The study uses flotation process optimization to explore how to improve copper recovery from the Kakula deposit. Given the variability in ore grade, achieving high recovery rates and maintaining an optimal copper grade is critical. This research employs the Taguchi experimental design and multi-objective optimization to determine the most effective flotation parameters. Key factors investigated include solid mass percentage, air flow rate, particle size, frother dosage (HYDOFROTH), collector dosage (SIBX), and secondary collector dosage (AERO). The Taguchi method determined optimal conditions for maximum copper recovery at 96.4%, with 14.2% copper content in concentrate. The multi-objective approach provided a more balanced result: 95.4% copper recovery, 48.0% mass pull, 12.2% copper content. Comparing the results obtained by these two methods, it is noted that the multi-objective approach contributes more to the minimisation of silica, 24% versus 35.4%. ANOVA analysis revealed that collector dosage (SIBX) was the most significant factor influencing copper recovery. At the same time, solid mass percentage had the most significant impact on copper content, mass pull, and silica yield. The findings provide practical insights for improving the flotation performance of the Kakula deposit, ensuring higher efficiency and better concentrate quality.
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