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The Doe Run Company (Doe Run) defined and characterized thermodynamicsThermodynamics, kineticsKinetics, hydrodynamics and phase equilibriaPhase equilibria of industrial flotationIndustrial flotation at IMPC 2024. Doe Run applied these first principlesFirst principles to develop an expert controlExpert control system for Cu ore flotationFlotation (Cu Special). Initially implemented at Fletcher millMill, with prior applications at Buick millMill (excluding liberation), the system integrates expanded FrothSense+™ technologyTechnology with the “Magnificent 4” Modules—particle density, modern reagents, bubbles, and froths—alongside “Intelligent Bulk Reagents.” These modules and reagents operate independently but synchronize through online X-ray Fluorescence (XRFXRF) assays of millMill feed, process froth and tail streams as flotationFlotation phase equilibriaPhase equilibria. This approach optimizesOptimize Cu recoveryRecovery while achieving target concentrateConcentrate gradesGrade with minimal Pb and Zn impuritiesImpurity. Reagents form the chemical foundation of flotationFlotation, making them a key validation point for expert controlExpert control. Buick millMill, followed by Fletcher millMill, successfully replaced xanthate with dual selective Cu collectorsCollectorone for primary collection and the other for scavenging. This breakthrough enabled efficient processingProcessing of lower-gradeGrade Cu ores with elevated pyritePyrite/marcasite that xanthate could not handle, significantly improving Cu concentrateConcentrate gradeGrade and recoveryRecovery. This advancement marks a paradigm shift in Cu flotationFlotation within Doe Run’s Viburnum Trend. The expanded FrothSense+™ enhances Doe Run’s ability to process lower-gradeGrade Cu ores and may enable economical Co/Ni concentrateConcentrate recoveryRecovery from Cu concentratesConcentrate containing siegenite (Ni, Co)₃S₄. Grounded in first principlesFirst principles, this technologyTechnology is scalable and extendable to Doe Run’s other millsMill, strengthening both Cu Special and Pb/Zn/Cu production and flotationFlotation optimizationOptimization.

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Advancements and Impacts of Expanded FrothSense+™ on Cu Special at Doe Run’s Pb/Zn/Cu Mill: A Case of Applied First Principles of Industrial Flotation

  • 会议论文

  • 发表日期：

    2025年

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  • Weishi Mang,
  • Adam Steimel,
  • Brian Mangogna,
  • Chris Hogan,
  • Craig Romrell,
  • Erwan Yap,
  • Dustin Rouleau

摘要

The Doe Run Company (Doe Run) defined and characterized thermodynamicsThermodynamics, kineticsKinetics, hydrodynamics and phase equilibriaPhase equilibria of industrial flotationIndustrial flotation at IMPC 2024. Doe Run applied these first principlesFirst principles to develop an expert controlExpert control system for Cu ore flotationFlotation (Cu Special). Initially implemented at Fletcher millMill, with prior applications at Buick millMill (excluding liberation), the system integrates expanded FrothSense+™ technologyTechnology with the “Magnificent 4” Modules—particle density, modern reagents, bubbles, and froths—alongside “Intelligent Bulk Reagents.” These modules and reagents operate independently but synchronize through online X-ray Fluorescence (XRFXRF) assays of millMill feed, process froth and tail streams as flotationFlotation phase equilibriaPhase equilibria. This approach optimizesOptimize Cu recoveryRecovery while achieving target concentrateConcentrate gradesGrade with minimal Pb and Zn impuritiesImpurity. Reagents form the chemical foundation of flotationFlotation, making them a key validation point for expert controlExpert control. Buick millMill, followed by Fletcher millMill, successfully replaced xanthate with dual selective Cu collectorsCollectorone for primary collection and the other for scavenging. This breakthrough enabled efficient processingProcessing of lower-gradeGrade Cu ores with elevated pyritePyrite/marcasite that xanthate could not handle, significantly improving Cu concentrateConcentrate gradeGrade and recoveryRecovery. This advancement marks a paradigm shift in Cu flotationFlotation within Doe Run’s Viburnum Trend. The expanded FrothSense+™ enhances Doe Run’s ability to process lower-gradeGrade Cu ores and may enable economical Co/Ni concentrateConcentrate recoveryRecovery from Cu concentratesConcentrate containing siegenite (Ni, Co)₃S₄. Grounded in first principlesFirst principles, this technologyTechnology is scalable and extendable to Doe Run’s other millsMill, strengthening both Cu Special and Pb/Zn/Cu production and flotationFlotation optimizationOptimization.