An Integrated Optimisation Study of the Barrick Osborne
Concentrator: Part B – Flotation
R Crosbie1, K Runge2, C Brent3, M Korte4 and T Gibbons5
ABSTRACT
The Barrick Osborne concentrator has gone through a number of upgrades
since commissioning and steadily increased production from the original
119 t/h design capacity to 265 t/h milling throughput in 2008. This was
achieved incrementally over several years, by maximising operating
efficiencies, in order to minimise capital expenditure, and take advantages
of economies of scale; but more importantly it was reached with no
measurable loss of recovery. Osborne currently processes a blend of under-
ground with open pit material from the nearby Trekelano deposit.
Following primary/secondary crushing, the material is processed through a
rod/ball mill grinding circuit ahead of rougher/scavenger flotation that
produces a copper concentrate.
Osborne was seeking a further increase in plant throughput of the order
of 15 per cent, but at more sustainable levels of secondary crusher plant
utilisation. In early 2008, Osborne contracted Metso Minerals Process
Technology Asia-Pacific and South America (MMPT) to review the
entire process from run-of-mine feed to final copper concentrate. This
review would be done concurrently, with surveys of both the crushing/
grinding and flotation circuits being performed at the same time. The
outcome would be a steady-state model of the complete flow sheet
allowing the crushing/grinding model to interact with the flotation circuit
model such that overall process optimisation was possible. Two key
outcomes for the operation are exploration of the operating limits of the
currently installed plant, and projection of the logical next stage of
potential capital plant expansions.
This paper covers Part B or the flotation component of the project. A
separate paper discussing Part A or crushing and grinding is also being
presented at this conference.
Surveys of the Osborne flotation circuit were performed along with a
comprehensive review of the cell characteristics including measurements
of the gas and froth phases of individual flotation cells. These data
resulted in a size-by-size floatability component model of the complete
circuit. This circuit model was then used to perform steady-state simulat-
ions to evaluate options to improve both overall circuit and individual cell
performance.
The grinding circuit model discussed in a separate paper or Part A of
this project was then used interactively with the flotation circuit model to
recommend the best operating regime to maximise overall efficiency. For
example, the balance between increased crushing and grinding costs
versus higher copper recovery and final concentrate grade.
Due to changes in market conditions in the fourth quarter of 2008, the
focus was shifted to prioritising operational changes rather than capital
expansion modifications, in order to improve circuit performance.
INTRODUCTION
In conjunction with Barrick Osborne staff, Metso Minerals
Process Technology Asia-Pacific and South America (MMPT)
1. Flotation Process Engineer, Metso Minerals Process Technology –
Asia Pacific and South America, PO Box 1028, Eagle Farm Qld
4009. Email: robert.crosbie@metso.com
2. Manager – Flotation Process Technology, Metso Minerals Process
Technology – Asia Pacific and South America, PO Box 1028, Eagle
Farm Qld 4009. Email: kym.runge@metso.com
3. MAusIMM, Processing Manager, Barrick Osborne Mine, PO Box
5170, Townsville Qld 4810. Email: cbrent@barrick.com
4. Project Metallurgist, Barrick Osborne Mine, PO Box 5170, Townsville
Qld 4810. Email: mkorte@barrick.com
5. FAusIMM, Group Metallurgist, Barrick Gold of Australia, Level 10,
2 Mill Street, Perth WA 6000. Email: tgibbons@barrick.com
Tenth Mill Operators’ Conference Adelaide, SA, 12 - 14 October 2009
conducted detailed surveys of the flotation circuit at Barrick’s
Osborne concentrator during May 2008.
These surveys collected sufficient data to allow the following
scope of work to be undertaken:
• Development of a comprehensive, sized mass balance around
the flotation circuit for solids, copper, iron, sulfur, silica and
water.
• Development of a one-dimensional (unsized) floatability
component model suitable for use in JKSimFloat.
• Development of a two-dimensional (sized) floatability comp-
onent model suitable for use in JKSimFloat.
• Analysis of mass balanced and MLA derived mineralogical
information to determine the characteristics of the copper
particles lost to final tailings and the mechanisms by which
gangue reports to the final concentrate.
• Analysis of flotation cell characterisation measurements to
determine strategies for improving copper recovery rates.
• Simulation to assess different strategies for improving flota-
tion circuit performance.
• Simulation to assess the impact of changes in the crushing
and grinding circuits on flotation performance. This was
ultimately used to express the overall circuit efficiency in
terms of kilowatts of electrical energy consumed per dollar of
revenue produced.
The objective of this paper is to outline the results of this
analysis – demonstrating how modelling and simulation techni-
ques performed in conjunction with traditional mass balancing
and mineralogical analysis can provide a powerful tool for
diagnosis indicating opportunities for both flotation circuit and
total process improvement.
CIRCUIT OPERATING CHARACTERISTICS
At the time of the flotation circuit surveys, the plant was
processing 265 t/h at an 80 per cent passing size (P80) of 170 μm,
(compared with a design throughput of 119 t/h at a P80 of 106 μm).
The impact of this higher throughput has reduced circuit residence
time and has gradually increasing the feed solids concentration to
flotation from 35 per cent solids (by mass) at original commission-
ing, to approximately 52 per cent solids at present.
The circuit consists of a number of flotation banks operating
in series, the concentrate of which is combined as a final
concentrate. This is illustrated in Figure 1. All the flotation
cells are rectangular and have volumes of either 8 m3 (the
rougher, scavenger 1A and scavenger 1B cells) or 16 m3 (the
scavenger 2, pyrite rougher and pyrite scavenger cells). The
rougher cells have four peripheral launders and all other cells
have single peripheral launders.
ANALYSIS OF CURRENT FLOTATION CIRCUIT
PERFORMANCE
Copper recovery and loss mechanisms
Copper in the feed to the circuit is relatively evenly spread across
a number of size fractions with a significant proportion of ultra-
fine copper. The two-dimensional mass balance data shows that
189
R CROSBIE et al

