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Optimizing industrial flow measurements in mineral processing: Utilizing radiotracers for enhanced data reliability within Mining 4.0

Barrientos Nelson, Diaz Francisco

Physicochemical Problems of Mineral Processing

2025

Vol. 61, iss. 1

art. no. 200742

As the mining sector undergoes rapid transformation, Industry 4.0 principles - such as data digitalization, process automation, and Big Data Analytics - are crucial for developing intelligent mineral processing plants. These principles advance processes towards an interconnected sequence of steps, each relying on high-quality data. Within this framework, low-uncertainty flowmeter data is vital for accurate metallurgical mass balance determination, efficient process control, and the correct application of advanced analytical tools. However, harsh mining conditions can cause significant deviations in flowmeter readings, necessitating robust data validation methods. This paper introduces the novel application of the radiotracer methodology, which provides certified uncertainties around 1%, to optimize flowmeter data accuracy and align with Mining 4.0 requirements. Three industrial validation examples are presented: Flow meter adjustment in leaching processes, evaluating a NaHS loop piping circuit in a molybdenum flotation plant and validating flow meters to assess the hydraulic behavior of recirculation pumping stations for water balance quantification. On-site validations at the leaching plant revealed that only 36% of the measurements were within the acceptable 5% error margin. Flow assurance was confirmed in the NaHS loop piping circuit as radiotracer velocity data showed no blockages. Deviations in the recirculation pumping stations, ranging from 6.91% to 22.55%, highlighted the need for flowmeter adjustments. These findings underscore the value of radiotracers as a validation method. This paper also provides insights for water and environmental impact assessment, metallurgical mass balance calculations, and process optimization, emphasizing the need to integrate radiotracer methodology within the Mining 4.0 framework.

Application of radiotracers as tools to determine feed flowrate imbalances and particle size segregation in industrial flotation circuits

Diaz Francisco, Barrientos Nelson

Physicochemical Problems of Mineral Processing

2023

Vol. 59, iss. 5

art. no. 174817

This publication presents the application of radiotracers in the characterization of industrial flotation circuits. Two examples are showcased: the detection of feed flow rate imbalances and the characterization of particle size segregation in automatic mineral-cutting machines. The feed pulp distribution was determined from the mean residence times. Particle size segregation was measured by sampling the cutting machines (≅ 25 grams samples) using coarse, intermediate, and fine-sized radiotracer particles. Radiotracers were injected into the feed streams and measured at various points of the circuit using nuclear instruments, allowing for non-invasive and real time detection. Results show that in the rougher flotation stage, the feed flow is distributed almost evenly in lines 2 and 3 (approximately 38% of the flow goes to each line) and to a lesser extent towards line 4 (approximately 24%). In lines 1 and 2 of the scavenger stage, a higher percentage of the flow goes towards line 1 (approximately 59%) and a lower percentage towards line 2 (41%). Line 6 of the rougher flotation is the fastest of the circuit (shortest residence time). In addition, the inlet mineral-cutting machine of the rougher stage segregates particles with a bias for fine sizes (11.4 % more fine-sized particles than coarse ones). This work is an example of how radiotracer technology can be applied to improve metal production and processes. Radiotracers provide reliable information to be used in combination with other metallurgical data to properly assess flotation circuits.