Flotation Plant Design with

Aminfloat Simulator
Roger Amelunxen, Director Aminpro
 Contents
An Explanation of the FKT model ingredients
Mass and flow volume
Floatability
Product pricing
How to optimize a flotation design
Cells and Regrind
The economics of a graphite case
Conclusions
 What Constitutes an Ideal Plant Survey
Feed t/h
Low range C(g) Fe11S12 Gangue Water
600 0.00 0.00 0.00 245
424
300
212
150
0.24
1.24
1.98
1.81
0.17
0.56
0.86
1.00
4.87
11.66
13.14
11.42
0
0
0
0
Good and
106
75
53
38
1.28
0.81
0.51
0.33
1.01
0.92
0.80
0.68
8.91
6.67
4.95
3.71
0
0
0
0
complete set
of data
0 0.81 3.72 15.95 0
t/h
0 9.0 9.7 81.3 100.0
A great and efficient team

Conc t/h
Tails t/h
Low range C(g) Fe11S12 Gangue Water
Low range C(g) Fe11S12 Gangue Water
600 0.00 0.00 0.00 5.43
600 0.00 0.00 0.00 239
424 0.15 0.00 0.05 0
424 0.09 0.17 4.82 0
300 0.76 0.02 0.19 0
300 0.48 0.54 11.47 0
212 1.17 0.04 0.25 0
212 0.80 0.82 12.89 0
150 1.03 0.06 0.22 0
150 0.79 0.94 11.20 0
106 0.68 0.06 0.16 0
106 0.60 0.94 8.75 0
75 0.40 0.05 0.10 0
75 0.41 0.87 6.57 0
53 0.23 0.04 0.06 0
53 0.28 0.76 4.89 0
38 0.13 0.02 0.03 0
38 0.19 0.65 3.67 0
0 0.26 0.02 0.09 0
0 0.55 3.70 15.86 0
t/h
t/h
0 4.8 0.3 1.2 6.3
0 4.2 9.4 80.1 93.7
 What Constitutes an Ideal Plant Survey
Feed t/h Specifi gravities, g/cm3
Low range C(g) Fe11S12 Gangue Water
600 0.00 0.00 0.00 245 Water Flow, m3/h
424 0.24 0.17 4.87 0
300 1.24 0.56 11.66 0 Mass Flow, T/h
212 1.98 0.86 13.14 0
150 1.81 1.00 11.42 0
106 1.28 1.01 8.91 0 Size Interval, mic
75 0.81 0.92 6.67 0
53 0.51 0.80 4.95 0
38 0.33 0.68 3.71 0 P100, P80 y P50 minerals
0 0.81 3.72 15.95 0
t/h
0 9.0 9.7 81.3 =100.0

Mass flow of minerals, T/h Total mass flow, T/h

Mineral assays, T/h
 Incorporating a graphite pricing scheme
Graphite pricing Priicing in US$/Tonne
Screen Ap., mic Cg Purity, % Price. US$/T
min max min max min max Graphite pricing is based
Small Flake 1 75 80 97 600 1,200
Medium Flake 75 150 90 98 900 1,500 on flake size and purity
Large Flake 150 180 93 98 1,300 1,800
Jumbo Flake 180 300 95 98 1,600 4,000
Battery Grade Flake 300 1000 99.9 99.9 5,000 20,000

/ = 8.31 106 3.466 + 5.46 104 3.183 It can be expressed

mathematically

Assay Pricing Revenue Ore Worth

Size, mic
1 Small Flake
T/h Conc
2.14
%C(g)
93.72
$/Ton
1,032
Tot $/Hr
2,212
$/T so it can be
75 Medium Flake 3.12 93.97 1,067 3,323 incorporated in the
150 Large Flake 1.77 93.62 1,318 2,327
180 Jumbo Flake 3.18 92.98 1,551 4,927 model
TOTALs 10.20 12,789 127.89
Giving a stream a monetary value
tons / hour %Cg Precio,$/T
Low range Midpoint C(g) Fe11S12 Gangue Water $/T
600 714 0.02 0.00 0.00 29.779 92.7 $ 36,420
424 505 0.17 0.00 0.01 0 92.5 $ 11,647
300 357 0.63 0.01 0.04 0 92.6 $ 4,199
180 240 2.13 0.03 0.13 0 93.1 $ 1,559
150 178 0.96 0.01 0.05 0 93.6 $ 1,320
106 126 1.66 0.02 0.09 0 93.9 $ 1,126
75 89 1.23 0.02 0.06 0 94.1 $ 1,073
53 63 0.78 0.01 0.04 0 94.1 $ 1,055
38 45 0.46 0.01 0.02 0 94.0 $ 1,045
0 25 0.76 0.01 0.04 0 93.2 $ 1,014