Lime ABS
RTD MIBC RTD/MIBC

Rougher
Scavenger 1A
Scavenger 1B Scavenger 2

pH = 8.4
Grinding
Circuit

Pyrite Rougher Pyrite Scavenger

Final Tail

Final
Concentrate

FIG 1 - Osborne flotation circuit configuration.

the majority of copper losses occur in the coarse (+106 μm) and 100
ultra-fine (-CS5) size classes with 75 and 12 per cent of the 90
copper present in the final tailings stream being accounted for by
80
these respective size classes. This is illustrated in Figure 2.
70
Copper
Recovery (%)

35 60
Sulphur
50
30 Iron
40 SiO2
Copper Distribution (%)

25 30

20
20
Feed
10
Tailing
15 0
-CS5

+106 μm
+150 μm
+212 μm
+300 μm
+425 μm
+38 μm
+53 μm
+75 μm
CS5
CS4
CS3
CS2
CS1

10

5 Size Fraction

0
FIG 3 - Recovery as a function of size.
+5 μm
μm

+1 μm

+ 1 μm
+2 μ m

+3 μm

+4 m
μm
μ
8
3

5
06

50
12

00

25
+3

+7

Size Fraction
40

FIG 2 - Copper distribution in the Osborne flotation feed and final 35

tailings.
30

Figure 3 shows the recovery of copper, iron, sulfur and silica 25

as a function of particle size. Recovery of copper is optimum in Wt% in Feed

20
the cyclosizer fractions with significant drops in recovery for
15
material coarser than 75 μm. There is also a smaller drop in
recovery for copper in the ultra-fine -CS5 size fraction. It is 10
therefore concluded that the copper lost to final tailings is +300
5
predominantly coarse in size and exhibits low recovery in the +150
+106
circuit. It is necessary to understand the reason for this coarse Size (μm)
+53
0

particle recovery loss in order to develop strategies for improving +CS5 50-80 80-100
100%
30-50
copper recovery. 0-10
10-30
Degree of Liberation (%)
Copper in the flotation feed occurs almost completely as
chalcopyrite and is very well liberated, even at the relatively
coarse P80 utilised, (with only 5.6 per cent of the chalcopyrite FIG 4 - Chalcopyrite distribution in the Osborne flotation feed
being less than 50 per cent liberated). This is illustrated in Figure 4 (+CS5).
which shows the chalcopyrite liberation distribution in the +CS5
fractions of the flotation feed. Liberation was found to be poorer which showed a significant proportion of chalcopyrite that was
as particle size increased but it was only the +300 μm material less than 50 per cent liberated. This may be seen in Figure 5.

190 Adelaide, SA, 12 - 14 October 2009 Tenth Mill Operators’ Conference

 AN INTEGRATED OPTIMISATION STUDY OF THE BARRICK OSBORNE CONCENTRATOR: PART B – FLOTATION

16
90

80 14

70 12
60
10
50 Wt% in each Size
8 Wt% in Tailing
Class
40
6
30
4
20
+300 +300 2
+150 10 +150
+106 0
+106 0
Size Size
+53 +53
100% 100%
+CS5 80-100 +CS5 50-80 80-100
50-80 30-50
30-50
0-10 10-30 10-30
0-10
Degree of Liberation (%) Degree of Liberation (%)

FIG 5 - Proportion of chalcopyrite in each liberation class in each FIG 7 - Proportion of chalcopyrite in each liberation class in each
size class of the Osborne flotation feed (+CS5). size class of the Osborne final tailings (+CS5).

