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By R. R. Klimpel

"SYNOPSISA discussion of the importance of flotation rate in the analysis of mineral flotation is presented. In particular, the highly interactive nature of the flotation ""system"" is emphasized where there are components of chemistry, equipment, and operating conditions simultaneously involved. It is further shown that: 1) flotation rate must be measured in order to economically optimize the performance of an industrial flotation circuit, 2) that consistent patterns exist in both flotation rate and equilibrium recovery when changing various settings of the system components, 3) that knowledge of these patterns is necessary in order to avoid making system changes that are either self-compensating or dramatically re-enforcing in some particular aspect of performance, and 4) the rate related role of the chemistry component (e.g.frothers and collectors) is often much bigger than is sometimes realized (especially in a negative sense involving overdosing of reagents). INTRODUCTIONFroth flotation is widely usedl-6 in mineral beneficiation processes as a method for separating different types of finely divided solids present in a liquid (usually aqueous) suspension. The approach is based on the contacting of solids with upward moving air bubbles in an agitated vessel where the solids are exposed to chemicals (collectors) which create a condition favoring the attachment of a certain portion of the solids to the air bubbles. This selected portion is then removed in a froth stabilized by chemicals (frothers) and subsequently recovered from the flotation vessel. Depending on the settings of the various components of the flotation ""system"" (see Figure 1) it is possible to achieve a wide range of flotation performance."

Jan 1, 1984

By M. Brändström, R. Dube, J. Moyo, T. Perkins, G. Bermudez, L. Bartsch, C. Smith, R. Sorensen

The Kennecott Copperton concentrator is currently the bottleneck for the Kennecott operation and several projects have been initiated to increase throughput. This increase in grinding circuit throughput has resulted in a coarser grind size which has impacted flotation circuit recovery. Metso Outotec 300m3 forced air tank flotation cells are currently utilized in the rougher flotation circuit at the Copperton concentrator. Higher overall recoveries have been observed on the newer Outotec tank cells compared to the original 85m3 self-aspirated flotation cells they replaced. However, coarse particle flotation response on these large, forced air cells did not show encouraging results when compared to smaller previously installed cells. This coarse recovery loss has been attributed to the longer froth transport duration and transport distance on large cells (100m3 and larger). Cell manufacturers addressed the risks of additional coarse particle losses in large cells by installing concentric circumferential launders and crowders (also called center launders). These are designed to reduce froth transport time and distance in the last cells in rougher stages where low residual floatable minerals causes a lack of froth mobility. The center launders also increase froth crowding, which also helps to increase froth transport velocity and increases copper and molybdenum recoveries. A trial set of the center launder retrofits were installed on the last three tank cells in one of the parallel rougher flotation rows at Copperton. The launder retrofits were installed at the end of October 2020 and monitored until March 2021. This six-month trial showed statistically significant improvements in copper and molybdenum flotation recoveries through the rougher circuit.

Mar 2, 2022

By Ian Coltrin, Steve Merrill, Dariusz Lelinski, Sudhir Kamath

Froth flotation has been the heart of mineral beneficiation for over a century. Over the years, developments have been made in flotation cell design, size, and in many other aspects of flotation technology. Despite the overall effectiveness of these improvements, valuable mineral particles are often lost along with waste material. These particles are lost when the froth recovery process within a flotation system is not designed for variable froth conditions seen in plant operations. Both the amount of froth generated and the type of froth in a flotation cell change as concentrate is removed down a row of cells. Traditionally, froth recovery has been designed using a froth carry rate averaged over the entire row of flotation cells with a static amount of open area at the top of the cell.

Sep 30, 2022

By J. -C. Sztuke, M. Cao

ABSTRACT The correlations between froth recovery of coal and air recovery were investigated using a hybrid mechanical flotation column. The particle slurry was fed onto the surface of air-water two phase froths to carry out the tests. Froth recovery was taken as the recovery of particles into the froth product, whereas air recovery was determined by the froth height method. The relationships between froth recovery and air recovery were nearly linear, with greater slopes for more hydrophobic particles. Inside the froth phase, the particles were stratified, with hydrophobic particles concentrated in the upper region and hydrophilic particles in the lower region.

