Evaluation of the selective detachment process in flotation froth

The improved selectivity between particles of varying degrees of hydrophobicity in flotation froths has been well documented in literature, especially in the deep froths utilized in flotation columns. The phenomenon is believed to be due to the selective detachment process whereby the least hydrophobic particles are released from the bubble surface upon bubble coalescence. To quantify the selective detachment process, column flotation experiments were performed under various operating conditions that provided varying amounts of reflux between the froth and collection zones. Entrainment was eliminated by the use of relatively coarse 250 × 75 micron material. The flotation column incorporated the ability to provide instantaneous stoppage of the process streams and separation between the collection and froth zones after ensuring steady-state operation of the column. The samples collected from the two zones and process streams were evaluated to quantify the flotation rate distribution of the particles comprising each sample. The flotation rate was used as an indicator of the degree of hydrophobicity and thus a relative measure of the binding force between the particle and bubble in the froth zone. The flotation rate data was used as input into well known flotation models to obtain the froth zone recovery rate and the quantity of material that refluxes between the collection and froth zones.     

Effect of entrainment in bubble load measurement on froth recovery estimation at industrial scale

Froth recovery was calculated in a 130 m³ mechanical cell of a rougher flotation circuit. This was done by bubble load determinations along with mass balance surveys. Valuable grade in the bubble load decreased in the −38 μm due to fine particles entrained to the chamber of the device. The effect of fine particle entrainment on froth recovery was evaluated. A comparison between results from the raw bubble load data (assuming all particles were transported by true flotation) with those from corrected bubble load information (subtracting fine particle entrainment) was carried out. Entrainment occurred due to hydraulic transport in the bubble rear, which corresponds to the worst case scenario for froth recovery estimation. Results showed that the relative error was less than 0.3%, which allowed validation of the bubble load measurement as an effective methodology for froth recovery estimation at industrial scale.     

Froth transport characterization in a two-dimensional flotation cell

A study of the froth bubble transport in a two-dimensional (2D) flotation cell was performed. Experiments were developed as a 2 × 2 factorial design, in which the effect of superficial air rate (1.2–1.8 cm/s) and froth depth (2–4 cm) on the froth transport for a two phase (air–water) system was characterized.Using image analysis techniques, bubble residence times, air recovery, bubble path and bubble size increase through the froth were obtained. This information was complemented by froth surface velocity measurements using the Visiofroth system.It was found that bubbles transported from the pulp–froth interface up to the overflow, showed a minimum residence time for bubbles entering the froth near the lip wall. Also, the air-recovery significantly changes in a range of 7–20% at different operating conditions.Higher residence times promoted bubble size increase by coalescence for bubbles transported from the interface. Conversely, for lower residence times, a smaller increase in bubble size was observed.     

Relationship between the bubble surface flux that overflows and the mass flow rate of solids in the concentrate of flotation processes

This paper presents the relationship between the bubble surface flux that overflows and the mass flow rate of solids in the concentrate. Even though this study was carried out in a flotation column, the knowledge derived from this paper may be applied to all froth flotation processes. The experimental set up was equipped with an image analysis system to estimate the froth bubble diameter and the air recovery. This study describes the difference between the bubble surface flux entering the froth zone (S_bI) and the flux that arrives to the top of the froth (S_bT) and then overflows to the concentrate (S_bO), the latter being most directly related to the mass flow rate of solids in the concentrate. It was observed that the superficial area of the overflow increased with increasing collector addition and air flow rate, but decreased with increasing froth depth and particle size distribution. Visual evidence and experimental results suggest that, it is common that the superficial area of air that overflows in the concentrate is covered by particles. Only when this condition is almost achieved does overflows occur; otherwise, a high level of coalescence and bubble bursting take place at the froth surface. This was concluded after finding compatible trends between the estimated and predicted mass flow rates of solids in the concentrate, when a tractable geometrical model was used (R² = 0.8).     

Modelling of entrainment in industrial flotation cells: Water recovery and degree of entrainment

Entrainment in flotation can be considered as a two-step process, including the transfer of the suspended solids in the top of the pulp region just below the pulp–froth interface to the froth phase and the transfer of the entrained particles in the froth phase to the concentrate. Both steps have a strong classification characteristic. The degree of entrainment describes the classification effect of the drainage process in the froth phase. This paper briefly reviews two existing models of degree of entrainment. Experimental data were collected from an Outokumpu 3 m³ tank cell in the Xstrata Mt. Isa Mines copper concentrator. The data are fitted to the models and the effect of cell operating conditions including air rate and froth height on the degree of entrainment is examined on a size-by-size basis. It is found that there is a strong correlation between the entrainment and the water recovery, which is close to linear for the fines. The degree of entrainment decreases with increase in particle size. Within the normal range of cell operating conditions, few particles coarser than 50 μm are recovered by entrainment. In general, the degree of entrainment increases with increase in the air rate and decreases with increase in the froth height. Air rate and froth height strongly interact with each other and affect the entrainment process mainly via changes in the froth retention time, the froth structure and froth properties. As a result, other mechanisms such as entrapment may become important in recovering the coarse entrained particles.     