Degree of particle liberation does have a significant impact on in the final tailings is fast-floating, 62 per cent is slow-floating
the recovery achieved, particularly for the coarser particle sizes. and 36 per cent is non-floating). This implies that coarse
This may be seen in Figure 6. Recovery of all liberation classes liberated copper is floating slowly in the circuit when it should
is much lower than expected though and based on previous be floating rapidly and be recovered after a very short residence
MMPT experience, chalcopyrite particles more than 50 per cent time – an indication that insufficient collection (or copper
liberated would be expected to float very quickly and exhibit depression) is occurring in this circuit. It was speculated by
MMPT that the formation of iron-hydroxide coatings on copper
very high recovery in the circuit in all size classes.
mineral surfaces would be consistent with all the observed
findings and is therefore considered as one of two major
100
mechanisms responsible for copper losses in this circuit (the
90 second mechanism is believed to be poor cell recovery as a result
80
of low air rates in the 8 m3 cells and poor recovery across the
froth phase in the 16 m3 cells). Opportunities for improving the
Chalcopyrite Recovery (%)

70
recovery of copper are discussed in more detail throughout the
+300
60
+150
later sections of this paper.
50 +106

40
30
20
10
0 increased gangue recovery. It is therefore important to
0-10 10-30 30-50
Degree of Liberation
FIG 6 - Chalcopyrite recovery as a function of particle size and
degree of liberation.
Mineralogical analysis of the final flotation tailings revealed
that a significant proportion of liberated, coarse chalcopyrite
particles are present in this stream. This is shown in Figures 7, 8
and 9. So although liberation does have an impact on
chalcopyrite and therefore copper recovery in the circuit, poor
liberation is not the primary reason for the presence of significant
quantities of coarse copper bearing particles in the final tailings.
This result must therefore be due to either insufficient residence
time in the circuit, poor recovery of coarse particles or
insufficient collector on the chalcopyrite surfaces. Insufficient
collector on surfaces could be a consequence of lower than
required collector addition or the inability of the collector to coat
the surfaces because of the presence of other hydrophilic
coatings on the chalcopyrite surfaces.
A batch flotation test conducted on the final tailings material
suggests that there is a significant quantity of floatable copper
being lost to the tailings (a copper recovery of approximately
60 per cent was achieved during this test). This copper does float
slowly though (with the floatability component model which was
fitted to the survey data showing that two per cent of the copper
+53 Gangue recovery mechanisms
+CS5
Gangue recovery results in a lower concentrate grade. The
amount of gangue recovered to concentrate also often limits
copper recovery in that additional recovery of copper results in
an unacceptable concentrate grade because of the corresponding
50-80 80-100 100%
understand the mechanisms of gangue recovery to assist with
developing strategies to prevent it from being recovered.
The major gangue minerals present are pyrite (five per cent of
the feed), iron oxide species (45 per cent of the feed) and quartz
(21.5 per cent of the feed). The predominant gangue component
reporting to the concentrate is pyrite which exhibits a 12 per cent
recovery in the circuit (and makes up approximately 14 per cent of
the final concentrate). Pyrite is recovered across all size classes
(Figure 10) and is largely liberated (Figure 11). This suggests that
a certain fraction of pyrite in the system is floatable and is being
recovered by true flotation rather than by entrainment or as
composites with chalcopyrite.
Since pyrite is the major diluent in the final concentrate and is
recovered by true flotation, the overall concentrate copper grade
(and therefore recovery) is largely related to the pH and reagent
scheme in use and its effect on pyrite floatability. Too much
collector (or too low a pH) can potentially result in excessive
pyrite recovery and a low concentrate grade whereas too little
collector, too high a pH or too much pyrite depressant can
decrease chalcopyrite recovery rates. It should be noted that the
Osborne circuit is set up to preferentially float copper at the front
of the circuit and then encourage some pyrite recovery at the
back end of the circuit. Some pyrite recovery is desirable since
the gold is recovered together with copper to the final concen-
trate and gold recovery is believed to be linked somewhat to
pyrite recovery.

Tenth Mill Operators’ Conference Adelaide, SA, 12 - 14 October 2009 191

R CROSBIE et al

FIG 8 - Mineralogy of the Osborne final tailings (+150 μm).

FIG 9 - Mineralogy of the Osborne final tailings (+53 μm).

20
35
18
30
16
Mineral Recovery (%)

14 25

12
20
Wt% of Final
10 Concentrate
15
8
10
6

4 +300 5
+150
2 +106 0
Size
+53
0 100%
+CS5 50-80 80-100
+300 μm +150 μm +106 μm +53 μm +CS5 30-50
10-30
0-10
Size Fraction (μm) Degree of Liberation (%)

FIG 11 - Pyrite distribution in the Osborne final concentrate

FIG 10 - Pyrite recovery as a function of particle size. (+CS5).

