirculating at least part of the water in the second flotation equipment may provide a very effective way of utilizing the water.

[0045] According to one embodiment, the first flotation unit (1) is [0046] i) at least one device comprising a closed vessel for a pressurized flotation, wherein flotation concentrate is removed by pressure from the vessel, and/or [0047] ii) at least one device comprising a flotation vessel and: [0048] an inlet (11) connected for receiving feed to be handled in said flotation vessel and arranged to a lower part of the flotation vessel, [0049] an overflow means for removing flotation concentrate, arranged to an upper part of the flotation vessel, and [0050] an outlet (12) for removing underflow, arranged to a lower part of the flotation vessel. The described first flotation units may be so called standard flotation units, which represent robust technology.

[0051] According to one embodiment, the dewatering system (3) is a dewatering cyclone. A dewatering cyclone is a preferred effective dewatering device in the combination of sections as described herein.

[0052] According to one embodiment, the dewatering system is arranged to provide a solid material stream with a solids content of above 50 weight-%, preferably 60 to 80 weight-%, of the total weight of the stream.

[0053] According to one embodiment, the mechanical agitator comprises means for mixing a slurry and creating bubbles therein. The robust technology using mechanical agitation creates bubbles, which can remove particles with a large particle size distribution. Thus, the mass pull to the following sections is reduced and a rather homogenous underflow from the first flotation section can be provided.

[0054] According to one embodiment, the first flotation unit (1) comprises at least three flotation vessels arranged in series such that the outlet for removing underflow of a preceding flotation vessel is connected to the inlet of a following flotation vessel. Using at least three flotation vessels enables removing a large part of the valuable material efficiently. An example of suitable robust flotation vessels for the first flotation unit may be the so-called TankCell®. Treating the ore stream in several vessels may ensure maximum recovery of the valuable material in the first flotation section.

[0055] According to one embodiment, the first flotation unit comprises a flotation vessel and the flotation vessel comprises devices for creating a froth layer.

[0056] According to one embodiment, the second floatation unit comprises a fluid bed device comprising devices for creating a fluid bed. Since the coarse flotation uses large amounts of water, reducing the size of this equipment reduces the amount of water considerably. Recovering and utilizing the separated water stream from the dewatering system is especially advantageous when using a fluid bed, because creating the fluid bed requires a rather large water consumption, so controlling the water balance is especially important.

[0057] According to one embodiment, the second flotation unit comprises

i) a fluid bed device comprising devices for creating a fluid bed, and
ii) a froth device comprising devices for creating a froth layer, wherein particles are fed for interaction with froth layer in the froth layer, under the froth layer close proximity thereof, or above the froth layer, or any combinations thereof.

[0058] The advantage is of this embodiment is that a device combining these two technologies may recover an even larger amount of the coarse particles in the feed.

[0059] According to one embodiment, the first flotation unit (1) comprises at least one flotation vessel and the flotation vessel comprises a device comprising [0060] an inlet connected for receiving feed to be handled in said flotation vessel and arranged to a lower part of the flotation vessel, [0061] an overflow means for removing flotation concentrate, arranged to an upper part of the flotation vessel, and [0062] an outlet for removing underflow, arranged to a lower part of the flotation vessel.

[0063] One example of such a flotation vessel is a TankCell®. The robust flotation technology described in this embodiment is suitable for many kinds of feed, since it does not easily clog. A rater large mass can be removed, so in case a mill is used its operation does not need to be very strictly adjusted, which facilitates operation of the flotation arrangement. In particular, the outlet for removing underflow enables the handling of a large range of different particle sizes before the second flotation unit.

[0064] According to one embodiment, the first flotation unit (1) comprises a flotation vessel and the flotation vessel comprises a closed vessel for a pressurized flotation, wherein flotation concentrate is removed by pressure from the vessel. The pressure enables moving the slurry/material to be handled up in the vessel and removing it. A very high amount of mass can be removed.

[0065] According to one embodiment, the arrangement further comprises a third flotation unit comprising a flotation vessel that comprises devices for pneumatical gas addition. When there is pneumatical gas addition, gas bubble size distribution can be adjusted according to required conditions. Small bubbles can be selected to remove small particles, after the mechanically agitated flotation arranged to remove mass largely and the second flotation to remove coarser particles. When there is separate pneumatical gas addition in the end of flotation system, process parameters can be selected in second flotation unit based on coarse particle need. Then coarse particle device can be small and requires less water. According to one specific embodiment, this flotation vessel comprises a froth separation device comprising devices for creating a froth layer, comprising [0066] an inlet connected for receiving feed to be handled in said flotation vessel and arranged to an upper part of the flotation vessel, and [0067] an overflow means for removing flotation concentrate, arranged to an upper part of the flotation vessel.