8.8 0.1 0.5 9.4 $ 1,714

 Giving a stream a flotability
Rmax K
C(g) Fe11S12 Gangue C(g) Fe11S12 Gangue
96.5 21.6 0.0 3.79 0.00 0.24
97.3 37.32 9.4 3.36 0.07 0.22
97.9 48.18 15.8 2.95 0.12 0.20
98.5 54.49 19.5 2.58 0.16 0.18
98.9 56.52 20.8 2.23 0.19 0.17
99.3 54.55 20.1 1.91 0.21 0.15 Rmax Conc K
99.6 48.85 17.7 1.62 0.22 0.14 C(g) Fe11S12 Gangue C(g) Fe11S12 Gangue
99.8 39.70 14.0 1.36 0.22 0.12
100.0 44.8 0.4 3.79 0.00 0.24
99.9 27.39 9.3 1.12 0.21 0.11
100.0 99.6 99.2 3.36 0.07 0.22
100.0 0.00 0.0 0.77 0.18 0.09
100.0 99.6 98.8 2.95 0.12 0.20
100.0 99.6 98.1 2.58 0.16 0.18
100.0 99.4 96.8 2.23 0.19 0.17
100.0 99.0 94.3 1.91 0.21 0.15
100.0 98.3 89.6 1.62 0.22 0.14
100.0 96.5 80.8 1.36 0.22 0.12
100.0 91.9 64.3 1.12 0.21 0.11
100.0 0.0 0.0 0.77 0.18 0.09

Rmax Tails K
C(g) Fe11S12 Gangue C(g) Fe11S12 Gangue
76.1 21.6 0.0 3.79 0.00 0.24
81.3 35.6 7.6 3.36 0.07 0.22
86.5 44.8 13.1 2.95 0.12 0.20
90.9 49.9 16.4 2.58 0.16 0.18
94.4 51.0 17.8 2.23 0.19 0.17
96.7 48.5 17.4 1.91 0.21 0.15
98.3 42.5 15.5 1.62 0.22 0.14
99.2 33.8 12.4 1.36 0.22 0.12
99.7 22.8 8.3 1.12 0.21 0.11
100.0 0.0 0.0 0.77 0.18 0.09
Grinding
Mill

FKT
FS1
Floatability can be
FS
300

212

53

PAN
FS2
FS3
FS4
Flotacin
Cell
determined
C1
C2
C3
C4

TS1
TS2
t4
300

TS 212 TS3
TS4
t3
53

PAN

t2
t1

Recuperacin

Tiempo
 Determination of pulp kinetics
t4
t3 Malla 1 Rec1 = ( 1 e-k1t )Rmax1
t2 Malla 2 Rec2 = ( 1 e-k2t )Rmax3
t1
TOTAL RecT = ( 1 e-knt )RmaxT
Malla 3 Rec3 = ( 1 e-k3t )Rmax3
Recuperacin

Malla 4 Rec4 = ( 1 e-k4t )Rmax4

(1-e-knt)Rmaxn =
Tiempo
Rmax = a + b.ln(dp) + c.ln(dp)2 + d.ln(dp)3
The existence of trends is k = e + f.ln(dp) + g.ln(dp)2 + h.ln(dp)3
part of nature
dp= tamao de partcula
 Circuit configuration-Starting off
Capacity and grades
Abide by lab conditions, specially if it requires
a special item of attention..i.e. impurities
Special Regrinding conditions?
Attrition?
Step regrind/flotation
Product purity in jeopardy
Final concentrate examination

muscovita
 Circuit Configuration
Design Criteria (Capacity and grades)
Abide by lab conditions
Equipment
Equipment CAPEX
OPEX of the operation
Sales contract for the concentrates
 Starting with a generic circuit
FEED Rougher
Ro TAIL