192 Adelaide, SA, 12 - 14 October 2009 Tenth Mill Operators’ Conference

 AN INTEGRATED OPTIMISATION STUDY OF THE BARRICK OSBORNE CONCENTRATOR: PART B – FLOTATION

Pyrite depression is currently achieved by adding ammonium these variables in the cells in the Osborne circuit. These
bi-sulfate and lime to the rod mill feed to achieve a pH of 8.5. It measurements were analysed to determine the reason for the
is a possibility that iron hydroxide coatings are forming on observed low cell recoveries.
chalcopyrite surfaces under thesec onditions and contributing Bubble surface area flux (Sb) is defined as the bubble surface
towards the poor recovery of coarse, liberated chalcopyrite in the area rising up through the cross-sectional area of the cell per unit
circuit. Further studies investigating a reduction in the use of time and is proportional to the superficial gas rate (Jg) and
these pyrite depressants to determine if an increase in copper inversely proportional to the bubble size. The higher the gas rate
recovery could be achieved were recommended. and the smaller the bubble size, the faster the kinetics achieved in
Non-sulfide gangue minerals do not usually float naturally and the pulp zone of a flotation cell. The superficial gas rate was
only report to the final concentrate via entrainment or when in measured to increase down the bank with a resulting increase in
composites with floatable minerals. They thus usually exhibit low bubble surface area flux (Figure 13). The bubble surface area flux
overall recoveries but show increased recovery in both the fine was found to be very low in the rougher cells (20 - 25 m2/sec/m2
size classes (due to entrainment) and the coarse size fractions compared with 55 - 60 m2/sec/m2 in the pyrite roughers and
where liberation is incomplete. scavengers) and is therefore contributing to the lower than
One of the significant non-sulfide gangue species present in expected recoveries achieved by these cells.
the Osborne feed is quartz (which comprises about 25 per cent of
the feed). Silica assays were therefore used as an indicator for the
recovery of non-sulfide gangue. Figure 12 shows the distribution 70.0 2.0
of silica in the final concentrate. A high proportion is silica in 1.8
60.0 Sb
this stream is ultra-fine (45 per cent -CS5) which would be

Superficial Gas Rate (cm/s)

Jg 1.6
expected to be due to entrainment. This is expected in a circuit 50.0 1.4
without a cleaning stage as multiple stage flotation is the best

Sb (m /sec/m )
2
1.2
way of minimising entrainment recovery to the final concentrate. 40.0
There is also a small but significant proportion of silica in the 1.0

2
30.0
coarse size fractions, supposedly reporting due to an association 0.8
with the floating chalcopyrite particles. 20.0 0.6
0.4
10.0
50 0.2

45 0.0 0.0

40
Silica distribution (%)

35

30

25

20 FIG 13 - Superficial gas rate and bubble surface area flux

15 measured in the Osborne flotation cells.
10

5
Two causes for this low bubble surface area flux in the rougher
cells were identified, firstly the superficial gas rate to these cells
0
is low and secondly the bubbles in these cells are relatively large
μm

μm

μm

μm

μm

μm
μm

+4 m

when compared with other cells in the circuit. This may be seen
μ
8

06

50

25
12

00
+3

+5

+7

in Figure 14 which shows the Sauter mean bubble size versus

+1

+1

+2

+3

Size Fraction
FIG 12 - Silica distribution in the Osborne final flotation
concentrate.
Reducing the recovery of non-sulfide gangue to the final
concentrate could therefore be achieved by reducing the
superficial gas rate for all the measured cells in the circuit. The
rougher cells have the lowest superficial gas rates and also the
largest bubbles. Normally as the superficial gas rate is increased
the bubbles become larger (Gorain et al, 1997) but in this case
the trend is reversed. It is also known that an increase in frother
1.80

entrainment recovery of these particles (by reducing the water 1.60

recovery in the circuit or by introducing a cleaning stage) or by
Sauter mean bubble diameter (mm)

reducing the recovery of copper/non-sulfide gangue composites 1.40

(by reducing the feed particle size or regrinding and then cleaning 1.20
the final concentrate).
1.00

Cell performance 0.80

Copper recovery was found to decrease down the circuit with 0.60
recoveries in the order of 20 per cent off the first two rougher
0.40 Roughers
cells and three to five per cent off the final cells in the pyrite
scavenger bank. It is the opinion of MMPT that a copper 0.20 Other cells
recovery of 20 per cent off the first flotation cell in a circuit is
0.00
very low and that this figure should more typically be in the
0.00 0.20 0.40 0.60 0.80 1.00 1.20
order of 50 per cent.
Recovery from a flotation cell has been shown to be a function Superficial Gas Rate (cm/s)

of ore floatability, bubble surface area flux, froth recovery and

cell residence time (Gorain et al, 1997). Measurements were FIG 14 - Measured Sauter mean bubble diameter as a function of
performed on site to determine or infer the magnitude of each of gas rate.

