Gold Recovery Improvement with Outokumpu FlashFlotation

Christian Kujawa
Outokumpu Technology Inc., christian.kujawa@outokumpu.com

ABSTRACT

Froth flotation has been applied extensively and with great success in the extraction of gold. However, beyond
conventional flotation, there exists further opportunity for improving the overall recovery of gold with the use of
FlashFlotation. The Outokumpu FlashFlotation concept has long been known as a strategic method for increasing
pay-mineral recoveries with an attractive return to investment ratio. This is especially true for the recovery of gold.
The potential applications of FlashFlotation in gold are mapped out and explained.

The principles behind the Outokumpu FlashFlotation technology, as well as the new Outokumpu FlashRoughing
and DualOutlet technologies are demonstrated by way of fundamentals. The validity of these technologies is then
demonstrated by way of presentation of FlashFlotation case studies in gold.

GOLD FLOTABILITY

Flotation as a means of recovering gold is well established and also documented in the literature (1,2,3,4,12). Gold
can be grouped typically in three main categories, namely as free gold, gold mineral and gold bearing minerals.

Free Gold

Under free gold one can typically group the placer type or alluvial (placer) gold, native gold, gold metal alloys (4).

Native gold Au
Electrum (Au,Ag)
Aurostibite AuSb2
Auricupride AuCu3
Maldonite Au2Bi

This ‘visible’ or cyanide digestible part of this group, typically greater than 0.1micron, is also characterised by the
GRG (gravity recoverable gold) concept as defined by A.R. Laplante, et al (5). The term GRG because of its
implication will be used frequently in this paper for the classification of the free and ‘visible’ gold group.

Free gold is naturally hydrophobic, exhibits a non-polar character and floats therefore well (1).

Gold Minerals

Among the gold minerals are typically the tellurides (4), with gold as major component and as a fixed ratio.

Calaverite AuTe2
Montbragite Au2Te3
Krennerite (Au,Ag)Te2
Petzite Ag3AuTe2
Sylvanite AgAuTe4
Gold Bearing Minerals

These are the sulphide and oxide minerals carrying gold, as a trace component, either in solid solution with the
minerals or in colloidal form encapsulated in the mineral. This gold is also often referred to as ‘invisible’ gold. The
most well known gold carrying minerals are among others:

Chalcopyrite CuFeS2
Arsenopyrite FeAsS
Tetrahedrite-tennantite Cu12(Sb3As)4S13
Bornite Cu5FeS4
Chalcocite Cu2S
Pyrite FeS2
Pyrrhotite Fe7S8

Carbonaceous material can be added to this group.

GOLD FLOTATION APPLICATIONS

The flow sheet application of flotation in the gold recovery process is a function of mineralogy, environmental and
economical factors.

Flotation as Primary Concentrating Step

Flotation is used as principle concentrating step when the gold is associated mainly with gold bearing minerals, in
very low concentrations, when the ore is essentially refractory, or when additional revenue can be recovered from
associated pay-metals. The flotation concentrate is then treated as mainstream.

Flotation as Scavenging Step

Here flotation is applied to the leach tailings to recover gold associated with gold-bearing minerals.

Flotation as Concentrating Step to Final Smeltable Gold

Here flotation has been added in the gravity circuit to upgrade gravity table concentrate to final smeltable
concentrate (3).

Flotation in the Milling Circuit

Recovery from the grinding circuit is at times desirable – to reduce the inventory pipeline, or produce a specific
concentrate to be treated more economically separately, or reduce the down stream process load on the more
refractory fraction, or allow the adoption of a more cost effective down stream process route, or to simply but
more importantly to increase the overall gold extraction recovery.

Flotation in the grinding circuit can be steered specifically for the recovery of free (GRG) gold only with the use of
very specific reagents (12), the trend being however towards the more comprehensive flotation of all gold.

The focus of this paper is on the flotation in the milling circuit, using the Outokumpu FlashFlotation technology.

BEHAVIOR OF GOLD IN THE MILLING CIRCUIT

Gold displays very unusual characteristics in the milling circuit. This is exploited with gravity separation and Flash
Flotation.
Free Gold

The heavy gold accumulates preferentially in the cyclone underflow. The grinding mechanism is one of
flattening/refolding/flattening because of gold’s malleability. The diminution process is one of tearing or serration,
six to twenty times slower than the diminution process for minerals and gangue (9).

Some flakes leave in the cyclone over flow by entrainment. These large flakes are generally lost to tailings since,
in the case of down stream flotation the machines are generally not geared in design nor control for coarse
particle flotation, in the case of a down stream leach generally insufficient leach retention time is available to
dissolve all of the large gold particle.

