Performance improvements provided by Mintek’s FloatStar™ advanced control system on reverse flotation of iron ore
T du Toit, M Crozier

Traditional iron ore beneficiation plants using washing, screening, and jigging processes require large volumes of process water. However, when a suitable large iron ore deposit is found in a location where rainfall is erratic and raw water sources are limited, innovative process designs are required to minimize water losses, maximize re-use of process water, and minimize raw water intake to ensure the project viability.
This case study provides an overview of the Khumani paste disposal facility (PDF) located in the Northern Cape Province of South Africa. The plant uses a central ring main water reticulation circuit combined with a two-stage thickening system to maximize water recovery.
At the process plant there are two large 90 m diameter traction thickeners and at the PDF two 18 m paste thickeners. The net raw water usage has been minimized, and water losses on the PDF are at levels of between 0.43 to 0.69 m3/t deposited.
Keywords: Khumani, paste thickening, paste disposal facility, iron ore, water recovery.