Tenth Mill Operators’ Conference Adelaide, SA, 12 - 14 October 2009 193

R CROSBIE et al
dose is generally accompanied by a decrease in bubble size
(Grau and Heiskanen, 2005). Additional frother is added to the
circuit after the rougher bank and the data presented here would
seem to indicate that this additional reagent has resulted in a
decrease in bubble size and an increase in the bubble surface area
flux in these cells. It is concluded that bubble surface area flux
values, particularly in the rougher cells, are lower than normal
and that there is scope for increased pulp phase recovery off
these cells. This could be done by increasing the frother dose at
the head of the circuit and the gas addition rates to these cells.
The modelling methodology employed by MMPT provides a
cell scale-up number (Cscale-up) for each flotation cell in the
circuit. This scale-up number is a fitted parameter and is a
measure of the rate of flotation of the cell independent of the
cell residence time and the ore’s flotation properties. One can
compare the cell scale up of the cells in a flotation process and
any variation can be attributed to differences in the bubble
surface area flux or froth recovery of these cells. The derivation
and use of the cell scale up number for the diagnosis of a
flotation cell’s performance is outlined in detail in Runge et al,
2001.
The cell scale-up numbers derived for the Osborne flotation
cells (Figure 15) are higher for the 8 m3 cells at the head of the
bank than the larger 16 m3 cells at the end of the bank. Since
bubble surface area flux is known to be higher in the 16 m3 cells
(Figure 13), it can be concluded that low froth recoveries must be
responsible for the low scale-up numbers obtained for these cells.
0.20
0.18
0.16
0.14
Cell scale-up
0.12
0.10
0.08
0.06
0.04
0.02
0.00
Roughers Scavenger Scavenger Scavenger Pyrite Pyrite
1A 1B 2 Rougher Scavenger
FIG 15 - Fitted cell scale-up numbers for the Osborne flotation
circuit.
Froth recovery is a function of the bubble stability and the time
bubbles remain in the froth. This is in turn a function of froth
depth, froth transportation distance and froth mobility. During the
surveys, bubble stability was assessed in the cells by measuring
dynamic froth stability (Barbian, Ventura-Medina and Cilliers,
2003). The time particles spent in the froth phase was character-
ised using paper tracers and a knowledge of the froth depth and
gas rate.
Dynamic froth stability was found to decrease down the bank
as is shown in Figure 16. The total froth residence time was
observed to be significantly longer in the 16 m3 cells than the 8 m3
cells at the head of the circuit. These cells had a significantly
larger surface area and exhibited significant froth dead zones.
The presence of these dead zones is detrimental to recovery in
that particles reporting to these zones must eventually drop back
into the pulp phase, resulting in a decrease in the overall
recovery achieved by the cell. It was therefore concluded that the
lower cell recovery rates observed in the cells at the end of the
bank in Figure 15 is a consequence of lower froth recovery
caused by poorer froth stability and longer froth residence times.
In order to overcome this froth recovery problem in the 16 m3
cells it was recommended that either froth crowders be installed
194 Adelaide, SA, 12 - 14 October 2009
80
70
Froth Dynamic Stability (sec)
60
50
40
30
20
10
0
FIG 16 - Dynamic froth stability measured in several cells in the
Osborne flotation circuit.
to increase concentrate flow or a strong frother be added prior
to these cells. The use of a stronger frother would improve froth
recovery by allowing particles to be held in the froth for a
longer period of time before being lost back to the pulp phase
of the flotation cell.
It is speculated that it is difficult to achieve an acceptable
concentrate grade from these relatively large cells and high froth
recoveries at the same time. These cells are deliberately run with
concentrate only gently or intermittently flowing over the lip in
order to meet the overall concentrate grade specification but these
operating conditions are not likely to result in high froth
recoveries. Making the changes suggested should therefore
increase the recovery achieved by these cells but will, in all like-
lihood, be accompanied by a decrease in concentrate grade. The
use of a cleaning stage would therefore be beneficial since it
would allow the rougher and scavenger cells to be operated in
order to maximise recovery while the cleaner circuit could be
operated to achieve an acceptable concentrate grade. The effect
of this scenario will be investigated using simulation techniques
in the subsequent section.
SIMULATION OF ALTERNATIVE STRATEGIES
FOR FLOTATION CIRCUIT IMPROVEMENT
In the previous section, an analysis of the current circuit
conditions highlighted a number of strategies that should be
trialled in the circuit with the objective of improving metallurg-
ical performance. Where possible, simulations were performed
using the models developed as part of the project to predict the
improvement in circuit performance that would result.
Increasing residence time
Batch testing of the pyrite scavenger tailing stream indicated that
there was a significant quantity of copper (more than 60 per cent)
that was still floatable and was not being recovered in the circuit.
Simulations were performed using the circuit model to determine
if an increase in the capacity of the circuit would result in an
increase in recovery. In these simulations, new scavenger cells
were added to the end of the circuit with cell recovery rates equal
to that measured in the last pyrite scavenger cell. The results
from these simulations are summarised in Figure 17 which shows
that copper recovery increases are possible in the circuit but only
with a significant increase in the installed capacity. Doubling the
circuit capacity is only expected to increase copper recovery by
2.8 per cent.
The small recovery increase with an increase in capacity is a
function of two effects. Although there is a significant quantity
Tenth Mill Operators’ Conference