Scv TAIL
Cleaner
Scavenger

R
You do not have to try it in the lab
You model it first
2nd Cl
You are looking for a circuit that works
Once found you can try it in the lab
CONC
Optimizing the Roughers
FEED
40 m3 cells
Ro TAIL

Scv TAIL

CONC
 Optimizing the Roughers Rougher Cells 4 6 8 10 12
CAPEX Flotation Cells k$/Y 24,927 28,648 32,369 36,090 39,811
Verti Mills k$/Y 1,430 1,430 1,430 1,430 1,430
CAPEX Other k$/Y 110,000 110,000 110,000 110,000 110,000
TOTAL Capex k$/Y 136,357 140,078 143,799 147,520 151,241
OPEX Rest of Plant k$/Y 41,400 41,400 41,400 41,400 41,400
Flotation + Reg k$/Y 3,500 3,900 4,400 4,800 5,300
TOTAL OPEX k$/Y 44,900 45,300 45,800 46,200 46,700
TOTAL Revenues k$/Y 96,370 106,270 110,140 111,930 112,830
NET Profit (Excl Tax) k$/Y 51,470 60,970 64,340 65,730 66,130

NPV, US$ MM 164.0 213.0 229.0 233.0 232.0

%IRR 36.0% 42.2% 43.5% 43.3% 42.5%

FEED Ro TAIL

R
Scv TAIL

CONC
Optimizing the 1st Cl and Cl-Scavenger
FEED
Ro TAIL
40 m3 cells

Scv TAIL

CONC
 Optimizing the 1st Cl and Cl-Scavenger
# Cells 6 8 10 12
CAPEX Crushing and Grinding 3.50
CAPEX Flotation Cells k$/Y 28,648 32,369 36,090 39,811
Verti Mills k$/Y 1,430 1,430 1,430 1,430
CAPEX Other k$/Y 110,000 110,000 110,000 110,000
TOTAL Capex k$/Y 140,078 143,799 147,520 151,241
OPEX Rest of Plant k$/Y 41,400 41,400 41,400 41,400
Flotation + Reg k$/Y 3,900 4,400 4,800 5,300
TOTAL OPEX k$/Y 45,300 45,800 46,200 46,700
TOTAL Revenues k$/Y 91,560 94,400 95,770 97,080
NET Profit (Excl Tax) k$/Y 46,260 48,600 49,570 50,380

NPV, US$ MM 131.0 141.0 143.0 144.0

%IRR 30.8% 31.6% 31.4% 31.1%

FEED 40 m3
cells
Ro TAIL

40 m3
cells

R Scv TAIL

CONC
 Optimizing the Regrind Section
ROUGHERS

40 m3 cells

Ro Tail

CL-SCAV

REG 1
160 kW
40 m3 cells
Cl Tail
1ST CL

40 m3 cells

Final Conc
REG 2
50 kW
2ND CL
2.25 m diam x 12m
 Optimizacion Remolienda

Name of Stage New Feed to Regrind, t/h % Passing Feed

Reg 1 Cg Fe11S12 Gangue
WaterORE Cg Fe11S12 Gangue = ORE
600 0.000 0.00 0.00 0.00 100.0 100.0 100.0 100.0
424 0.24 0.02 0.29 0.55 97.9 99.1 96.5 97.5
300 1.27 0.15 1.15 2.56 87.1 93.1 82.3 86.0
180 3.09 0.51 2.35 5.95 60.6 72.2 53.2 59.2
150 1.01 0.24 0.76 2.01 52.0 62.6 43.8 50.2
106 1.56 0.46 1.16 3.18 38.6 43.9 29.5 35.9
75 1.11 0.40 0.78 2.29 29.1 27.8 19.8 25.6
53 0.80 0.29 0.49 1.58 22.2 16.0 13.8 18.5
38 0.59 0.18 0.29 1.06 17.2 8.8 10.2 13.7
0 2.01 0.22 0.82 3.05 Slope 0.71 0.57 0.69 0.91
Intercept 0.19 0.57 0.20 -0.28
11.7 2.5 8.1 22.2 Pm 601 601 601 320
P80 266 215 288 251
P50 137 95 146 149
Optimizing the Regrind Section
Regrind #1 Calculation module
Cg Fe11S12 Gangue Total Ore
SE Reg, kWh/T 1.96 0.44 1.41 3.81
Wi , kWh/T 47 11 12 29.91
P80 229 195 205 216
F80 257 217 284 247

