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Article history:
Received 4 August 2010
Received in revised form 20 February 2011
Accepted 3 April 2011
Available online 12 April 2011
Keywords:
Grinding environment
Copper sulphides
Flotation
a b s t r a c t
The reported effects of the grinding method and grinding medium upon the otation performance of sulphide
minerals has shown that the pulp chemical environment, the ore composition, the properties and type of the
grinding media, the size reduction method employed, pre-conditioning stages prior to otation, and reagent
interactions during grinding (and conditioning) can inuence the subsequent otation process. These factors
are reviewed and discussed in relation to the otation of copper sulphide minerals.
Galvanic interactions between sulphide minerals and steel grinding media increase iron levels, lower the
dissolved oxygen concentration in the slurry, and result in the formation of iron hydroxides. These changes
can be deleterious to copper otation. It has been shown that chrome alloy balls can have benecial effects on
otation performance in some systems by limiting the formation of hydroxides in the pulp. As well, galvanic
interactions between the sulphide minerals can occur, depending on the mineralogy of the ore, and they can
inuence the separation efciency in otation.
While reagent additions, such as collector, lime, or cyanide, during milling can alter the pulp chemistry during
grinding, there is little clear evidence in the literature that their addition during grinding has any strong
inuence on the subsequent oatability of copper sulphide particles.
Improvements in copper recovery by otation following fully autogenous milling in comparison with
conventional milling using steel rod and ball mills at the same grind size have been noted in several laboratory
and plant studies.
Crown Copyright 2011 Published by Elsevier B.V. All rights reserved.
Contents
1.
2.
3.
4.
Introduction . . . . . . . . . . . . . . . . . . . . . . . . .
Chemical interaction of grinding media and sulphide minerals .
2.1.
Effect of pulp potential . . . . . . . . . . . . . . . .
2.2.
Effect of galvanic interactions between sulphide minerals
2.3.
Effect of dissolved oxygen . . . . . . . . . . . . . . .
2.4.
Effect of oxyhydroxide species . . . . . . . . . . . . .
2.5.
Effect on froth characteristics . . . . . . . . . . . . .
Physical effects of media type . . . . . . . . . . . . . . . .
3.1.
Sources and nature of wear detritus . . . . . . . . . .
3.2.
Inuence of media composition . . . . . . . . . . . .
3.3.
Relevant laboratory ndings . . . . . . . . . . . . . .
3.4.
Corrosion control . . . . . . . . . . . . . . . . . . .
3.5.
Flotation of wear detritus . . . . . . . . . . . . . . .
3.6.
Methods for removing wear detritus . . . . . . . . . .
Effect of added reagents . . . . . . . . . . . . . . . . . . .
4.1.
Collector . . . . . . . . . . . . . . . . . . . . . . .
4.2.
Lime . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.
Sodium sulphide . . . . . . . . . . . . . . . . . . .
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2
2
2
3
4
4
5
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6
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8
8
W.J. Bruckard et al. / International Journal of Mineral Processing 100 (2011) 113
4.4.
Cyanide . . . . . . . . . . . . . . . .
4.5.
Wood extracts . . . . . . . . . . . .
5.
Effect of the gaseous atmosphere during milling
6.
Effect of grinding method . . . . . . . . . .
6.1.
Autogenous grinding . . . . . . . . .
6.2.
Semi-autogenous grinding . . . . . . .
6.3.
Re-grinding . . . . . . . . . . . . . .
6.4.
Dry grinding . . . . . . . . . . . . .
7.
Summary . . . . . . . . . . . . . . . . . .
Acknowledgements . . . . . . . . . . . . . . . .
References . . . . . . . . . . . . . . . . . . . .
