BauxiteBauxite is the main raw material for aluminaAlumina production. BauxitesBauxite can be karst-type, associated with limestone and dolomiteDolomite, or lateritic-type, formed from the weathering of silicate rocks. In the Amazon region, bauxiteBauxite processingProcessing plants remove the kaolinite through classificationClassification steps using hydrocyclones after comminution and scrubbing steps. The fraction smaller than 38 µm (considered finesFines) tends to follow the tailings stream (hydrocyclone overflow). The reduction of this fraction is necessary to reduce the reactive silicaSilica grade on bauxiteBauxite, which directly impacts refinery operating costs due to the formation of DSP on bauxiteBauxite digestionsDigestion, that consumes caustic soda. Kaolinite is a clay mineral that tends to be concentrated in the finer fractions of bauxiteBauxite (−10 µm). Due to the decline in the quantity of high-grade ores worldwide, the beneficiation of low-grade ores has become increasingly important. However, processingProcessing low-grade ores is considered a challenge, as most of them are associated with the presence of ultrafine particles. The study investigates the influence of air flowAir flow and wash waterWash water rates during a flotation pilot tests using column to promote the concentration of bauxiteBauxite ultrafine particles (−38 + 10 µm) from tailings generated at Hydro’s bauxiteBauxite processingProcessing plant in Brazil. Approximately 4000 L of bauxiteBauxite tailings slurry were collected at the Hydro’s bauxiteBauxite processingProcessing plant. The sample contained approximately 6% solids by weight. The sample was submitted to desliming process with 3 desliming stages using a small-diameter hydrocyclone. The underflow of the third stage was submitted to flotation using column with dispersantDispersant and amide-amine as collector. An analysis of the variation in air and wash waterWash water flow was performed via Minitab. The main conclusions were that increasing the air flowAir flow rateFlow rate in the flotation columnFlotation column produces concentrates with a better Al/Si ratio but causes a significant drop in alumina recoveryAlumina recovery (a drop of approximately 30 percentage points). Increasing the wash waterWash water improves alumina recoveryAlumina recovery, but it is not possible to achieve concentrates with an Al/Si ratio of at least 10. With the higher air flowAir flow rateFlow rate (1.47 L/min) and lower wash waterWash water rate (0.12 L/min), it was possible to achieve a concentrate with an Al/Si ratio of 10. The aluminaAlumina and silicaSilica grades were 47.8 and 4.7, respectively. In this test, the alumina recoveryAlumina recovery was 47%. Considering a cycloning and column flotation circuit, the overall alumina recoveryAlumina recovery was 13.5%. Through simulationSimulation, this recovery level would increase the alumina recoveryAlumina recovery of Hydro's bauxiteBauxite beneficiation plant by approximately 4 percentage points, with no negative impact on product qualityQuality.

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Influence of Air Flow and Wash Water Rates on Fine Bauxite Recovery by Column Flotation

  • Geraldo Magela Pereira Duarte,
  • Allan Suhett Reis

摘要

BauxiteBauxite is the main raw material for aluminaAlumina production. BauxitesBauxite can be karst-type, associated with limestone and dolomiteDolomite, or lateritic-type, formed from the weathering of silicate rocks. In the Amazon region, bauxiteBauxite processingProcessing plants remove the kaolinite through classificationClassification steps using hydrocyclones after comminution and scrubbing steps. The fraction smaller than 38 µm (considered finesFines) tends to follow the tailings stream (hydrocyclone overflow). The reduction of this fraction is necessary to reduce the reactive silicaSilica grade on bauxiteBauxite, which directly impacts refinery operating costs due to the formation of DSP on bauxiteBauxite digestionsDigestion, that consumes caustic soda. Kaolinite is a clay mineral that tends to be concentrated in the finer fractions of bauxiteBauxite (−10 µm). Due to the decline in the quantity of high-grade ores worldwide, the beneficiation of low-grade ores has become increasingly important. However, processingProcessing low-grade ores is considered a challenge, as most of them are associated with the presence of ultrafine particles. The study investigates the influence of air flowAir flow and wash waterWash water rates during a flotation pilot tests using column to promote the concentration of bauxiteBauxite ultrafine particles (−38 + 10 µm) from tailings generated at Hydro’s bauxiteBauxite processingProcessing plant in Brazil. Approximately 4000 L of bauxiteBauxite tailings slurry were collected at the Hydro’s bauxiteBauxite processingProcessing plant. The sample contained approximately 6% solids by weight. The sample was submitted to desliming process with 3 desliming stages using a small-diameter hydrocyclone. The underflow of the third stage was submitted to flotation using column with dispersantDispersant and amide-amine as collector. An analysis of the variation in air and wash waterWash water flow was performed via Minitab. The main conclusions were that increasing the air flowAir flow rateFlow rate in the flotation columnFlotation column produces concentrates with a better Al/Si ratio but causes a significant drop in alumina recoveryAlumina recovery (a drop of approximately 30 percentage points). Increasing the wash waterWash water improves alumina recoveryAlumina recovery, but it is not possible to achieve concentrates with an Al/Si ratio of at least 10. With the higher air flowAir flow rateFlow rate (1.47 L/min) and lower wash waterWash water rate (0.12 L/min), it was possible to achieve a concentrate with an Al/Si ratio of 10. The aluminaAlumina and silicaSilica grades were 47.8 and 4.7, respectively. In this test, the alumina recoveryAlumina recovery was 47%. Considering a cycloning and column flotation circuit, the overall alumina recoveryAlumina recovery was 13.5%. Through simulationSimulation, this recovery level would increase the alumina recoveryAlumina recovery of Hydro's bauxiteBauxite beneficiation plant by approximately 4 percentage points, with no negative impact on product qualityQuality.