Speed analysis of quartz and hematite particles in a spiral concentrator by PEPT

Activated quartz and hematite tracers between 1180 and 1700 μm in diameter were tracked in two sections of the first two turns of a spiral concentrator to ascertain information on valuable and gangue particle motion. The tracking took place while the tracer was flowing in a 20% solids by mass iron ore slurry. The direct activation of mineral particles, combined with the use of an adjustable height circular assembly of modular positron emission particle tracking detectors, has made this tracking possible. The tracer particle trajectories and speeds are presented in this paper. An early separation into two streams (concentrate or loss to tailings) can be seen for certain runs of the hematite tracers. Tracers speeds and radial position from the centre of the spiral give more details about the presence of the slurry film’s secondary flow in the middle zone of the spiral trough. Particle inward and outward migration speed in this secondary circulation is presented. The speed of this migration is approximately 0.12 m/s inward and 0.15 m/s outward for the set-up used.     

Froth touch samples viewed with Scanning Electron Microscopy

The stability of the thin films found in the froth phase of flotation plays an important role in the overall efficiency of the separation process. In turn, the physical behaviour of the particles attached to the films has a direct impact on the lamella stability. This effect is not fully understood. The film solids loading, or attached mass to area ratio, is an indicator of froth stability and has been measured by touch sampling of surface bubbles. Multiple samples can also be assayed as an indicator of maximum possible grade. Here the touch sample technique is used to show the particle packing arrangement on the film. This work presents images of touch samples from the top of the froth viewed under a Scanning Electron Microscope (SEM). Froth samples were obtained during batch flotation of glass beads with a size fraction of 90–150 μm. The packing arrangement of the particles attached to the surface lamellae were clearly resolved, making it possible to obtain a measure of film packing density using image analysis. These results can be used to validate and expand physical models that predict film stability.     

Factors involving the solids-carrying flotation capacity of microbubbles

Dissolved air flotation (DAF) is a technique used extensively for separating fine particles in water and wastewater treatment, but, unfortunately, its use is still limited for froth flotation of minerals. This appear to be due to the very low lifting power of the microbubbles (40–70 μm) and low airflow rate because of the low solubility of air in water. Thus, the efficiency of DAF in treating mineral particles has shown to be poor and as a solid/liquid separation technology is limited to slurries with no more than 3% solids. This work presents results showing (measuring) the limits of DAF as a function of particle size distribution, solids content and air superficial velocity. Interestingly, the microbubbles were found to be not selective with respect to particle size, floating both fine and coarse particles, which is most likely due to the existence of several mechanisms acting on the flotation of particles by these minute bubbles.     

Selective transport of attached particles across the pulp–froth interface

A technique for determining the recovery of attached particles across the froth phase in flotation that relies on measuring the rate at which bubble–particle aggregates enter the froth is used to investigate the selectivity of attached particles across the froth phase. Combining these measurements with those of other techniques for determining the froth recovery of attached particles provides an insight into the different sub-processes of particle rejection in the froth phase. The results of experiments conducted in a 3 m³ Outokumpu tank cell show that the detachment of particles from aggregates in the froth phase occurs largely at the pulp–froth interface. In particular it is shown that the pulp–froth interface selectively detaches particles from aggregates according to their physical attributes.     

The influence of submicron particles and salt on the recovery of coarse particles

Coarse particles are more difficult to float. One of the factors that contributes to poor floatability is the stability of froth. The froth formed in industrial flotation cells is typically not strong enough to provide adequate support for coarse and dense particles. The present study investigates how the presence of hydrophobic submicron particles at low concentration increases the recovery of relatively coarse particles through improvement in the froth stability. Silica particles with d₈₀ of approximately 230 μm were floated in a laboratory mechanical flotation cell in a collector-free environment in the presence of poly(propylene glycol) 425 as a frothing agent. The hydrophobicity of the feed particles was modified through an esterification process with different alcohols ranging from 3 to 8 hydrocarbon groups to form a coating of intermediate hydrophobicity. Hydrophobised silica submicron particles of 300 nm in size were added to the flotation cell at 0.01 and 0.1 wt% concentration. The effect of electrolyte, sodium chloride, in the concentration range 10⁻⁵–10⁻¹ M on the recovery of coarse particles was also investigated. For the feed employed, 1-butanol was found to provide relatively good flotation properties with a possibility for improvement by stabilising the froth phase. Both additives slightly stabilised the froth phase, which resulted in an increase in the maximum recovery of up to approximately 8%. It appeared that the additives had no significant effect on the first-order flotation rate constant.     

