Case Study - Flotation – Au Specific Reagent Addition Strategy

CLIENT OVERVIEW

The client is a gold processing operation focused on optimising site wide performance and reducing operational expenditure (OPEX). With high reagent costs, particularly for Au-specific collectors, the business sought data-driven insights to improve recovery without unnecessary chemical use.

THE CHALLENGE 

The primary objective was to determine whether gold-specific collector addition could be reduced without negatively impacting gold recovery in the rougher circuit. The high cost per unit of the reagent made this a critical area of focus for cost efficiency and overall circuit optimisation.

APPROACH 

Interlate ingested site data into its analytics platform, performing rigorous filtering to remove inconsistencies from varying operating modes, sensor faults, and outliers. A comprehensive suite of exploratory analytics including scatterplots, histograms, and binned scatterplots was used to understand trends.

To accurately assess the impact of the Au collector on recovery, the team normalised recovery data for confounding variables like feed grade and grind size. This was followed by statistical testing to confirm relationships and trends with confidence.

SOLUTION 

The analysis revealed that collector dosage had a significant impact on gold recovery, identifying a previously unnoticed underdosing issue. Trials were conducted to increase the dosage, and analytics helped define the point of diminishing returns, establishing an optimal addition rate.

IMPACT

The implementation of optimal collector dosing resulted in a +2.6% improvement in gold recovery equating to approximately AUD $17.6 million in additional annual revenue. The insights enabled the client to optimise reagent use and maximise recovery without unnecessary expenditure.