Effects of Process Parameters on Selective Flotation

of Lead-Zinc Ore
R. Singh, B. Banerjee and J.P. Srivastava

Mineral Processing Division,

National Metallurgical Laboratory,
Jamshedpur - 831 007
e-mail: [email protected]

Abstract
The present paper deals with the results of the characterisation and flotation studies carried out
on a typical lead-zinc ore sample under varying process conditions. A detailed characterisation
was carried out by chemical analysis, X-ray, optical microscopic and electron probe microanalysis
techniques. The sample assayed 2.47% Pb with 13.6% Zn. The ore was predominantly made up of
spahlerite and pyrite in association with subordinate amounts of galena, minor amounts of
pyrrhotite and chalcopyrite. Dolomite was the main gangue. The modal analysis showed the
probability of fair liberation of sulphides from gangues around 60 mesh but the locking of galena
with sphalerite and other sulphides continued to finer sizes. The effects of various parameters like
granulomery for rougher and cleaner flotation, pH of the pulp, dosage of collector, depressant and
activator were studied in detail. The flotation performance was assessed in terms of yield,
recovery and grade of the concentrates and the results were analysed graphically to establish the
trend.

Keywords: Selective flotation, Lead-zinc ore, Process parameters, Characterisation.

Introduction

Bulk of the world's lead and zinc is supplied from their sulphide deposits which generally occur
as finely disseminated bands of galena and sphalerite with varying amounts of pyrite. Froth
flotation is widely used for concentration of low grade lead-zinc ores for meeting the required
specifications of the concentrates for extraction of metals (Wills 1988). The recovery of lead and
zinc bearing minerals as well as the selectivity of separation are greatly influenced by the
mineralogical characteristics of the ore and the various process parameters. Selective flotation of
lead-zinc ore depends on a number of parameters like particle size distribution of the feed,
collector, frother, depressant, activator, pH of the pulp, regrinding and multi-stage cleaning- of the
rougher concentrates etc.While designing the process flow-sheet for a given ore sample it is
necessary to examine the effects of different variables on the process performance (Pradip, Das
and Singh 1995).

The present work was undertaken to study the effects of various process parameters on
concentration of a typical lead-zinc ore sample by froth flotation. Prior to flotation studies, the
sample was characterised with respect to chemical and mineralogical characteristics. The basic
flotation scheme adopted for concentration of the lead-zinc ore sample consisted of differential
flotation separation by depression of zinc bearing minerals using a combination of sodium
cyanide and zinc sulphate as depressant and flotation of lead minerals using potassium ethyl
xanthate as collector and methyl iso-butyl carbinol (MIBC) as frother. Lime was used as pH
regulator and this also helped in depression of pyrite. Subsequently zinc was floated using copper

425
sulphate as activator and xanthate and MIBC as collector and frother respectively at a higher pH.
These studies were found quite useful for developing flotation based technology for beneficiation
of the ore to individual lead and zinc sulphide concentrates. This paper presents the results of
characterisation and flotation studies carried out on the lead-zinc ore sample with a particular
reference to the effects of various process parameters.

Experimental

Materials

The lead-zinc ore sample used for this study analysed 2.47% Pb and 13.63% Zn with 16.64%
CaO and 11.89% MgO. The silica and alumina contents of the sample were low i.e. 0.56% and
0.97% respectively. The mineralogical and liberation characteristics of the sample were
determined and are discussed in the subsequent paragraph.

A combination of laboratory grade sodium cyanide and zinc sulphate from M/s BDH India Ltd.,
Bombay was used as depressant and copper sulphate as activator for zinc bearing minerals.
Commercial grade potassium ethyl xanthate (KEX) from M/s Suyog Chemical Pvt. Ltd., Nagpur
was used as collector and laboratory grade methyl iso-butyl carbinol as frother for lead and zinc
minerals. Commercial grade lime was used as pH regulator and depressant for pyrite.

Methods

Bench scale flotation experiments were carried out in standard Wemco Fagergren Laboratory
Flotation Cell. For this purpose 0.5 kg -1.68 mm sample, crushed in stages in jaw and roll
crushers, was wet ground in laboratory rod mill at 66% pulp density and floated, after
conditioning, at a pulp density of 22%. All the products from the flotation experiments were
assayed for % Pb and % Zn by standard wet chemical method and material balance was
computed.