The free gold exhibits excellent flotation characteristics. This is thought to be because the flaky gold particles
generally attach easily to the air bubbles, given the extreme good angle of contact, the extended surface contact
area and also because the serrated edges allow easy penetration of the liquid film boundary around the air
bubble. The lighter the gold flake, the more likely the buoyancy effect of the flotation air leading to successful
flotation.

Gold Minerals and Gold- Bearing Minerals

These minerals display considerably faster grinding characteristics than the free gold. Typically cleavages occur
along crystal grain boundaries. Often minerals themselves are very amorphous or brittle, tending to accumulate in
the slimes fractions. The over grinding leads to losses in the fine fractions, as the flotation machines are not
necessarily geared toward fines flotation.

OUTOKUMPU’S CONVENTIONAL FLASH FLOTATION

The first developments in the Outokumpu Flash Flotation were made in the early 1980’s for the recovery of
floatable material from the grinding circuit. The early development originated from findings of surveys made in the
company’s own concentrators, initiated to find ways of improving flotation plant recoveries with increasingly more
complex and lower grade feeds. The results showed that due to the classification nature of hydro-cyclones, not
only by size but also by mass, that heavier minerals and metals such as gold, even though sufficiently sized
would remain in the mill-circulating load until virtually overground. In the case of free gold, the chance of –
25micron particles remaining in the mill-circulating load has been seen to be as high as 88-90% (11). This would
lead to an enriched cyclone underflow stream with grades significantly higher than the original fresh plant feed,
with significant metal values in particle sizes fraction ideal for flotation. The cyclone underflow constitutes the ideal
flotation feed material – enriched feed grade, ideal particle size and de-slimed, yielding very high flotation rate
kinetics.

The Outokumpu SkimAir® Flash Flotation machine is a special purpose-build flotation machine to handle the
coarse and high pulp density cyclone underflow in a milling circuit. Short retention times, of a few minutes, utilize
the high kinetic rates for the pay-metals in contrast to the gangue kinetic rates to produce a final grade
concentrate at very acceptable recoveries, typically 40-60% of new plant feed.

Since over grinding of the pay-mineral is effectively prevented this increases the overall plant recovery. Additional
recoveries of 2-5% are typically reported. Other benefits typically seen are an overall lower reagent consumption,
improved thickening and filtering rates, reduced filter cake moistures and more a more stable down stream
flotation plant operation.

Figure 1 is reflecting a typical standard FlashFlotation configuration.

 FIGURE 1

Typical configuration of a standard Flash

Flotation installation.

The advent of the larger FlashFlotation machines, SK500 (500mth-1 throughput) in 1990 and the SK1200
(1200mth-1 throughput) in 1996 has lead to extensions of the standard Outokumpu FlashFlotation technology. The
DualOutlet and the FlashRoughing innovations have made FlashFlotation more universally usable in grinding
circuits, overcoming limitations such as high solids densities and mass pull restrictions, and extending the
FlashFlotation principle.

FLASH FLOTATION OF GOLD

The floatability of free gold and gold-bearing minerals is well illustrated by the results from Macraes Gold Mine in
New Zealand (7).

GRAPH 1

Particle size distribution of the

FlashFlotation feed (cyclone under flow).

Graph 1 above shows that the gold in the cyclone under flow is indeed coarser than the average solids particles
as result of the gold’s slower grinding kinetics, and the sulphur minerals finer than the average solids particles as
a result of their faster grinding characteristics.
 GRAPH 2

Particle size distribution in the Flash

Flotation concentrate.

Graph 2 illustrates the coarseness of the concentrate in terms of sulphur and gold, compared to the entrained fine
gangue material.

GRAPH 3

Gold/sulphur ratio as a function of mean

particle size in FlashFlotation feed and
concentrate.

The gold/sulphur ratio is a very convenient way to verify preferential flotation characteristics. Graph 3 shows that
in the 55 to 250micrometer range the gold/sulphur ratios in the feed and concentrate are very similar, showing
that both free gold and gold in gold-bearing minerals and the gold-bearing sulphide minerals themselves are
floated equally well.

In the particle sizing greater than 250micrometer it appears that sulphide minerals float preferentially. The reason
for the lower free gold flotation rate could be ascribed either by incomplete liberation of the free gold or that the
free gold is simply too heavy to be removed by flotation.

In the particle sizing smaller than 55micrometer the reverse is evident. Free gold floats preferentially to the gold
bearing sulphide minerals. This is thought to be as a result of the poorer flotation rates of the finer sulphide
particles, but enhanced flotation of free gold because of improved liberation.