PEPT studies of heavy particle flow within a spiral concentrator

Future improvements of gravity concentrators require an increased knowledge of the mechanics behind the separation, including the motion of the particles. This work details the investigation of particle motion through a spiral concentrator. The results of tracking the motion of individual particles using the positron emission particle tracking (PEPT) technique are described. Tracer particles of different sizes and density were tracked along the trough of a laboratory scale spiral. Multiple passes of one tracer through the spiral are combined to represent the bulk of flow of this particle type and size, with the position and time recorded to allow for the particle trajectory and speed to be determined. Finally, the use of PEPT will be shown to be a powerful method to visualise the behaviour of particles during the concentration process, providing data that will be used for the validation of new models of spiral concentrator performance.     

Flotation of coarse composite particles in mechanical cell vs. the fluidised-bed separator (The HydroFloat™)

In principle, carrying out flotation of coarse and composite particles in a quiescent flow field is decisive to prevent particles detaching from bubbles. To overcome or limit detachment of coarse composite particles from bubbles in flotation, a fluidised bed separator, the HydroFloat™, which provides a quiescent environment has been used, and the results compared to the performance of a mechanical (Denver) cell. Model synthetic composites of quartz (value mineral) in lead borate (gangue) matrix with simple and complex locking texture were used for the study. The flotation behaviour of particles with different locking textures was studied at a coarse size distribution of 250–600 μm in both the HydroFloat separator and the Denver cell. The recovery of composite particles with the different locking textures was analysed on an un-sized and size-by-size basis. Recovery was improved in the HydroFloat separator, with both simple and complex locking composite particles having almost the same recovery. Again, comparison of recovery with the HydroFloat to the Denver cell indicates that the separator greatly out-performs mechanically agitated cells for the upper particle size of about 500 μm, with a significant effect on complex locking texture composites. This is attributed to the minimum or absence of turbulence and minimal froth zone which causes detachment of coarse particles in most conventional cells.     

New directions in flotation machine design

The theoretical background for flotation kinetics of ultrafine and coarse particles are explored. Recent advances in flotation technology for these difficult areas are reviewed, with a focus on improving the flotation rate of ultrafines, and extending the upper limit for coarse particle flotation.For ultra-fine particles, the theory suggests that the rate of flotation can be improved by increasing the rate of shear in the suspension of particles and bubbles. A new cell has been developed, the Concorde Cell, in which the pre-aerated feed is raised to supersonic velocities before passing into a high-shear zone in the flotation cell. The local dissipation rate is of the order of 100 kW/m³, one to two orders of magnitude higher than is available in conventional mechanical cells. The Concorde Cell has been trialed on a finely ground PGM feed in South Africa, with excellent results. By recycling the tailings, and using the mass pull or solids recovery as the control variable, the Cell is capable of producing a high-grade concentrate at high recoveries, over a wide range of particle sizes.Theory for the upper limit of coarse particle flotation suggests that a quiescent flow field is necessary to prevent the particles from becoming detached from the bubbles. A liquid-fluidized bed provides a suitable environment. The flotation feed is introduced into the fluidized bed, and air bubbles are dispersed in the fluidizing water. Coarse particles attach to the bubbles rising through the bed and are lifted into the froth layer that is maintained on top of the cell in the usual way. Particles of galena up to 1 mm in diameter have been recovered in such a bed, while for particles of lower density such as quartz and coal, the upper limit for flotation has been extended to at least 2 mm and 5.6 mm respectively. The fluidized bed technology provides major advantages beyond the ability to recover coarse particles currently lost in existing operations. Thus, if the upper flotation limit can be extended, the top size for grinding can be raised, with significant reductions in energy costs. Liberation of the values is the key limitation. Also, a fluidized bed flotation cell can accept a feed with much higher percent solids, leading to significant reductions in water requirements.     

Packing of particles on the surface of bubbles

In this paper, geometrical packing models were derived to determine the coverage of particles on an air bubble. Nearly spherical glass beads of two size fractions and galena particles were used in the study. The coverage of air bubbles by glass beads was carried out in the concentration range 2.74 × 10^?5–1.65 × 10^?3 mM of CTAB. The results indicated that coverage at all concentrations could be approximated with a hexagonal model with monodispersed particles using the value of d_[4,3]. This could be done with a relative deviation of the packing factor within 15%. The coverage of an air bubble by galena particles was carried out in a collectorless environment. The best models were found to be a hexagonal or square cell using the value of d_[1,0]. Experimental observations on particle packing are given and implications for the froth phase of flotation are discussed.     