2
10
80 =
10
+
800.5
 Regrind Optimization
P80 294 280 265 234 172
CAPEX Flotation Cells k$/Y 32,585 32,585 32,585 32,585 32,585
Verti Mills k$/Y 33 163 325 650 1,300
CAPEX Other k$/Y 110,000 110,000 110,000 110,000 110,000
TOTAL Capex k$/Y 142,617 142,747 142,910 143,235 143,885
OPEX Rest of Plant k$/Y 41,400 41,400 41,400 41,400 41,400
Flotation + Reg k$/Y 4,000 4,000 4,100 4,200 4,400
TOTAL OPEX k$/Y 45,400 45,400 45,500 45,600 45,800
TOTAL Revenues k$/Y 97,460 97,080 96,750 96,180 95,230
NET Profit (Excl Tax) k$/Y 52,060 51,680 51,250 50,580 49,430

NPV, US$ MM 161.0 159.0 156.0 152.0 145.0

%IRR 34.6% 34.3% 33.9% 33.3% 32.3%
ROUGHERS

40 m3
cells
Ro Tail

CL-SCAV
REG 1
40 m3
cells Cl Tail

1ST CL 40 m3
cells

Final Conc
REG 2

2ND CL
 Column Optimization Column Diameter 1.50 1.75 2.00 2.25 2.50
CAPEX Flotation Cells k$/Y 31,952 32,158 32,369 32,585 32,805
Verti Mills k$/Y 1,365 1,365 1,365 1,365 1,365
CAPEX Other k$/Y 110,000 110,000 110,000 110,000 110,000
TOTAL Capex k$/Y 143,317 143,523 143,734 143,950 144,170
OPEX Rest of Plant k$/Y 41,400 41,400 41,400 41,400 41,400
Flotation + Reg k$/Y 4,300 4,300 4,300 4,400 4,400
TOTAL OPEX k$/Y 45,700 45,700 45,700 45,800 45,800
TOTAL Revenues k$/Y 102,050 104,370 111,520 114,160 105,290
NET Profit (Excl Tax) k$/Y 56,350 58,670 65,820 68,360 59,490

NPV, US$ MM 184.0 197.0 237.0 251.0 201.0

%IRR 37.7% 39.4% 44.7% 46.4% 39.8%
Recovery 98.2 98.2 98.2 98.3 98.3
Grade 94.9 95.1 96.0 96.2 95.4
 Concentrate Pricing

Assay Pricing Revenue Assay Pricing Revenue

T/h Conc %C(g) $/Ton Tot $/Hr T/h Conc %C(g) $/Ton Tot $/Hr
Small Flake 2.30 98.20 1,197 2,755 Small Flake 2.29 85.03 757 1,733
Medium Flake 4.38 98.32 1,228 5,376 Medium Flake 2.60 85.23 789 2,051
Large Flake 1.61 98.14 1,485 2,383 Large Flake 1.87 85.14 1,050 1,964
Jumbo Flake 2.03 97.86 1,729 3,502 Jumbo Flake 3.80 85.19 1,306 4,965
TOTALs 10.31 14,017 TOTALs 10.56 10,713

Concentrate Tonnage Distribution Concentrate Tonnage Distribution

2.0 3.0
Mineral tonnage, t/h

Mineral tonnage, t/h

2.5
1.5
2.0
1.0 1.5
1.0
0.5
0.5
- -
600 424 300 180 150 106 75 53 38 0 600 424 300 180 150 106 75 53 38 0
Screen Opening, mic Screen Opening, mic
C(g) Fe11S12 Gangue C(g) Fe11S12 Gangue
 Conclusions
Modeling advances and better computing
power allow us to model plants based on size
classes.
One can apply the graphite pricing to other
base materials in order to optimize the value
of sales.
Flotation equipment is no longer sized with
factors. They are now designed based on
economics.