The results show that Flash Flotation is applicable for free gold particles up to a size of 250micrometer, and
certainly even larger particle sizes in the case of sulphide minerals. The flotation of the gold in the range below
55micrometer is of importance as this is the range in which gravity separation equipment is not effective.
 GRAPH 4

Gold recovery as a function of mean

particle size fraction.

Graph 4, read in conjunction with Graph 3, shows however that the free gold dominates in the coarse particle gold
recovery and that the gold in sulphide mineral dominates the fine particle gold recovery. This shows that in the
coarse particle size fractions, 150micron to 250micron, free gold is more abundant with good recoveries from
those coarser size fractions. This is in line with findings by others (12), that gold particles up to 500 and
710microns have been seen to float.

The curve is also confirming the well-known fact that recovery by flotation decreases with decreasing particle size.

DUAL OUTLET INNOVATION

The natural classification action within the SkimAir® flotation machine promotes flotation in the upper zones of the
cell. The presence of liquid medium facilitates the dispersion of the flotation air and creates a less hindered
passage for the particle/bubble aggregates upwards.

Lack of liquid medium and the purposely-kept short retention time limit the concentrate mass pull and overall
recovery from the standard Flash Flotation machine.

Water dilution of the feed to the FlashCell is therefore necessary at times to promote flotation kinetics. This
typically leads to a situation in which a balance has to be found by operations between improved pay-metal
recovery and the loss in throughput because of mill feed dilution.

The Dual Outlet innovation by Peter Bourke from Outokumpu Australia provides improved flotation kinetics with
better dilution to the FlashCell, but keeping the mill feed pulp densities at the same level or higher than the
original cyclone underflow.

In essence, classification in the FlashCell is promoted even further by a reduction in feed dilution water and
increased cell retention time. A low pulp density profile is maintained above the mixing mechanism through the
use of a top outlet. This promotes control and the possibility to keep the water from the FlashCell bottom
discharge. The fines and water from the top outlet are routed to the mill discharge sump.

These fines therefore by-pass the milling process. Over grinding is prevented. The re-feed to the cyclone ensures
that at improved separation is achieved over the whole circuit. At constant re-circulating load to the mill, the fines
by-pass means that more fresh feed can be fed to the circuit. This has a significant effect on payback.

A typical Dual Outlet implementation is shown in Figure 2.

 FIGURE 2

Typical configuration of a Dual Outlet Flash

Flotation installation.

COMPARATIVE MILLING CIRCUIT CONFIGURATION STUDY

The standard by-pass facility provided with every FlashCell means that the mill circuit equipped with a DualOutlet
FlashCell can be operated in three different configurations of no FlashCell (using the by-pass to the FlashCell), or
conventional FlashFlotation (not using the top outlet on the FlashCell), and DualOutlet mode (using the FlashCell
top outlet).

Figures 3,4,5 show the respective reconstituted mass balances for such an exercise.

FIGURE 3

Simplified flow sheet and mass balance of a milling circuit without Flash Flotation.
FIGURE 4

Simplified flow sheet and mass balance of a milling circuit with standard FlashFlotation.

FIGURE 5

Simplified flow sheet and mass balance of milling circuit with DualOutlet FlashFlotation.

The readings for each test run were taken at steady state. The objective was to create a best possible
comparison between the flow sheet configurations, keeping the plant feed rate, dilution water and cyclone
operation and plant output constant. No attempt was made to optimise any flow sheet configuration in terms of
throughput or any other variable. The recirculation load is defined as ratio of material mass recycled to the 2nd mill
to new feed to the 2nd mill.
 TABLE 1

Summary of the configuration mill

performances.

The comparison revealed the following:

Constant Parameters

Fresh feed, circuit dilution water, and cyclone operation (feed, overflow, underflow solids content) were kept
constant.

FlashCell Feed

Moving to DualOutlet has allowed the treatment of the total cyclone under flow by FlashFlotation. Part of the
functionality of the DualOutlet is that the feed to the FlashCell should not be diluted too much. DualOutlet
configuration feed was 60.8% solids as opposed to the 52.8% solids needed for the conventional FlashFlotation
configuration.

Mill Discharge Pulp Density

The parameter of interest is the discharge pulp density of the closed loop secondary mill. A drop from 68% to
60.5% was necessary for the proper operation of the conventional FlashFlotation machine. The pulp density was
however brought up again to 71.7% with the DualOutlet configuration.

Recovery

When the conventional SkimAir® SK500 was installed in 1992 it yielded an additional 2.63% recovery over and
above the plant recovery, at a FlashCell recovery of 64.9% of fresh feed and a FlashFlotation concentrate grade
of 137g/t (7). The results show that the conversion to DualOutlet has not impinged on the recovery.

