From 2020-2025, the first phase of the Collaborative Consortium for Coarse Particle Processing Research undertook a range of projects across a range of coarse particle flotation technologies.
Phase 1: 2020-2025
An Experimental Study of the Hydrodynamics Inside a Fluidised Bed Flotation Cell
The aim of this project was to develop a detailed understanding of the hydrodynamic behaviour of fluidised bed flotation cells under varying particle size distributions, densities, and operating conditions, and to link this behaviour to flotation performance. Specifically, the project sought to:
- Quantify hydrodynamic behaviour (bed expansion and porosity) under two- and three-phase conditions, using both synthetic materials (silica and hematite) and real copper ore (El Soldado).
- Measure flotation outcomes across a controlled range of particle sizes, water rates, and air rates, in order to identify how hydrodynamics influence metallurgical performance.
- Develop and validate CFD models of the laboratory-scale cells, using them to mechanistically explain observed fluidisation and flotation behaviour and provide predictive capacity for scale-up.
For more information, please contact project leader Dr Bellson Awatey (b.awatey@uq.edu.au).
An Assessment of the use of the Loesche VRM for HydroFloat® Feed Preparation
This project had the following objectives:
- To conduct "proof of concept" testing of VRM treatment strategies in preparing the feed for the HydroFloat®.
- To compare the characteristics of the feed prepared by VRM and the conventional laboratory-scale grinding circuit and the related HydroFloat® performances.
For more information, please contact project leader Associate Professor Kym Runge (k.runge@uq.edu.au).
Development of a Robust Bubble Size Measurement Method
The project aimed to develop a software solution for improved (speed and accuracy) bubble size measurement in images collected with the PVM probe
The specific objectives were:
- Identify the best CNN architecture for bubble detection.
- Train CNN on labelled image dataset.
- Evaluate the effectiveness of the trained CNN.
- Develop easy-to-use software solution.
For more information, please contact project leader Dr Gordon Forbes (g.forbes@uq.edu.au).
Development of a Semi-Empirical Model of the HydroFloat® Cell
The objective of this project was to develop a semi-empirical model of the HydroFloat® flotation cell.
- Designing,constructing and commissioning a fully instrumented pilot plant rig capable of performing HydroFloat® experiments.
- Development of a procedure for measuring bubble size in theHydroFloat® pilot cell.
- Deployment of the pilot rig to Newcrest’s (now Newmont’s) Cadia operation to measure performance in theHydroFloat® pilot cell, when processing deslimed scavenger tail, under a range of different conditions.
- Regression analysis of the pilot plant data to determine key performance drivers.
- Full scale surveys of the two different installations of HydroFloat® cells at Cadia and analysis of the data produced to assess whether the drivers observed at pilot scale, remained applicable at larger scale.
- Use of the learnings developed in the pilot and full-scale testing to assess different process modelling options.
For more information, please contact project leader Associate Professor Kym Runge (k.runge@uq.edu.au).
Improving Coarse Particle Recovery in Conventional Flotation Cells
The aims of this project were to improve coarse particle recovery in a conventional flotation cell.
This project is a PhD study which consists of the following scope of work:
- Literature review to identify cell design and operational modifications for testing that would have the potential to minimise coarse particle detachment and maximise coarse particle froth recovery in a conventional cell.
- Design, construction and commissioning of a 1m3 conventional cell, in partnership with Tailings Technology, to test the identified cell design and operational modifications.
- Test work in a 60-litre laboratory flotation cell to determine measurement protocols for assessing suspension and perform a preliminary suspension study,
- Test work using the pilot 1m3 cell to measure suspension capability, froth disturbance and gas distribution when the cell was operated using different impeller sizes, baffling arrangements, impeller clearance, air rate and % solids.
- Construction of a froth mesh and test work to determine the extent to which it can reduce froth disturbance.
- Use of regression analysis and optimisation to determine the design and operation conditions that have the greatest potential to increase coarse particle flotation recoveries
- Development of a 2 phase CFD model of the 1m3 conventional flotation cell and simulation to hydrodynamically explain the reasons for the results obtained in the pilot plant test work.