Results and Discussion

A detailed characterisation and froth flotation studies were carried out on the sample. The salient
results are discussed below :

Mineralogical Characteristics of the Sample

Mineralogical characterisation of the sample indicated that the ore was predominantly made up of
sphalerite and pyrite in association with subordinate amounts of galena, minor amounts of
pyrrhotite and chalcopyrite. Dolomite was the main gangue. The other accessory minerals and
mineral impurities namely, mica, cerussite, smithsonite, quartz, garnet, rutile, magnetite,
goethite/limonite were in minor to trace amounts. The ore minerals were widely varying in size
from 1.4 cm to less than 5 micron but the bulk of sulphide mineral was 148 micron and above in
size. Pyrites were mostly euhedral while other sulphides were anhedral to subhedral in shape. The
sulphide minerals showed replacement, exsolution textures and triple junction points. Typical
photomicrographs are shown in Figs. 1 and 2.

426
 Table - 1 : Analysis of sphalerite

Elements Weight (%)

Zn 60.529 60.062 59.997 62.35
S 32.901 33.328 33.484 32.931
Fe 3.491 6.032 5.920 3.771
Cu - - - -
Pb - 0.048 0.054 0.058
Cd 0.063 0.078 0.034 0.087
Co 0.021 - - -
Ni 0.018 - - -
Mn - 0.011 0.005 -
Total 97.022 99.556 99.495 99.204

Table - 2 : Analysis of galena

Weight (%)
Elements
Pb 86.104 87.618 87.145
S 13.088 13.020 13.102
Fe 0.097 0.020 0.001
Zn 1.626 - -
Cu 0.036 - -
Cd - - -
Co - 0.014
Ni - - -
Mn 0.024 0.017 -
Total 100.974 100.689 100.248
" - " indicates not detected

As it can be observed from the electron probe microanalysis (EPMA) results (Table- 1), the
constant presence of iron in all grains of sphalerite could be due to structural substitution while
out of the three grains of galena analysed only one grain showed the presence of zinc (Table-2).
X-ray diffraction study (Fig. 3) carried out on the sample also corroborated the peterographic
findings (Singh et al 1998).

The modal analysis showed the probability of fair liberation of sulphides from gangue around
0.250 mm but the locking of galena with sphalerite and other sulphides continued to finer sizes.
This indicated the need of fine grinding below 0.105 mm for liberation of galena and sphalerite
from rest of the sulphides.

Flotation Studies

As mentioned in the previous section the basic flotation scheme consisted of differential flotation
separation by depression of zinc bearing minerals using a combination of sodium cyanide and
zinc sulphate as depressant and flotation of lead minerals using potassium ethyl xanthate (KEX)
as collector and methyl iso-butyl carbinol (MIBC) as frother. Lime was used as pH regulator and

427
this also helped in depression of pyrite. Subsequently, zinc was floated using copper sulphate as
activator and xanthate and MIBC as collector and frother respectively at a higher pH. The results
on the studies of the effects of various process parameters on flotation performance are discussed
below :

Effects of Granulometry of the Flotation Feed

Flotation experiments were carried out to study the effects of granulometry on flotation behaviour
of lead and zinc bearing minerals. For this purpose, -10 mesh ore sample, wet ground for different
length of time in laboratory rod mill was floated under fixed process conditions as pre-determined

Fig.1: Polished specimen showing triple Fig.2 Polished specimen showing gangue
junction and assemblage of pyrite X 160 containing sphalerite (Sp) and their locking
Parallel light, Reflected Light Microscopy. with galena (Ga) and chalcopyrite (Cp) X 160
Parallel light, Reflected Light Microscopy.

Sp - SPHALERITE
G _GALENA
Ch - CHALCOPYRITE SP,Ch,FY
D - DOLOMITE
Py - PYRITE
. n. Py
SP C GI

Ch
D

Cu {roc 2O()
70 65 60 55 50 45 40 55 30 25 70

Fig. 3 : X-ray powder diffraction spectrum of lead-zinc ore sample

by trial experimentation. The flotation results are shown in Fig. 4. We can see from this figure due
to better liberation an increase in -74 micron particles in flotation feed from 21.5% to 38.5%
showed an improvement in lead and zinc recovery. It was also observed that overall flotation
kinetics was better. But a further increase in fineness of feed to 57% -74 micron did not show any
favourable results rather it caused a loss in lead and zinc recovery. So a flotation feed consisting
of 38.5% particles passing below 74 micron was considered suitable for rougher flotation of lead
and zinc bearing minerals from the ore.

