This paper investigated the effect of mineral surface oxidation on the floatability of Kevitsa low-grade Ni-Cu ore. Physicochemical measurements, ethylene diamine tetra acetic acid (EDTA) extraction, and oxygen uptake experiments were carried out with slurry and recycled process water samples obtained from the Kevitsa Cu-Ni sequential concentrator plant. The pH of recycled process water, copper flotation feed, and nickel flotation feed dropped by 0.7, 0.4, and 0.7 points, respectively, from May to July. The oxygen demand increased from recycled process water to the copper flotation feed, then dropped for the nickel flotation feed. The nickel flotation feed Redox potential (ORP) was lowest for July, while EDTA extractable metals increased from May to July. There was a 20% drop in nickel recoveries from May to July. Based on ORP measurements of the nickel flotation feed, good nickel flotation takes place in a moderately oxidizing (75–170 mV) and alkaline (9.2–9.7 pH) environment. Therefore, the ORP/pH of the nickel flotation feed is important to the nickel flotation. The results showed that at the Kevitsa plant, the grinding process is an electrochemically active environment, which, together with the incoming recycled process water quality, defines the degree of mineral surface oxidation for flotation. The increasing corrosiveness of the recycled process water increased mineral surface oxidation and depressed pentlandite flotation. Laboratory flotation experiments confirmed the observed poor plant flotation response when the corrosiveness of recycled process water increased. Total dissolved solids (TDS) was proven to be a reliable online parameter for the corrosiveness of the recycled process water and was inversely proportional to the pentlandite recovery. The findings of this study may help the plant develop ways to enable a timely response to changes in recycled process water quality to prevent harmful impacts on pentlandite flotation.

The pressure for saving water by closing the water loops in mineral processing is increasing continuously. The drivers for higher recirculating rates include water scarcity in dry areas, environmental legislation that is becoming stricter in most countries, limitations set for wet tailings management and the increased demands for social licenses to operate. At the same time, to make mineral processing sustainable, the recovery of valuable minerals should be maximized. This leads for a need to close the process water circulation. To see the effect of closed water circulation on metallurgical performance, flotation tests were carried out with nickel concentrate thickener overflow water before and after the process of water purification by dissolved air flotation (DAF). Both total nickel recovery and concentrate grade in laboratory scale flotation tests to the Ni rougher-scavenger concentrate increased after DAF treatment. Chemical and mineralogical characterizations revealed that after DAF treatment, the process water contained fewer metal hydroxides and less fine-grained silicate mineral particles, which is most likely the reason for the improvement in the nickel flotation performance. Based on the feasibility study, improved nickel recovery by DAF treatment of process water can bring economic benefits at a concentrator plant.

Blending of different ore types in the concentrator feed contributes significantly to maintaining a high recovery of valuable minerals with required grades in the concentrate. It is feasible to develop an ore-blending scheme over the life of a mine already in the design phase of the plant. In addition to ore characteristics, water quality is known to impact mineral recovery. A blending plan could also be developed for the different water streams of a future concentrator. This paper describes a novel modeling and simulation approach to predict metallurgical response combining ore types and water quality. The model is based on kinetic laboratory flotation test data, and it was tested on a case study. As a result, rougher flotation grade-recovery curves dependent on ore types and water quality are presented over the predicted life of the mine. The simulation results can be exploited in project design to maximize the recovery of valuable minerals and to ensure environmentally sound and profitable mining operations. Overall, the developed modeling tool can be applied widely for minerals processed by using froth flotation and water types available for kinetic laboratory flotation tests.

Earlier studies at the Kevitsa Cu-Ni concentrator plant have indicated that seasonal variations of the properties of the process water affect the oxidation of the surface of the minerals, and further, the pentlandite flotation performance. However, it is not clear whether the differences in flotation performance are solely due to changes in the mineral surface oxidation, and/or also due to surface oxidation-induced changes in the aqueous phase of the pulp. This paper investigates the effects of the mineral surface oxidation of Kevitsa Cu-Ni ore on the properties of the aqueous phase of the slurry. A systematic study was formulated to monitor the surface oxidation related changes in the mill circuit of the Kevitsa concentrator plant. The study was timed to coincide with a seasonally observed drop in the concentrator plant’s flotation performance, which happens during the summer months (June, July, and August). Both physicochemical parameters, as well as sulphur oxyanions in the plant process water, mill discharge, and hydrocyclone overflows were monitored. Also, the bubble size in selected rougher and cleaner cells was monitored. The results show that season-related changes in mineral surface oxidation cause clear differences in the aqueous phase chemistry of the mill circuit. The increased concentration of reduced sulphur species in the mill discharge is an indication of extensive oxidation of the ore during milling. Also, the bubble size of the flotation cells reacts to the observed seasonal change. The findings of the study confirm that the consequences expected, based on the theory of mineral surface oxidation, are observable downstream in the aqueous phase of the milling circuit. Based on these results, it is not yet possible to say whether the poor flotation performance is caused solely by the oxidation of the mineral surface or also by the properties of the aqueous phase of the slurry after milling. However, the results show that the plant needs both to find ways to limit oxidation rates in the summer, and to consider installing a more robust frother, capable of maintaining efficacy during the warm season. The findings of this study may help the plant to develop ways to enable a timely response to changes in the recycled process water quality, to prevent harmful impacts on pentlandite flotation. The former could be achieved by lowering the temperature of the process water and flotation air, whereas the latter could mean using a different frother.