[0068] One example of this is a so-called column flotation cell. One advantage with this embodiment is that it can be used without screening or classification before the third flotation unit. It is able to process a rather broad range of particles, even coarse. The whole underflow from the second flotation unit may thus be led to the third flotation unit. For example, if there is only a very little amount of fine material to be removed, the third flotation unit of this embodiment is advantageous, because it can recover the finer material even if there is coarse material in the feed.

[0069] According to another very specific embodiment of an arrangement comprising a third flotation unit, the flotation vessel comprises a downcomer for slurry infeed, the downcomer equipped with a nozzle for feeding pressurized flotation gas in slurry therein. Furthermore, the flotation the downcomer may comprise an outlet nozzle configured to induce a supersonic shockwave into the slurry as it exits the downcomer. The flotation arrangement of this embodiment may also comprise a separation unit arranged for preventing large particles entering in the third flotation unit. Further, the separation unit may comprise a grizzly and/or a grating.

[0070] Described is also a flotation plant comprising the flotation arrangement according to any one of the embodiments described herein.

[0071] According to one embodiment, the flotation plant comprises a pre-milling section comprising a mill selected from the group consisting of an autogenous grinding mill, a semi-autogenous grinding mill, and a high-pressure grinding roll or any combination thereof. The combination of pre-milling, a first robust flotation section, the dewatering system and a second flotation section for coarse particles is especially effective. The standard flotation can handle the material from the pre-milling well and remove a large mass and even the stream (underflow). Thus, the dewatering system, such as especially a dewatering cyclone, can function better, when placed after the first section and before the second flotation section. Again, the dewatered stream fed to the second (coarse) flotation unit is more even. The combination can reduce the energy required for milling as there is no need to regrind all underflow from first flotation unit.

[0072] Further, described is a flotation method for separating valuable minerals from a slurry, wherein the method comprises the steps wherein [0073] the slurry is treated in a first flotation section including a first flotation unit (1) comprising a mechanical agitator, [0074] subsequently, the slurry is treated in a second flotation section including a second flotation unit (2), which comprises
i) a fluid bed device comprising devices for creating a fluid bed, and/or
ii) a froth device comprising devices for creating a froth layer, wherein particles are fed for interaction with froth layer in the froth layer, under the froth layer close proximity thereof, or above the froth layer, or any combinations thereof,
wherein the method further comprises treating the slurry in a dewatering system (3) for separating solid material and liquid to obtain a dewatered solid material stream (31) and a separated liquid stream (32), and said dewatering system is arranged before the second flotation unit (2) and said dewatered solid material stream (31) is led to said second flotation unit (2) and the separated liquid stream (32) is recovered.

[0075] FIG. 1 illustrates one embodiment of the flotation arrangement of this disclosure. It shows a first flotation unit 1 and a second flotation unit 2. The arrangement also comprises a dewatering system 3 for separating solid material. The figure shows a dewatered solid material stream 31 and a separated liquid stream 32. The dewatering system 3 is arranged before the second flotation unit 2 and connected by leading the dewatered solid material stream 31 to the second flotation unit 2. The figure also shows that the arrangement includes recovery means 33 for recovering the separated liquid stream 32. An overflow comprising fines is led out from the second flotation unit via line 23. Additional water is optionally added to the second flotation unit via line 22.

[0076] FIG. 2 illustrates another embodiment of the flotation arrangement of this disclosure. At least part of the separated and recovered liquid stream 33 is led directly to the second flotation unit 2.

[0077] FIG. 3 illustrates another embodiment of the flotation arrangement of this disclosure. The arrangement further comprises a third flotation unit (3) and means for feeding the underflow 21 from the second flotation unit to the third flotation unit.

[0078] It will be understood that any benefits and advantages described above may relate to one embodiment or may relate to several embodiments. The embodiments are not limited to those that solve any or all of the stated problems or those that have any or all of the stated benefits and advantages.

[0079] The term “comprising” is used in this specification to mean including the feature(s) or act(s) followed thereafter, without excluding the presence of one or more additional features or acts. It will further be understood that reference to ‘an’ item refers to one or more of those items.