428
 W1%.,1. -74 MU:14qt. In FEED

Fig. 4 : Effects of granulometry on recovery of lead and zinc bearing minerals

Depression of Zinc Bearing Minerals

As mentioned earlier, a combination of sodium cyanide and zinc sulphate (1:2.4) was used as
depressant for zinc and selective flotation of lead minerals. The dosage of the depressant was
varied from 0.215 kg/t. to 1.7 kg/t. The flotation results are graphically shown in Fig. 5. It is
evident from the data shown in Fig. 5 that an increase in dosage of depressant from 0.215 kg/t. to
0.425 kg/t. resulted in improvement in recovery as well as grade of lead concentrate to 95.3% and
30.82% respectively. But a further increase in depressant dosage also caused depression of lead as
shown by a sharp fall in grade and recovery of lead.

Variation of Collector Dosage

The effects of variation of collector dosage (potassium ethyl xanthate in this case) was studied on
flotation of lead and zinc bearing minerals. For flotation of zinc the xanthate dosage was varied
from 0.094 kg/t to 0.752 kg/t. The results are shown in Fig. 6. These experiments were carried out
using feed with 38.5% -0.074 mm at pH 8.5. As it is evident an increase in xanthate dosage from
0.0.094 kg/t to 0.350 kg/t there is an improvement in zinc recovery but as expected concentrate
grade shows a decline. An increase in xanthate dosage beyond 0350 kg/t although leads to a
sharp deterioration in recovery as well as concentrate grade. For lead collector dosage was varied
from 0.125 kg/t to 1.0 kg/t. Like zinc, in this case also it was observed that an increase in dosage
from 0.125 kg/t 0.250 kg/t resulted in improvement in metallurgical performance but a further rise
in xanthate dosage affected recovery of lead (Singh et al 2000).

Effects of Activator for Zinc Bearing Minerals

Copper sulphate is widely used as activator for zinc bearing minerals. Experiments were
conducted varying dosahe of copper sulphate from 0.25' kg/t to 1.0 kg/t. It was found that an
increase in activator dosage from 0.25 kg/t to 0.5 kg/t resulted in decrease in zinc loss in the
tailings from 65.5% to 1.8%. But a further increase in the activator dosage to 1.0 kg/t affected the
flotation selectivity due to undesirable activation at higher dosage (Singh et al 1998).

429
Influence of pH of Flotation Pulp

pH of the pulp governs the charge on the mineral surface and plays an important role in the
adsorption of the reagents and hence separation of minerals. For the flotation of zinc bearing
minerals, pH was maintained using lime and was varied from 9.5 to 11.5. The results are shown in

95

RECOVERY -0-

GRADE

55

3d

-49
0

47
0.2 1.0 1.4
DOSAGE OF DEPKSSAIII.Kwt, BO
45
0.05 0:35 065 0:95
COL LECTOR DOSAGE K/p,

Fig. 5 : Effects of dosage of depressant Fig. 6 : Zinc flotation results with

on flotation of lead minerals varying dosage of collector

Fig. 7. The results indicated that an increase in pH from 9.5 to 10.5 leads to higher zinc recovery
with faster kinetics and results in slight loss in concentrate grade. But a further increase in pulp
pH to 11.5 caused a sharp decline in both grade as well as recovery. The effect of pH was also
studied for flotation of lead minerals. A pH of 8.5 was considered suitable for effective flotation
of lead minerals.