Jan 1, 2013

By Duong Huu Hoang, Nathalie Kupka, Urs A. Peuker, Martin Rudolph

"The froth ability, froth stability and the froth structure are strong influences in flotation process i.e. on water recovery, bubble size, entrainment of gangue particle, flotation rate constants, grade and recovery. The labscale flotation of rich apatite ore with a high mass pull leads to significant changes in pulp and froth properties over time. The froth stability decreases with increasing the flotation time. These changes can be related to different solid contents, reagent concentration, froth heights and bubble size distributions. This study presents the results from froth studies and discussions on the particle size of fully liberated silicates and degree of entrainment based on automated mineralogy size-by-size analysis. The change of entrainment in a rich apatite ore batch flotation with time will describe more precisely by measuring froth properties using a Dynamic Foam Analyzer. It is concluded that the degree of entrainment is not only dependent on particle size but also the pulp density due to its effect on particle settling and also froth properties in varying resistance to particle drainage. Furthermore, entrainment models are applied to predict the effect of size, flotation time on entrainmentINTRODUCTIONFroth flotation belongs to the group of heterocoagulation separation techniques. Froth flotation is classically divided into two active zones, the pulp zone (where particle collection occurs) and the froth zone. A schematics drawing of the interaction between both zones is plotted in Figure 18 (Yianatos and Contreras, 2010). In froth flotation, the collision probability in the collection zone is governed by the physics of the process or hydrodynamics (Wills and Finch, 2016). The true flotation event in the pulp occurs when the hydrophobic valuable mineral particles collide with bubbles and formation of a stable particle-bubble aggregates moving upwards against gravity to the froth phase (Yianatos et al., 2009)."

Jan 1, 2018

By Pavol Loderer

Mineral froth pumping utilising centrifugal slurry pumps is a major engineering challenge for the end users and pump manufacturers due to the undesirable outcome of unstable pump performance. Most of these challenges occur due to incorrect pump selection and suction tank design. The traditional approach is to oversize the pump for pumping mineral froth. New horizontal slurry froth pump designs offer opportunities to improve the mineral froth with challenging (high) Froth Volume Factor while maintaining high efficiency, long wear life and stable pumping performance. This paper examines the flotation process in detail and how froth pumps are designed to handle this arduous process.

By M. C. Harris

The past twenty to thirty years have seen unprecedented research activity aimed at understanding the performance of flotation froths. In 1990, Finch and Dobby coined the term froth recovery factor, Rr, to represent the efficiency of the froth in delivering particles from the pulp-froth interface to the concentrate. Originally defined for flotation columns, Rr has also been found useful in modeling mechanical flotation cells, and a number of techniques, based on quite different approaches, have been developed for measuring the froth recovery in industrial flotation cells. None of these techniques is universally successful. This paper reviews the concept of the froth recovery factor, and the basis of each of the techniques that have been proposed to measure Rr, and examines the reasons for this parameter being so difficult to pin down. Advances in Mineral Processing Science and Technology Proceedings of the 48th Annual Conference of Metallurgists of CIM Sudbury, Ontario, Canada Edited by

Jan 1, 2009

By Reza M. Rahman

The froth phase plays an important role in the flotation and upgrading of the final concentrate. At present, the techniques that have been used in the mineral industry to measure the froth recovery have limitations. The aim of this paper is to investigate the performance of the froth in an industrial flotation cell. A unique device has been developed which is capable of decoupling the froth zone from the pulp zone. It consists of two concentric tubes. The inner tube acts as a dropback collection chamber or catcher. The particles that detach from the froth phase fall directly into the catcher and are collected as froth dropback. The froth recovery measurements were carried out in a rougher bank of a copper concentrator treating sulphide minerals. The dropback device is designed so that it can be immersed into a plant size flotation cell and plant froth recovery measurements can be taken at any given time. During the experiments, the bubbles laden with valuable mineral particles entered the device from the plant flotation cell, subsequently rising to form a froth layer at the top of the device. The particles that detached from the froth zone were collected in the dropback collection chamber whereas the concentrate sample was collected by a launder. By drying, sizing and chemical analysis of the concentrate and dropback samples, the froth recovery, was estimated on the basis of the valuable component. The effect of air rate on froth recovery was also investigated. Keywords: flotation, froth, dropback, froth recovery