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1. Introduction
Wet milling in ball mills followed by otation is the general
practice employed in the beneciation of copper sulphide ores in
which the major minerals of commercial signicance typically are
chalcopyrite (CuFeS2), bornite (Cu5FeS4), covellite (CuS) and chalcocite (Cu2S). The otation response of ground minerals can be
inuenced by the grinding conditions used, including interaction of
the minerals with the grinding media, the generation or presence of
oxyhydroxide species in the pulp, the gaseous atmosphere used in the
milling, the effects of any added reagents or chemicals, and the type of
grinding method employed. The complex interactions that occur
between sulphide minerals in the ore assemblage, and between the
sulphide minerals and the grinding media, are poorly understood. In
general these interactions are thought to occur through the aqueous
phase by dissolution and re-deposition of metal ions or their
hydrolysis products, direct electrochemical interaction (galvanic
coupling), and in situ surface reactions, for example oxidation.
The specic topic of galvanic coupling, or interaction between
sulphide minerals and grinding media, has attracted much attention
in recent years. Despite numerous studies on the effect of galvanic
interactions during grinding, there is little documented evidence of
the effects of the milling environment on the subsequent stage of
otation, particularly for plant operations. Much laboratory work has
been conducted on isolated minerals, in solutions only, in small-scale
otation cells at low pulp density, or in batch laboratory grinding mills
using media and conditions unseen and impracticable in modern
sulphide concentrators. These limitations were seen by Graham and
Heathcote (1982) who reduced the efciency of their laboratory
otation cell and added metallic iron to lower the levels of dissolved
oxygen in the pulp to better simulate plant conditions.
Evaluating changes at plant scale often is costly, due to tests
usually being run over a prolonged period of time to ensure the effects
of any changes in the circuit are clearly seenconducting on-off plant
trials will rarely produce statistically reliable information. The
development of the Magotteaux Mill (Greet et al., 2004) has allowed
better simulation of laboratory and plant conditions by enabling the
pH and pulp potential to be controlled during grinding and postgrinding conditioning (Pietrobon et al., 2004).
The key factors such as media-mineral interactions, milling
methods, media type, (copper) mineral properties, redox potential
and hydroxide effects, and the inuence of the gaseous environment
are discussed in detail in this review. It should be noted that there is
much overlap between many of these factors with respect to their
effects on otation of copper sulphides.
2. Chemical interaction of grinding media and sulphide minerals
Sulphide minerals are generally more noble electrochemically
than steel grinding media (balls, rods, and liners) and consequently
develop higher rest potentials under most conditions (Rao et al., 1976;
Yelloji Rao and Natarajan, 1989a). During the intimate contact in
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8
8
8
9
9
10
10
10
11
11
12
Fe 2OH
FeOH2 2e
FeOH2 OH
FeOH3 e
4OH
W.J. Bruckard et al. / International Journal of Mineral Processing 100 (2011) 113
2X
X2 2e
MS 2X
MX2 S 2e
0:5O2 H2 O 2e
2OH
5
6
The pulp potential will control the extent of these reactions, and so
inuence the efciency of otation. These reactions will also modify
the pulp potential, but only to a limited extent.
Yuan et al. (1996b) have speculated that the effect of pulp
potential during otation dominates over other effects. All other
things being equal, once the pulp potential reaches the threshold level
necessary for otation, copper sulphide minerals generally oat well,
and as such, their oatability is independent of the previous grinding
conditions.
2.2. Effect of galvanic interactions between sulphide minerals
The effects of galvanic interactions between sulphide minerals and
grinding media need to be considered in conjunction with the
galvanic interactions that occur between sulphide minerals. This has
been discussed by Rao and Finch (1988), Cheng and Iwasaki (1992),
Cheng et al. (1993, 1999), and Li and Iwasaki (1992). Their laboratory
ndings all t a similar theoretical background. Galvanic interaction
or coupling can occur when two sulphide minerals are brought into
contact. Each metal sulphide mineral (MS) has a different electrochemical reactivity indicated by its rest potential, which can be
represented by the following redox equilibrium:
2
MS M
S 2e
E E RT=2F lnaM2
8
0
W.J. Bruckard et al. / International Journal of Mineral Processing 100 (2011) 113
W.J. Bruckard et al. / International Journal of Mineral Processing 100 (2011) 113
W.J. Bruckard et al. / International Journal of Mineral Processing 100 (2011) 113
W.J. Bruckard et al. / International Journal of Mineral Processing 100 (2011) 113
4.1. Collector
3.5. Flotation of wear detritus
Flotation of wear detritus, either inadvertently or deliberately, in
the treatment of copper ores is rarely considered. However, this can
be an important factor when using nickel-containing grinding balls
because the contained nickel can contaminate the nal copper concentrate leading to increased electro-rening problems in the nal
stages of the production of pure copper.