Prediction of the metallurgical performances of a batch flotation system by image analysis and neural networks

It is now generally accepted that froth appearance is a good indicative of the flotation performance. In this paper, the relationship between the process conditions and the froth features as well as the process performance in the batch flotation of a copper sulfide ore is discussed and modeled. Flotation experiments were conducted at a wide range of operating conditions (i.e. gas flow rate, slurry solids%, frother/collector dosage and pH) and the froth features (i.e. bubble size, froth velocity, froth color and froth stability) along with the metallurgical performances (i.e. copper/mass/water recoveries and concentrate grade) were determined for each run. The relationships between the froth characteristics and performance parameters were successfully modeled using the neural networks. The performance of the developed models was evaluated by the correlation coefficient (R) and the root mean square error (RMSE). The results indicated that the copper recovery (RMSE = 2.9; R = 0.9), concentrate grade (RMSE = 1.07; R = 0.92), mass recovery (RMSE = 1.94; R = 0.94) and water recovery (RMSE = 3.07; R = 0.95) can be accurately predicted from the extracted surface froth features, which is of central importance for control purposes.     

Optimization of operating parameters for coarse sphalerite flotation in the HydroFloat fluidised-bed separator

Increasing the upper size limit of coarse particle flotation has been a long-standing challenge in the minerals processing industry. The HydroFloat separator, an air-assisted fluidised-bed separator, has been used in this study to float 250–1180 μm sphalerite particles in batch flotation tests and compared to results achieved utilizing a laboratory-scale conventional Denver cell. The quiescent environment within the HydroFloat cell significantly reduces the turbulent energy dissipation within the collection zone, hence decreasing the detachment of particles from bubbles during flotation. Three operating parameters including bed-level, superficial water and gas rates have been studied, and their effect on the flotation of coarse sphalerite particles is reported. It is shown that coarse sphalerite recovery increases with increasing bed-level, superficial water and gas flow rates. However, there are thresholds for each operating parameter above which recovery starts to decrease. A comparison of recovery with a conventional Denver flotation cell indicates that the HydroFloat separator vastly outperforms the conventional flotation machine for the very coarse particles (+425 μm), and this is mainly attributable to the absence of turbulence and the minimization of a froth zone, both of which are detrimental to coarse particle flotation.     

Gravity separation of coarse particles using the Reflux Classifier

A comprehensive study examining the potential of the Reflux Classifier to be applied to the beneficiation of coarser coal up to 8 mm in size was undertaken. It was demonstrated that efficient combustible recovery and control of the separation density to target low ash products could be achieved. The major finding from the study was the critical importance of providing sufficient fluidization water, though beyond the critical level the process was largely insensitive to the fluidization rate. It was concluded the required fluidization velocity is nominally 10 m/h per mm of top-size, hence for a nominal 4 mm top size the required velocity is 40 m/h. In an extended campaign the control of the process was investigated by varying the set point density from high to low levels and then returning the process to the original settings, and demonstrating a return to the original separation. Further analysis was conducted to determine the partition curves and the shift in the separation density with particle size. The variation in the D₅₀ with particle size approaches a level that is independent of the particle size. Previous data (Galvin et al., 2002, Galvin et al., 2004) covering particles up to 2 mm in size are consistent with the results from this study, involving feeds with top sizes of 4 mm and 8 mm. Beyond a particle size of 2 mm the Ep is typically less than 0.05 and approaches about 0.03 as the particle size increases to 8 mm.     

Influence of particles on the formation of bubbles from a submerged capillary

This paper will explore the possibility of using colloidal particles as a bubble stabilising agent in froth flotation. Nearly monodisperse 300 nm silica particles were subjected to surface modification through an esterification reaction using a long chain alcohol to create an advancing contact angle of 73.5 °. To study the influence of particles on the growth and departure of a single bubble, experiments were performed with a capillary tube submerged in the hydrophobised silica suspension. A high-speed camera was used to capture the bubbling phenomena in real time. The acquired videos were then analysed to extract the parameters such as bubble size, departure frequency, and growth time through an image-processing software. Experiments were also carried out with MIBC (methyl isobutyl carbinol) and a polyglycol type surfactant (poly(propylene glycol)), PPG) for comparison. The results showed that an increase in the particle concentration resulted in a decrease in mean bubble size produced at the tip of capillary. The same trend was also observed with both frothers.