Optimization of the flotation process of copper ore

with high pyrite and clays bearing in seawater

utilizing response surface methodology.
María P. Arancibia-Bravo, Freddy A. Lucay, Jean López, José
Mercado, Felipe D. Sepúlveda, Luis A. Cisternas
CONTENDS

1 Introduction

2 Methodology

3 Results

4 Conclusions
INTRODUCTION: MOTIVATION

<0.3% 28%

Challenges

46%
Principal challenges Reference: www.cochilco.cl
SUPERFICIAL RESPONSE METHODOLOGY AND ARTIFICIAL NEURAL
NETWORKS
2^k

DoE Methodology ANN-SI

RSM
METHODOLOGY

Mineral characterization of copper

72.22%
METHODOLOGY Mineral characterization of iron

25.93%
METHODOLOGY Mineral characterization of clays

25.93%
METHODOLOGY
STEP 1
Experimental design
“DoE”

RSM involves three

steps:

STEP 2 STEP 3
Response Surface Experimental
methodology validation
“RSM”

Optimal operational
condition
“ANN-SI”
METHODOLOGY Box-Behnken design
In BBD, the 𝑁 = 2𝑘 𝑘 − 1 + 𝐶𝑜
STEP 1 experimental
Response surface points are located
“RSM” on a 3D cube
equidistant from
central point.

STEP 2
Second-order polynomial
𝑘 𝑘 𝑘

𝑦 = 𝛽0 + 𝛽𝑗 𝑋𝑗 + 𝛽𝑗𝑗 𝑋𝑗2 + . 𝛽𝑖𝑗 𝑋𝑖 𝑋𝑗 + 𝜀

𝑗=1 𝑗=1 𝑖<𝑗=2

METHODOLOGY
STEP 2
Optimal operational
condition
“ANN-SI”

Mathematically, the output of the

ℎ
network is computed as:
𝑦𝑖 = 𝑤𝑗𝑖 𝜑𝑗 (𝑥
𝑗=1

The activation function used in this work 2

𝑥 − 𝑐𝑗
was the gaussian radial basis function: 𝜑𝑗 𝑥 = 𝑒𝑥𝑝 − 2
2𝜎𝑗2

The position of the particles in 𝑖

𝑣𝑗+1 = 𝑤 ∙ 𝑣𝑗𝑖 + 𝑐1 𝑟1 ∙ (𝑝𝑗𝑏𝑒𝑠𝑡 − 𝑥𝑗𝑖 ) + 𝑐2 𝑟2 ∙ (𝑝𝑗𝑖 − 𝑥𝑗𝑖
PSO is updated according to its
velocity: 𝑖
𝑥𝑗+1 = 𝑥𝑗𝑖 + 𝑣𝑗+1
𝑖
CASE STUDY

Factors selection
criteria for
experimental tests

Coded variable level

Factors Low Center High
-1 0 1
XA : Air flow, cm/s 0.34 0.51 0.68
XP :Particle size, µm 150 210 250
XC : Collector, gpt 8 12 16
XF : Frother, gpt 7 13 19
RESULTS
Test 6 show the
Copper recovery obtained by DoE . best performance
for Cu in grade
and recovery

Test 6 operate
conditions

Air p80 Collector Frother

cm/s µm ppm ppm
1 0 -1 0

Cu=80.5%
Fe=27.3%
RESULTS
Determination of the optimal conditions

ANN-SI optimised
parameters increase
Cu recovery and
reduce Fe

Air p80 Collector Frother

cm/s µm ppm ppm

0.5334 180 11.54 15.38

Cu=81.06%
Fe=35.3%
RESULTS
Metamodels and sensitivity analysis in copper recovery.

A) Polynomial model for BBD B) ANN-SI model.

RESULTS
Copper recovery and ANN-SI optimization.
RESULTS Iron recovery and ANN-SI optimization.
CONCLUSION

• The sensitivity analysis of both techniques (BBD

and ANN-SI) only has one coincidence, and which
is the most sensitive parameter was Air flow, but
for the other parameters they do not match, in
addition, RSM shows a different behavior under
the same conditions of collector and frothers
deuces, generating false optima in the case of the
BBD.
• One of the main difficulties of this investigation
was the low copper grade and the high content of
clays, producing a greater variability of the
recovery data.
ACKNOWLEDGEMENTS

CSiro Fondecyt

Authors thank the L.A.C thanks the financial

financial support from support from CONICYT
INNOVA CORFO Projects (Fondecyt 1180826).
Csiro Chile 10CEII-9007.

Universidad de Antofagasta Mathiesen S.A.C.

Doctoral program Fabrizio Colombo,
of Minerals Technical and
processing Commercial Assistance
Engineering Engineer .
ABOUT US

PhD. Freddy Lucay Jean López

Académico Estudiante
Pontificia Universidad Universidad de Antofagasta
Católica de Valparaíso

José Mercado PhD. Felipe Sepúlveda PhD. Luís Cisternas

Estudiante Académico Académico
Universidad de Antofagasta Universidad de Antofagasta Universidad de Antofagasta