Woodcock (unpublished data) studied some aspects of this
problem using Ni-hard balls and ceramic pebbles for comparison
during grinding, and typical laboratory otation procedures on 500 g
ore charges. It was found that the amount of Ni-hard abraded from the
balls was comparable with that obtained on similar ores to those used
in the tests. It was also found that the amount of Ni-hard reporting in a
copper rougher concentrate, based on nickel assays, was about 5% of
that abraded. The increase of the nickel content of the concentrate
ranged from about 13 ppm to 33 ppm, depending on the quantity of
concentrate produced. That is, low grade ores showed the larger
increases because less concentrate was produced.
The effect of pH was uncertain, but more Ni-hard seemed to oat in
slightly acid solution, but there was not much difference between
soda ash and lime circuits. Collectors such as ethyl xanthate, secondary butyl xanthate, or Aerooat 208 seemed to oat about the
same amount of Ni-hard. There was some evidence that Reagent 404
oated more Ni-hard than the other collectors.
3.6. Methods for removing wear detritus
If it is shown that wear detritus is detrimental to otation of
copper sulphides in a particular operating plant, then consideration
could be given to changing the grinding media or to removing the
detritus from the otation feed. Changing the media to something less
detrimental could be a cost-effective approach, provided a material is
available.
It may be possible to remove the detritus, at least partly, by
gravity separation, magnetic separation, or both. All ferrous media
have a high density (about 11 g/cm3), which is useful for gravity
W.J. Bruckard et al. / International Journal of Mineral Processing 100 (2011) 113
4.2. Lime
Lime (as CaO or Ca(OH)2) is added to many copper sulphide
otation plants, partly as a pH modier to depress iron sulphides, and
partly to improve, in general, the oatability of copper sulphide
minerals.
Kalapudas et al. (2000) and Leppinen et al. (1998) conducted
laboratory and pilot plant grinding and otation studies on a porphyry
copper ore. They found that the reducing effect of iron, caused by
grinding in a mild steel environment, could be largely eliminated by
adding lime to the mill. They conrmed that the copper sulphides
present (chalcocite and chalcopyrite) oated more strongly after noniron or autogenous grinding, but also conrmed that the lime addition
to the grind could compensate for the differences between the
grinding methods, in most cases obtaining similar otation results
from the two different grinding environments. They found that
dissolved oxygen concentrations were much lower with mild steel
grinding than with autogenous grinding but levels were the same
when the lime was added. They attributed the effects of the lime to its
role in eliminating dissolved iron ions in the ground slurry by the
precipitation of iron hydroxide species favoured at the alkaline pH
levels generated by the lime addition. However, the deleterious effects
on otation caused by the precipitation of iron hydroxides were
largely ignored. This would seem to indicate that hydroxide effects
were not important in otation for the ore tested. The amount of lime
added to milling was unfortunately not quoted and no size-by-size
data were presented.
