Modeling and Simulation of Hydroxyapatite Recovery in the Desliming Circuit of the Tapira Industrial Plant, Brazil

The modeling and simulation of industrial mineral processing operations are traditionally used for cyclone sizing and optimizations of industrial operations. However, the main models used are based on the total population of particles in the pulp, thus not distinguishing the individual minerals. This article presents the results of an innovative method that investigated the optimization of the metallurgical recovery of P2O5 in the desliming circuit of a phosphate ore processing plant in Brazil. A survey campaign was carried out in the existing industrial circuit, followed by determining the partition curves for the overall particles and specifically for the hydroxyapatite particles. The results were used to calibrate the Narasimha-Mainza cyclone model. From a Base Case determined with reference to the industrial survey, three optimization scenarios were simulated through cyclone geometries and respective operating conditions changes. Simulated scenarios indicated the possibility of P2O5 metallurgical recovery increasing from 9.4% to 12.7% compared to the Base Case.