Flotation of copper sulphides assisted by high intensity conditioning (HIC) and concentrate recirculation

This paper describes the effect of the partial concentrate (rougher floated product) recirculation to rougher flotation feed, here named concentrate recirculation flotation – CRF, at laboratory scale. The main parameters used to evaluate this alternative approach were flotation rate and recovery of fine (“F” 40–13 μm) and ultrafine (“UF” <13 μm) copper sulphide particles. Also, the comparative effect of high intensity conditioning (HIC), as a pre-flotation stage for the rougher flotation, was studied alone or combined with CRF. Results were evaluated through separation parameters, grade-recovery and flotation rates, especially in the fine and ultrafine fractions, a very old problem of processing by flotation. Results showed that the floated concentrate recirculation enhanced the metallurgical recovery, grade and rate flotation of copper sulphides. The best results were obtained with concentrate recirculation flotation combined with high intensity conditioning (CRF–HIC). The kinetics rate values doubled, the Cu recovery increased 17%, the Cu grade increased 3.6% and the flotation rates were 2.4 times faster. These were accompanied by improving 32% the “true” flotation values equivalent to 2.4 times lower the amount of entrained copper particles. These results were explained and proved to proceed by particle aggregation (among others) occurring after HIC, assisted by the recycled floatable particles. This “artificial” increase in valuable mineral grade (by the CR) resulted in higher collision probability between hydrophobic particles acting as “seeds” or “carrier”.