 AN INTEGRATED OPTIMISATION STUDY OF THE BARRICK OSBORNE CONCENTRATOR: PART B – FLOTATION
100
90
80
Copper Recovery (%)
70
60
50
40
Cu Recovery Current residence time
30
Baseline Cu Rec
20
Cu Grade
10
Baseline % Cu
0 20.0
0 10 20 30 40 50 60
Circuit Residence Time (min)
FIG 17 - Copper grade and recovery as a function of circuit
residence time.
of floatable copper present in the pyrite scavenger tailing, it is
predominantly slow floating (model fitting estimates the copper
present in this stream to be 2.1 per cent fast floating, 62 per cent
slow floating and 34 per cent non-floating). The poor cell
recovery rates in the last cells of the circuit (caused by poor
recovery across the froth phase) also contribute to the low
copper recovery achieved in each additional cell that is added to
the circuit.
Since very significant changes in residence time are necessary
to materially affect the copper recovery achieved this is not seen
to be a viable means of addressing the copper losses being
experienced at Osborne.
Increasing cell recovery rates
If one can increase the recovery rates of the cells in a process (by
operating at higher bubble surface area flux or froth recovery for
example) then this can be equivalent to adding additional cells to
a circuit. Cell recovery rates can be increased by increasing pulp
recovery or froth recovery. Pulp recovery is a strong function of
bubble surface area flux and opportunities to do this in the
rougher cells have already been identified. There are also oppor-
tunities to increase cell froth recovery by either stabilising the
froth or reducing the time that particles spend in the froth.
Examples of strategies which can be employed to increase cell
recovery rate include:
• the use of higher air rates (already recommended for the
rougher cells);
• the generation of finer bubbles through the use of higher
frother dosage at the head of the circuit (already
recommended prior to roughing);
• stabilisation of the froth phase through a change in circuit
chemistry (through the use of a stronger frother for
example, already recommended for the scavenger 2, pyrite
rougher and pyrite scavenger cells); and
• increasing the rate of concentrate removal (by froth
crowding or the use of shallower froth depths for example,
already recommended for the scavenger 2, pyrite rougher
and pyrite scavenger cells).
The effect of increasing cell recovery rates across the circuit
was simulated and the results obtained are summarised in Table 1
which shows that operating the existing cells more aggressively
can give similar increases in copper recovery to doubling the
installed flotation capacity.
Strategies to increase cell recovery rates are not employed by
the operators at present because they do have a deleterious effect
Tenth Mill Operators’ Conference
32.0 TABLE 1
Simulations performed using different cell recovery rates.
30.0
Cell recovery rates Final concentrate grade Cu recovery
(% Cu) (%)
Copper Grade (%)
28.0
Baseline 27.2 89.3
26.0 10% increase 27.5 90.4
20% increase 27.6 91.1
24.0
30% increase 27.0 90.2
22.0 40% increase 26.9 91.0
50% increase 26.7 91.7
70
on concentrate grade. These strategies would therefore not be
able to be employed in isolation; cleaning would be required to
achieve acceptable concentrate grade.
Cleaning of the final concentrate
As has been stated above, Osborne is a single stage flotation
circuit – a regime not very commonly used in MMPT’s
experience. Even a relatively simple flotation circuit commonly
employs a cleaning stage in conjunction with roughing. This
allows for flexibility in circuit operation; the rougher can be
operated so as to maximise recovery and the cleaner can be
operated so as to achieve the final concentrate grade required.
Because of the high degree of liberation of the Osborne ore,
very good metallurgical performance could be achieved in a single
stage rougher when the feed rate was low and the grind was fine.
With the increases in throughput and grind size, the copper
recovery achievable has been reduced and it’s likely there is scope
for improved metallurgical performance through the use of a
cleaning stage. Cleaning significantly reduces the recovery of
entrained material and sharpens the circuit’s separation efficiency
– allowing better separation between fast floating chalcopyrite and
slower floating pyrite at a particular copper recovery.
Simulations were performed using the one-dimensional model
to assess the improvement in circuit performance that would be
achievable with the use of a cleaning stage, making use of six
1.3 m3 old flotation cells available on site. The following
cleaning scenarios were evaluated:
• open circuit cleaning, rougher and scavenger bank operated
within normal operating limits;
• closed circuit cleaning, rougher and scavenger bank operated
within normal operating limits; and
• closed circuit cleaning, 50 per cent increase in cell recovery
rates off the rougher and scavenger in base case.
The results obtained for 200 Monte Carlo simulations for each
cleaner circuit configuration are summarised in Figure 18. Monte
Carlo is a technique that can be used to create multiple circuit
operation scenarios. For each scenario, the cell recovery rates of
the different banks in the circuit are randomly adjusted. This is
equivalent to an operator either pulling the banks of the process
more slowly or quickly to adjust overall circuit performance. The
grade and recovery of each simulation scenario can then be
simulated using the model to map the range of circuit operation.
Figure 18 indicates that for a similar copper recovery, a circuit
utilising the current cell recovery rates and cleaning can result in
a 2.5 to three per cent increase in grade. It is expected that this
would allow the rougher/scavenger circuit to be pulled harder in
order to obtain additional recovery. This is simulated by
increasing the cell recovery rates in the existing rougher and
scavenger cells and shows that it is possible to achieve a 2.5 to
three per cent increase in copper recovery while still maintaining
the concentrate grade benefits associated with cleaning.
Adelaide, SA, 12 - 14 October 2009 195
R CROSBIE et al