9.0 10 11 12
PH

Fig. 7 : Influence of pH on flotation of zinc minerals

430
Fineness of Rougher Concentrate for Subsequent Cleaning Flotation

As indicated by liberation data and microscopic observation, in particular the high zinc content of
the lead rougher concentrate was mainly due to locking problem. Hence experiments were carried
out to improve the flotation selectivity by grinding rougher concentrate followed by cleaning
flotation of the ground product. The fineness of the lead rougher concentrate was varied from
33% 44 micron to 89.4% 44 micron. For flotation of lead the results are shown in Fig. 8. As we
can observe from the data shown in Fig. 8 that two cleaning of the lead rougher concentrate
resulted in cleaner concentrate with 63.32% Pb and 1.01% Zn. Grinding the lead rougher
concentrate to 85.2% 44 micron improved the concentrate grade to 65.42% Pb with 5.26% Zn.
The improvement in grade was mainly due to enhanced liberation of sulphides at finer particle
sizes. However, with further grinding of lead rougher concentrate to 89.6% -44 micron, there was
increase in lead content of the concentrate but zinc assay was slightly higher (6.24%). This may
be attributed to the flotation of the finely ground zinc minerals due to entrainment and entrapment
phenomena. Thus a regrinding size with 85% particles passing below 44 micron was considered
suitable for cleaning flotation of lead rougher concentrate.

For zinc rougher concentrate although the lead content was low but in order to study the effects of
grinding for improving overall grade, regrinding flotation experiments were carried out. But in
this case regrinding of the rougher concentrate adversely affected the flotation performance. It
seems due to undesirable activation of pyrite during regrinding, it floated along with zinc
minerals. So, these results indicated that for zinc circuit regrinding was not necessary.

90^ WT..
.0 DIST. qe.pb
80^
ASSAY00 Pb
ASSAIV.Zn
70•
0

0- 50.
0 it
(..)
5°.

40.

.6
30 4
LEAD CONCENTRATE

Fig. 8 : Effects of granulometry on cleaning flotation performance of lead minerals

Multi-stage cleaning flotation and process flow-sheet

Above studies on the influence of different process variables helped in establishing trends and
conditions for rougher flotation and the granulometry for cleaning flotation. The lead rougher and
zinc recovery were observed to be 96.3% and 90% respectively. The next task was to study the
improvement in the grade of the individual lead and zinc concentrates by multi-stage cleaning

431
flotation. For this purpose three stages of cleaning were performed for lead rougher concentrate
ground to 85% -44 micron. The final lead concentrate assayed 79.11% Pb with 4.23% Zn and
with, a lead recovery of 83.4%. The zinc rougher concentrate was subjected to two cleanings
resulting in zinc cleaner concentrate, analysing 60.08% Zn with 0.12% Pb with a zinc recovery of
80.4%. Based upon the studies undertaken a flotation based process was recommended for the
concentration of lead-zinc ore sample under consideration.

Conclusions

Characterisation and flotation studies were carried out on a lead-zinc ore sample assaying 2.47%
Pb and 13.6% Zn. The effects of various process parameters like particle size for rougher and
cleaner flotation, pH of the pulp, dosage of collector, depressant and activator were studied on the
selective flotation of lead and zinc bearing minerals. The studies proved quite helpful in
establishing the trends on the effects of these variables on the metallurgical performance and also
in designing flotation based process for concentration of the ore to individual lead and zinc
sulphide concentrates.

Acknowledgements

The authors wish to express their sincere thanks to Prof. S.P. Mehrotra, Director, National
Metallurgical Laboratory, Jamshedpur for his keen interest in the work. Thanks are also due to Dr.
D.S Rao and Dr. A. Chattopadhyay for EPMA and XRD studies and other colleagues from MNP
Division and ANC Centre of NML for their co-operation in executing the project.

References

1. Bills, B.A., 1988. Froth flotation. In Mineral Processing Technology, p.457-598. 4th edn. New
York :Pergamon Press.
2. Pradip, Das, K.K. and Singh, R., 1995. Flotation of Complex Sulphide Ores. In Selected Topics in
Mineral Processing, p. 119-147. New Delhi : Wiley Eastern Ltd.
3. Singh, R. et al, 1998. Further Bench Scale Beneficiation studies on Ganesh-Himal Lead-zinc Ore
from Nepal", Report of Investigation Carried out at NML, Jamshedpur.
4. Singh, R. et al, 2000. Designing flotation process for lead-zinc ore from Nepal. In Proceedings of
international symposium on processing of fines, 188-198. NML, Jamshedpur, India._

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