Sep 1, 2012

By Jan J. Cilliers, Nicolas Barbian, Esther Ventura-Medina

"Froth structure and stability are known to play an important role in determining flotation recovery and selectivity. An industrial sampling campaign was performed to develop a clearer understanding of the effect of flotation variables on froth stability and the role played by the resulting stability on flotation performance.Froth stability was estimated as the fraction of bubbles bursting on the surface of the froth through image analysis and the solids loading on the bubbles at the top surface. The image processing was performed using the Smartfroth software on the top surface of the froth. The system gives measurements of bubble size distribution, average bubble size and froth velocity. The froth velocity was used to estimate the volume of bubbles overflowing the weir yielding to the fraction of air overflowing the cell. This measurement is the complement of the rate of bubble bursting on the top surface. Also samples of the lamellae were taken by touching the top surface of the bubbles with a glass slide. Then, the amount of solids and liquid per unit area in the bubble lamellae was estimated gravimetrically. Both measurements were used to establish stability criteria.It was generally found that high air flowrates resulted in a drop of froth stability showed by a drop in the fraction of air overflowing and a decrease in the solids loading and simultaneously produced low copper recoveries and low concentrate grades. Deep froths only allowed a small fraction of air to overflow and consequently produced low recoveries. An increase to high frother dosage did not result in an improved fraction of air overflowing, hence producing low recoveries. Likewise, low frother addition only allows low recoveries because the resulting unstable froth cannot support itself. Low aeration was found to be preferential as it allowed high particle loading, therefore high bubble stabilisation, and low gangue entrainment, resulting in the highest flotation performance."

Jan 1, 2003

By Jan J. Cilliers, Nicolas Barbian, Esther Ventura-Medina

"Froth structure and stability are known to play an important role in determining flotation recovery and selectivity. An industrial sampling campaign was performed to develop a clearer understanding of the effect of flotation variables on froth stability and the role played by the resulting stability on flotation performance.Froth stability was estimated as the fraction of bubbles bursting on the surface of the froth through image analysis and the solids loading on the bubbles at the top surface. It was generally found that high air flowrates resulted in a drop of froth stability showed by a drop in the fraction of air overflowing and a decrease in the solids loading and simultaneously produced low copper recoveries and low concentrate grades. Deep froths only allowed a small fraction of air to overflow and consequently produced low recoveries. An increase from a standard to high frother dosage did not result in a larger fraction of air overflowing, hence producing low recoveries. Likewise, low frother addition only allows low recoveries because the resulting unstable froth cannot support itself. Low aeration was found to be preferential as it allowed high particle loading, therefore high bubble stabilisation, and low gangue entrainment, resulting in the highest flotation performance.Additional laboratory tests were performed to introduce a new stability parameter and to give a clearer understanding of the effect of flotation variables on froth stability. The results confirmed some of the observations made on the plant."

Jan 1, 2003

By S. H. Morar

Froth stability is widely recognized as a key driver of flotation selectivity. It is well known that froth stability is affected by the type and quantity of surface active reagents present (frothers), and the concentration and hydrophobicity of solid particles present. While some studies have been performed on the effect of frothers on froth stability in three-phase systems and the hydrophobicity of particles present, very little work has been performed on the effect of solids loading on froth stability. This may be due to insufficiently robust measurement techniques. This paper investigates the use of a new machine vision measurement to measure solids loading, and the relationship between this measurement, bubble size, and bubble burst rate on the froth surface. Keywords: froth flotation, machine vision, solids loading

Sep 1, 2012

By M. Kaya

This paper presents an experimental method to determine the degree of gangue entrainment in mechanical flotation cells and proposes new and inexpensive methods to lessen it. The applicability of froth washing and vibration was studied in laboratory, pilot plant, and plant scales. The effect of wash water on metallurgical performance was tested with various streams from the Falconbridge Strathcona mill at laboratory, pilot, and plant scales, with the 2nd cleaner at the Eastmaque Kirkland Lake mill, and with the 2nd and 3rd zinc and 3rd and 4th copper cleaners at Les Mines Selbaie mill. It was found that gangue recovery was closely related to water recovery in all systems. Wash water at an optimum superficial rate from 0.03 to 0.07 cm/s reduced entrainment by anywhere from 30X to 70X. Wash water can be further assisted by mechanical and ultrasonic vibration of the froth. A further rejection of 10 to 20X becomes possible. As a result of this work, a number of plants in Canada and in the United States have evaluated and/or are now using froth washing.