100 decrease in selectivity is due to pyrite recoveries being optimal in

the intermediate size fractions. It is therefore concluded that
95
higher recoveries of chalcopyrite are expected at a finer grind but
90 that other modifications will be necessary in order to maintain
Copper Recovery (%)

85 concentrate grade (such as a modified reagent suite and/or the

80
75
70 Baseline
65 O/C cleaning
60 C/C cleaning
55
C/C cleaning increased cell recovery rates
50
20 25 30
Copper Grade (%)
FIG 18 - Copper recovery versus concentrate grade predicted in
200 Monte Carlo simulations performed with different cleaner
configurations.
It is thus concluded that the introduction of a cleaning circuit
to the Osborne flotation circuit would be beneficial to flotation
performance allowing recovery improvements to be realised
together with improved concentrate grades.
Finer grind
Copper recovery was found to decrease significantly in the coarser
size classes and the majority of copper lost to tailings (80 per cent)
was coarser than 75 μm. It is therefore possible that a finer grind
size could increase the overall copper recovery achievable.
Surveys of the crushing and grinding circuits at Osborne
(outlined in part A of this paper) suggest that it is possible to
achieve a finer grind and it was therefore considered important to
assess the impact of grind size on flotation performance.
Using the two-dimensional flotation model, the metallurgical
performance at different grind sizes can be predicted. A
technique proposed by Bazin et al, 1994 was used to link the
grinding circuit and flotation circuit models (as demonstrated
by Runge et al, 2007). This technique enables the copper
distribution of each size class to be predicted by assuming the
cumulative copper distribution versus cumulative mass
distribution in the feed remains the same regardless of grind size.
Figure 19 shows the predicted grade versus recovery relationship
developed by running 200 Monte Carlo simulations for each
grind size. These simulations indicate that a reduction in grind
size increases the proportion of floatable copper and therefore
copper recovery achievable in the circuit. Copper recovery
increases but chalco-pyrite/gangue selectivity deteriorates. This
use of a cleaning stage). These results are also another indication
that optimising the Osborne circuit is more complex than simply
changing the feed grind size or the circuit residence times.
Although there are several ways in which the copper recovery
can be increased (increasing air addition rates, increasing froth
recoveries, a finer grind size), all of these will also impact on the
concentrate grade to some extent. It is very difficult to achieve an
increased recovery with no impact on concentrate grade in what
is essentially an open-circuit rougher.
35 40
MAXIMISING OVERALL CONCENTRATOR
EFFICIENCY
As has been demonstrated, a finer grind will give a higher copper
recovery (Figure 19). This will however be associated with the
consumption of more energy during grinding. Conversely, a
higher throughput will reduce the flotation residence time and
therefore reduce recovery but will generally reduce the specific
energy consumption during grinding. Optimisation of the overall
concentrator efficiency must therefore take both the energy
consumption during grinding and the downstream performance
of the flotation circuit into account. In order to do this a number
of simulations were therefore performed for the milling circuit
giving different combinations of throughput, power draw and
final product size. These simulations have been discussed in Part
A of this paper. The two-dimensional model of the flotation
circuit was then used to assess the impact of these changes in
throughput and grind size on flotation performance.
The unit cost of energy and revenue generated per pound of
copper recovered to the concentrate at Osborne were used to
make these parameters comparable by converting them to cost
and revenue components respectively. Note that this simple
economic model does not take cost factors outside of the
concentrator into account (such as the cost of mining and the cost
of transport). Other concentrator costs (such as maintenance,
staff, etc) are also excluded since it is assumed that these will be
constant for all considered scenarios. The results obtained are
summarised in Figure 20 which shows the net revenue
(concentrate copper revenue less the cost of energy per tonne
processed) generated for a number of specific energy
consumptions at three throughputs. These results suggest that it
is more efficient to operate the plant at lower throughputs with
the 240 t/h scenario giving higher revenues per tonne of ore
processed. This data also suggests that for the range of
throughputs evaluated, using as much grinding power as possible

60.6
100
60.4
95 240tph
Current grind 60.2
Net Revenue (A$/t)
Cu Recovery (%)

90 60.0 265tph
P80 = 254 μm
59.8 290tph
85 P80 = 209 μm
P80 = 169 μm 59.6 Baseline
80 P80 = 127 μm 59.4
P80 = 101 μm 59.2
75
P80 = 80 μm
59.0
70
58.8
20 22 24 26 28 30 32
4.00 5.00 6.00 7.00 8.00 9.00 10.00 11.00
Final Concentrate Cu Grade (%) kWh/t

FIG 19 - Copper recovery versus concentrate grade predicted in FIG 20 - Specific net revenue versus specific energy consumption
200 Monte Carlo simulations performed at different grind sizes. in the Osborne concentrator.

