Process optimization and modelling of sphalerite flotation from a low-grade Zn-Pb ore using response surface methodology

Abstract In this research sphalerite flotation from a low-grade lead-zinc ore containing 3% Zn and 1% Pb was studied. Three control parameters including activator (CuSO 4 ) dosage, collector (potassium amyl xanthate (PAX)) dosage and pH, each in five levels, were investigated. Response surface methodology (RSM) was implemented for statistical design and analysis of experiments and process modelling. Four quadratic mathematical models were derived for prediction of Zn grade, Zn recovery, Zn separation efficiency and Pb recovery. Analysis of variance showed that collector dosage was the most significant factor affecting Zn recovery and separation efficiency. In process optimization, maximum values of Zn recovery and separation efficiency were achieved as 79.12% and 64.59%, respectively. Using CuSO 4 concentration of 150 g/t, PAX dosage of 120 g/t, and pH of 10.4, Zn recovery of 61.5% and separation efficiency of 51.49% were obtained. However, in optimization studies, a case proposed by the model in which using the same consumption of reagents, Zn recovery and separation efficiency were improved about 9% and 5%, respectively. This study showed that RSM could effectively be applied for the modelling of flotation process and for finding an economical optimum condition to achieve maximum separation efficiency under minimum consumption of flotation reagents.

[1]  N. Aslan,et al.  Optimization of Pb flotation using statistical technique and quadratic programming , 2008 .

[2]  M. Bezerra,et al.  Response surface methodology (RSM) as a tool for optimization in analytical chemistry. , 2008, Talanta.

[3]  N. Aslan.  Application of response surface methodology and central composite rotatable design for modeling the influence of some operating variables of a Multi-Gravity Separator for coal cleaning , 2007 .

[4]  N. Aslan,et al.  Application of Box-Behnken design and response surface methodology for modeling of some Turkish coals , 2007 .

[5]  Pallavika,et al.  Optimization of a Laboratory-Scale Froth Flotation Process Using Response Surface Methodology , 2005 .

[6]  Timothy J. Napier-Munn,et al.  Application of central composite rotatable design to modelling the effect of some operating variables on the performance of the three-product cyclone , 2005 .

[7]  A. Martı́nez-L,et al.  Study of celestite flotation efficiency using sodium dodecyl sulfonate collector: factorial experiment and statistical analysis of data , 2003 .

[8]  Mark J. Anderson,et al.  DOE Simplified: Practical Tools for Effective Experimentation , 2000 .

[9]  R. H. Myers,et al.  Response Surface Methodology: Process and Product Optimization Using Designed Experiments , 1995 .

[10]  N. Aslan,et al.  Optimization of process parameters for producing graphite concentrate using response surface methodology , 2008 .

[11]  D. Fornasiero,et al.  Effect of surface oxide/hydroxide products on the collectorless flotation of copper-activated sphalerite , 2006 .