Grano (2010) showed that, with addition of lime to a laboratory
grinding mill to obtain pH values above ten, pyrite recovery was
markedly decreased while chalcopyrite recovery and its otation rate
were increased. In practice these results indicate that addition of lime
in grinding to passivate, or oxidise, the pyrite would allow collector
added after grinding to be directed towards chalcopyrite, and not
pyrite, resulting in improved otation performance.
the ne sizes. It was speculated that the ne particles may have been
more oxidised than the coarse particles in the ores and hence the
greater improvement in copper oatability was for the minus 10 m
size fractions. Unfortunately, no account of the effects of NaHS on
frothing and hence entrainment was considered. Of note is that in the
paper by Orwe et al. (1998) there is reference to other unpublished
work by the same authors of improved copper recoveries from an
unspecied monzodiorite ore by NaHS additions to the laboratory
grinding mill (rather than after grinding). It should also be noted that
oxidation of minerals like chalcocite and digenite can occur not only
during milling but also in re-grinding and otation.
4.4. Cyanide
Cyanide is a reagent commonly added in copper sulphide otation
circuits to help depress pyrite otation. Often all, or a portion, of the
cyanide addition is made to the mill ahead of otation. Its presence
can also affect the otation of copper minerals. Grano et al. (1994)
found in plant and laboratory studies at Mount Isa that chalcopyrite
otation was retarded by excess cyanide addition to the milling
circuit. Data obtained from plant studies where a conventional
grinding circuit (crusher/rod mill/two stage ball milling) and a
modern circuit (fully autogenous grinding/one stage ball milling)
were compared showed that the onset of chalcopyrite depression
occurred at lower cyanide additions for the autogenous line. The
authors proposed mechanisms for cyanide depression of chalcopyrite
and for the differences observed between the results from the two
different milling circuits are not discussed here. However, of
importance here are the size-by-size data presented for the study
which show that, for both the conventional and autogenous circuits
the recovery of chalcopyrite from the ne (10 m) size fractions
remains unchanged when sodium cyanide additions of up to 80 g/t
are made to the grinding circuit.
4.5. Wood extracts
W.J. Bruckard et al. / International Journal of Mineral Processing 100 (2011) 113
10
W.J. Bruckard et al. / International Journal of Mineral Processing 100 (2011) 113
steel charge, are more commonly used. In spite of this, much of the
research reported in the literature focuses on either fully autogenous
or conventional grinding (and otation) studies and little pilot or fullscale studies involving semi-autogenous milling are found.
Plant data from the Majdanpek copper mine in Yugoslavia (Gruji
et al., 1983) indicated improved copper metallurgy (higher copper
recovery) was possible with the use of semi-autogenous milling
(compared with conventional ball milling)they too attributed the
effects to an improved degree of liberation brought on by preferential
fracture of the copper ore along grain boundaries. No size-by-size data
were presented.
6.3. Re-grinding
In many sulphide otation concentrators, rougher concentrates,
rougher-scavenger concentrates, or other products are re-ground and
re-oated to obtain acceptable nal concentrate grades. In recent
years, tower mills (or Vertimills) and other stirred mills have been
used for this application, particularly when very ne re-ground
products are required. These mills can be charged with ne steel balls,
or pebbles, or other non-steel-based media. When non-steel-based
media or steel with modied properties (e.g. elevated chromium
levels) are used, it has been suggested (Johnson, 2002) that improved
metallurgical performances as well reduced media consumption can
be achieved. The former relates not only to a cleaner otation
system (e.g. lower iron hydroxide levels), but also to reduced reagent
consumptions and improved otation kinetics.
Improved grade-recovery responses for copper sulphide systems
have been reported by Davey (2004) when using a Metso stirred
media detritor (SMD) in copper sulphide otation plants. In one
operation, copper concentrate grades were increased by about 12%
(from 27.5% Cu to 29.8% Cu) and copper recoveries by about 1% (from
91.7% to 93.2%). However, no data were presented to substantiate or
otherwise the size or size range of the particles whose oatability was
improved as a result of the use of the detritor.