196 Adelaide, SA, 12 - 14 October 2009 Tenth Mill Operators’ Conference

 AN INTEGRATED OPTIMISATION STUDY OF THE BARRICK OSBORNE CONCENTRATOR: PART B – FLOTATION
should give increased net revenue since all of these scenarios
have positive slopes over the range of energy inputs evaluated.
The need to maximise energy input during grinding becomes
more pronounced at higher plant throughputs and has a weaker
influence on net revenue as the throughput is decreased (since
coarse or slow/poorly floating particles present under these
conditions have more residence time in the flotation circuit).
The data in Figure 20 does not give an indication of the total
amount of revenue generated by the concentrator on a time basis.
If the same data is expressed with revenue per time (rather than
per tonne), the results presented in Figure 21 are obtained. This
suggests that even though it may be more efficient to operate at
lower throughputs and higher energy inputs, more revenue per
hour can be generated by operating at a higher throughput despite
the negative impact that this has on recovery in the flotation circuit
(due to both decreased residence time and a coarser particle size)
for the range of values evaluated. This data also confirms that it is
best to try and maximise power draw from the Osborne grinding
circuit, particularly at higher plant throughputs. Any attempts to
reduce power consumption, (in the new reduced power cost
scenario that Osborne finds itself in after conversion of the on-site
power station to gas fuel), are therefore more now likely to incur
slightly greater revenue losses than savings.
18000
17000
Net Revenue (A$/hour)
16000
15000
240 t/h
14000 265 t/h
290 t/h
13000
Baseline
12000
4.00 5.00 6.00 7.00 8.00
kWh/t
FIG 21 - Net revenue versus specific energy consumption in the
Osborne concentrator.
An alternative way of looking at this information is to say that
it will be possible to reduce specific power consumption and
maintain concentrate revenue by increasing the feed rate to the
concentrator slightly (although this will actually move the plant
to a less efficient operating condition).
CONCLUSIONS
This paper has demonstrated that the use of traditional size by
size and mineralogical analysis in combination with cell
characterisation measurement and modelling analysis can
provide valuable insight and strategies for circuit improvement
which would often otherwise be overlooked. Performing
Tenth Mill Operators’ Conference
combined grinding/flotation model simulations allows for the
optimisation of the total process rather than the traditional
individual process evaluation.
In the case study presented, chalcopyrite recovery in the
circuit was strongly influenced by its degree of liberation and
its particle size – the coarser and less liberated the chalcopyrite,
the lower its recovery in the flotation circuit. There were
significant amounts of well liberated chalcopyrite lost to the
final tailing. It is believed that these coarse copper losses were
due to insufficient collector coating of coarse chalcopyrite
surfaces (possibly due to the presence of iron hydroxide
coatings) and poor recovery across the froth phase in the larger
flotation cells installed at the back end of the circuit.
Liberated pyrite was the predominant mineral contaminating
the final concentrate and is recovered by true flotation rather than
by entrainment.
Modelling and simulation of the circuit indicates that copper
recovery can be increased (through finer grinding, increasing cell
recovery rates by increasing air rates, reducing bubble size,
improving froth stability or using froth crowders to improve froth
mobility). It may also be possible to increase copper recovery
rates by reducing the amount of pyrite depressant added to the
circuit. Almost all of these strategies would result in lower
concentrate grades if adopted in isolation. It was therefore
concluded that the use of a cleaner stage of flotation would be
very beneficial. Simulations indicated that the use of cleaning
would enable both grade and recovery improvements in the
circuit.
The main driver for concentrator revenue at Osborne is
throughput and for the range of values evaluated, decreases in
plant efficiency are compensated for by increased throughput in
all cases.
REFERENCES
9.00 10.00 11.00 Barbian, N, Ventura-Medina, E and Cilliers, J J, 2003. Dynamic froth
stability in froth flotation, Minerals Engineering, 16(11):1111-1116.
Bazin, C, Grant, R, Cooper, M and Tessier, R, 1994. A method to predict
metallurgical performances as a function of fineness of grind,
Minerals Engineering, 7(10):1243-1251.
Gorain, B K, Burgess, F, Franzidis, J P and Manlapig, E V, 1997. Bubble
surface area flux: A new criterion for flotation scale-up, in
Proceedings AusIMM Sixth Mill Operators’ Conference, pp 141-148
(The Australasian Institute of Mining and Metallurgy: Melbourne).
Grau, R A and Heiskanen, K, 2005. Bubble size distribution in laboratory
scale flotation cells, Minerals Engineering, 18(12):1164-1172.
Runge, K C, Dunglison, M E, Manlapig, E V and Franzidis, J P, 2001.
Floatability component modelling – A powerful tool for flotation
circuit diagnosis, in Proceedings Fourth International Symposium on
Fundamentals of Minerals Processing, pp 93-107 (The Canadian
Institute of Mining, Metallurgy and Petroleum: Montreal).
Runge, K C, McMaster, J K, Ijsselstijn, M and Vien, A, 2007.
Establishing the relationship between grind size and flotation
recovery using modelling techniques, in Proceedings Flotation 2007
Minerals Engineering Conference, Cape Town.
Adelaide, SA, 12 - 14 October 2009 197