For more information, please contact project leader Associate Professor Kym Runge (k.runge@uq.edu.au).
Key Chemistry Drivers for HydroFloat® Flotation Performance
The project aimed to achieve the following:
- Understand the interaction mechanisms between chemistry and hydrodynamics in the fluidised bed flotation system, examining how these factors influence the system's operation and efficiency.
- Understand the coalescence mechanisms, specifically within the novel hydrodynamic environment created by the fluidised bed flotation system.
- Develop a basis for optimising bubble size using frothers in the coarse particles' flotation process.
For more information, please contact project leader Associate Professor Liza Forbes (l.forbes@uq.edu.au).
Novel Reagent Addition Method
The project aimed to improve coarse particle recovery by dosing collector reagents as an aerosol.
The specific objectives were:
- Develop an effective and safe method of dosing aerosol collectors to laboratory-scale flotation systems
- Determine whether aerosol collector dosing increases coarse particle recovery in conventional- and fluidised bed flotation systems
- Determine the mechanisms by which aerosol collector dosing improves coarse particle recovery
For more information, please contact project leader Associate Professor Liza Forbes (l.forbes@uq.edu.au).
Side Quest: Antapaccay Zero Conditioning
The overall objective of this project was to test the impact of collector aerosol dosage compared to more traditional method of collector pre-conditioning.
The specific objectives of the work were to:
- To investigate the impact of different collector dosing methods on copper recoveries in fluidised bed flotation.
- To investigate collector deportment in coarse particle flotation using different collector dosing methods.
For more information, please contact project leader Associate Professor Liza Forbes (l.forbes@uq.edu.au).
Side Quest: Building Additional JKHFmini Units
The objective of this project is to build and provide additional JKHFmini prototype units for the CPR Program sponsors. While it is acknowledged that the JKHFmini is not yet developed to the point of commercialisation, these additional units are intended for "beta testing" at the sponsor's laboratories.
For more information, please contact project leader Lizette Verster (l.verster@uq.edu.au).
Side Quest: Developing and scaling up a commercial laboratory fluidised bed flotation cell
The work aims to test the ability of the JKHFmini to predict full-scale fluidised bed flotation performance and develop a scale-up procedure. The work is supported by the Resources Technology and Critical Minerals Trailblazer to:
- Commercialise the JKHFmini prototype
- Develop models and scale-up procedure for circuit design and optimisation with fluidised bed flotation
- Develop CFD capability to perform equipment design and optimisation for fluidised bed flotation devices
- Deliver knowledge transfer of the models and scale-up procedure to industry
The JKHFmini prototype is an essential component for model development as it provides information about ore characteristics and will be used to calibrate empirical models.
For more information, please contact project leader Lizette Verster (l.verster@uq.edu.au).
Small-Scale Test Development
This project aimed to design and build a novel small-scale test apparatus, requiring approximately 1-2 kg of sample per test, and to develop a test procedure to assess an ore’s amenability for treatment by the HydroFloat®.
The outcome was the development of the JKHFmini that enables rapid and efficient testing for essential operations such as ore amenability and metallurgical evaluation, circuit modelling and design, and routine metallurgical assessment of fluidised bed flotation.
For more information, please contact project leader Lizette Verster (l.verster@uq.edu.au).
Teeter-Bed Flotation Waste Rejection Circuit Options
This project aimed to develop a methodology for characterising ore breakage response, mineral deportment, and liberation to support the simulation of grinding circuits incorporating HydroFloat® technology
The scope of work of this project consisted of:
- Use of density separation to produce particle classes of similar mineral liberation for different sized particles ranging from -2.36mm to +300 micron.
- Measure single particle breakage behaviour of these proxy liberation classes in Short Impact Load Cells (SILC) and Rigidly Mounted Roll Mill (RMRM) devices.
- Characterise progeny in terms of size, liberation and surface exposure using Xray tomography
- Demonstrate the application of these data in an integrated circuit simulation.
For more information, please contact project leader Professor Mohsen Yahyaei (m.yahyaei@uq.edu.au).