The recovery of liberated nes (up to 10 m) has been suggested to
be more affected than coarser particles by the presence of iron
hydroxides in the pulp due to the higher surface area of the nes
resulting in greater adsorption of the iron hydroxides on the surface
inhibiting collector adsorption (Johnson, 2006). Peng and Grano
(2010) reported that minus 10 m particles were more easily oxidised
than the coarser 53 + 10 m particles, resulting in a higher concentration of metal oxidation species on their surfaces. Grano (2009) has
shown that the use of a stirred mill with fully electrochemically inert
grinding media (large diameter ceramic media) can signicantly
increase recovery of a chalcopyrite ore by preventing the formation of
iron hydroxides. In practice, grinding with inert ceramic media has
been claimed to include increased recovery of ne valuable minerals,
improved selectivity between sulphide and gangue minerals and
lower collector consumption (Pease et al., 2006).
6.4. Dry grinding
In the processing of sulphide minerals, wet milling is generally
preferred to dry grinding because of the following reasons:
W.J. Bruckard et al. / International Journal of Mineral Processing 100 (2011) 113
11
same otation feed size) has been observed at CSIRO Minerals (K.R.
Weller, personal communication, 1999) to produce improved selectivity of chalcopyrite over pyrite in subsequent otation. Whether the
improved copper metallurgy is due to morphology/textural effects or
pulp potential effects is not clear. Particle size effects have also not
been established.
One side issue with dry milling relates to media wear. Media wear
rates in wet grinding have been estimated to be several times greater
than in dry grinding (Bond, 1964) and this effect is enhanced when
the grinding pulp is acidic, especially below pH 5.5.
7. Summary
This review into the effects of grinding and the grinding medium
(usually iron-based) upon the otation performance of copper
sulphide minerals has identied and discussed the key factors
important in the otation of copper sulphide minerals.
Most evaluations of the effects of grinding on otation have been
made at the laboratory scale where operating conditions are closely
controlled. While there often is debate as to whether laboratory scale
results apply at the plant scale, the key issues in evaluating media
meaningfully at plant scale relate to the high cost of the trials and the
need for prolonged testing periods to ensure a full charge of the new
media is obtained and that statistically reliable information results.
Galvanic interactions between sulphide minerals and steel media
can affect the pulp potential, dissolved oxygen level, or the extent of
iron hydroxide formation and this is often deleterious to copper
otation. The use of more inert chromium alloy balls can limit the
formation of hydroxides in the pulp with resulting improvements in
otation performance. Further research is required to understand
more fully the factors affecting the formation of hydroxides during
grinding and their effects on subsequent otation, especially that of
ne particles. There is some evidence that galvanic interactions
between sulphide minerals and media during grinding can also affect
froth stability and hence selectivity.
In addition to the interactions between the grinding media and the
sulphide minerals, there are also galvanic interactions between the
sulphide minerals themselves, and these galvanic interactions play an
important role in the separation efciency in subsequent otation.
Grinding under an inert gas (such as nitrogen) has been employed
(chiey in the laboratory) to exclude oxygen from the grinding
environment. The benets of this include minimising sulphide
oxidation, minimising corrosion effects, and minimising the formation
of iron hydroxides.
The common reagents added to milling circuits in copper sulphide
concentrators are collector, lime, cyanide, and rarely, sulphide. There
is little hard evidence in the literature that collector, lime, or cyanide
addition during grinding has any signicant effects on the oatability
of copper particles.
Numerous laboratory and plant studies demonstrate an improvement in copper recovery by otation following fully autogenous
milling when compared to conventional (steel) milling at the same
grind size. A few selected studies indicate that improved otation of
copper minerals can be achieved after dry grinding (relative to wet
milling) although in many of these studies collectorless otation has
been used.
Acknowledgements
The authors wish to acknowledge comments from CSIRO colleagues Mr Graeme Heyes and Mr Steve Suthers, the journal referees
for their critical comments and suggested changes that have improved
this review, and the assistance of CSIRO library staff in obtaining
references. Permission from Rio Tinto Australia to publish this paper is
gratefully acknowledged.
12
W.J. Bruckard et al. / International Journal of Mineral Processing 100 (2011) 113
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