Concentrate Grade

A substantial increase in concentrate grade with the DualOutlet is evident, showing that the performance has
shifted on a new recovery/grade performance curve. This corresponds to the decrease in mass pull to
concentrate.

CONCLUSION

The Dual Outlet therefore improves flotation kinetics and throughput. The upper outlet stream bypasses the mill
directly to mill sump, not only reducing over grinding and overall mill classification efficiency, but reduces the
circulating load to the closed looped mill, therefore allowing an increased mill throughput. High bottom discharge
pulp densities from the FlashCell ensure that high millwork densities are maintained.
FlashFlotation is imminently suitable to capitalize on the suitable conditions for flotation on the cyclone underflow
and the characteristic of gold in the milling circuit to increase the overall gold extraction recovery.

ACKNOWLEDGMENTS

These go to foremost to Peter Bourke (Outokumpu in Australia), Professor Laplante (McGill University) and Dr.
Steve La Brooy (Macraes Gold Mine).

BIBLIOGRAPHY

1. Kallionen, J.; Niitti, T.; “The basis of coarse flotation kinetics and practical realisation of classifier sands
flotation”, XVth IMPC, Cannes, June 2-9, 1985.
2. Bourke, Peter; “Recent developments in Outokumpu flotation technology”, 1998.
3. Green, David; “Advances in flotation – Flash Roughing with the Dual Outlet SkimAir® flotation cell: Increasing
revenues and reducing costs”, Proceedings, Randol Gold & Silver Forum ’99, Denver, Colorado, USA, May
11-14, 1999, pp 145-147.
4. Jackman, Irene; Williams, Steve; “The role of flotation in the recovery of gold”, Lakefield Research, 1995.
5. Sarbutt, K.W.; Williams, S.R; “Flotation flow sheet development for copper-gold ores”, Proceedings, Copper
’95, Santiago, Chile, November 26-29, 1995.
6. Bourke, Peter; “The impact of recent developments in Flash Flotation technology on both precious metals and
base metals sulphide flotation”, Proceedings, IIR Nickel Conference, February, 1998.
7. Green, David; “Flash Roughing in an Outokumpu SkimAir® flotation cell: New developments create new
opportunities”, Proceedings, Randol Gold & Silver Forum ’99, Denver, Colorado, USA, May 11-14, 1999.

REFERENCES

1. Wenqian, Wang; Poling, George W.; “Methods for recovering fine placer gold”, The Canadian Mining and
Metallurgical Bulletin, December, 1983.
2. Bulatovic, S.; Wyslouzil, D.M.; “Flotation behaviour of gold during processing of porphyry copper-gold ores
and refractory gold-bearing sulphides”, Proceedings, The Second International Gold Symposium, Lima, Peru,
May 7-10, 1996.
3. De Kok, S.K.; “Gold concentration by flotation”, Journal of the South African Institute of Mining and Metallurgy,
October, 1975, pp 139-141.
4. Chryssoulis, S.L.; Cabri, L.J.; “Significance of gold mineralogical balances in mineral processing”, Trans. Instn
Min. Metall. (Sect. C: Mineral Process. Extr. Metall.), 99, January-April, 1990.
5. Woodcock, F; Laplante, A.R.; “A laboratory method for determining the amount of gravity recoverable gold”,
Randol Gold Forum, Beaver Creak, September 1993, pp 151-155.
6. Laplante, A.R.; Personal communication, May, 2000.
7. Bourke, Peter; “Flash Flotation in the gold industry”, Proceedings, Randol Gold Conference, March, 1995.
8. Oravainen, Heikki; “Flotation of Native Gold”, Internal communication. Outokumpu, April, 2000.
9. Banisi,S.; Laplante, A.R.; Marois, J.; “The behaviour of gold in Hemlo Mines Ltd. grinding circuit”, Paper 25,
Proceedings, CMP Conference, Ottowa, January, 1991.
10. Bourke, Peter; “Flotation of Native Gold”, Internal communication, Outokumpu, April, 2000.
11. Xiao, Z.; Laplante A.R.; Huang L.; “Predicting Gold Recovery in Grinding Circuits: Parametric Estimation and
Representation of Results”, Proceedings, Interactions in Mineral Processing, COM2001, Toronto, August 26-
29, 2001, pp. 443-457.
12. Forrest, K.; Yan, D.; Dunne, R.; “Optimisation of Gold Recovery by Selective Gold Flotation for Copper-Gold-
Pyrite Ores”, Minerals Engineering, Vol. 14, No. 2, 2001, pp. 227-241.
13. La Brooy, Steve; “Macraes Gold Mine Data”, Communication, April, 2000.