Jan 1, 1990

By M. Kaya, A. R. Laplante

"Since the beginning of eighties the use of flotation columns has surged in Canada and abroad; the metallurgical superiority of columns over mechanical cells is in great part due to froth washing, which ensures higher gangue rejection and selectivity. Can wash water, which has proven so beneficial, be used in mechanical cells? Although froth washing technology was widely implemented in Soviet plants for bi tuminuous coal, and alusite, powellite, scheelite, molybdenite, etc. more than 25 years, it has been neglected in the western world. Published data suggest 10 to 15~ increases in grade and/or recovery with wash water in mechanical cells (Klassen and Mokrousov, 1963). There are at least three wash water plant applications in Zaire, Chile, and Canada, but little, if any, published information is available. This research work, which is the first extensive fundamental study related to froth washing in mechanical cells, attempts to answer the questions of how, how much, and where should wash water be added.This project was undertaken in three stages:1. Bench-scale laboratory tests with a 6.5 L Denver cell at McGill using a silica flour and a slime reject from Niobec (St.Honor6).2. Pilot-plant scale tests with a 65 L Denver cell at McGill using the silica flour and a complex Cu-Ni sulphide ore from the Strathcona mill of Falconbridge.3. Plant-scale tests with a bank of 2800 L Denver cells at Falconbridge Ltd. for complex Cu-Ni sulphide ore and Eastmaque Gold Mines Ltd. for Au tailing reclaimation."

Jan 1, 1989

By D. Mesa, J. Karvonenb, A. López, P. R. Brito-Parada, R. Grau, D. Davoise

The froth zone in flotation cells plays an important role in determining metallurgical performance. This is even more critical as cell sizes increase, since larger bursting surface areas can easily result in poor froth transport and even stagnant froth zones, which are detrimental to recovery. Generating additional overflowing lip length by adding internal launders and reducing surface area (while also directing the froth to the overflow) by adding crowders are well established design strategies to enhance froth mobility. However, comparative experimental studies of froth zone design modifications at industrial scale are scarce and often lack detailed froth characterisation. In this work, we present the results of two experimental campaigns that were carried out at Atalaya’s Riotinto concentrator in order to determine the effect of a new froth zone design on the flotation performance of a TankCell® e300 cell that operates as the first cell of the rougher bank. These campaigns provided a unique opportunity to assess froth phase phenomena and metallurgical performance before and after changes in design. The original cell design had an internal peripherical launder and a froth cone, while the new concentrate launder technology adds a centre launder and an adjustable froth crowder to the existing launder design. The new concentrate launder arrangement reduces significantly the froth area as well as the froth transport requirements, aiming to improve froth recovery and, consequently, enhance flotation performance, allowing copper recoveries in the TankCell® e300 cell to increase dramatically. In addition, radial profiles of froth height and froth velocity at the surface were determined, which provide valuable insight into the effect of design changes on froth stability and mobility. Keywords: Flotation performance, enhanced recovery, launder, crowder, froth stability

Jan 1, 2020

By A. Zangooi, J. A. Finch

Flotation is a separation process based on the collection of particles on the surface of bubbles. Flotation machines disperse air into bubbles using a variety of techniques. The characteristics of the bubble population are strongly affected by the selection of frother type and concentration. As metallurgical results depend on the bubble distribution, the measurement of frother concentration is vital to understand and control performance. A previously developed colorimetric technique was refined to work with low solubility frothers and to increase daily analysis rate. Field-testing demonstrated that the method is robust, reliable and accurate. As well as relating frother concentration to gas dispersion measurements, the results can be used to answer operational questions including: how well a frother dissolves, how reliable and stable frother delivery is, how evenly frother is distributed down a bank, and whether frother distributes between the pulp and froth zones. Some of these points are illustrated from plant experiences. Advances in Mineral Processing Science and Technology Proceedings of the 48th Annual Conference of Metallurgists ofCIM Sudbury, Ontario, Canada Edited by

Jan 1, 2009

By F Cappuccitti

A colourimetric technique, originally developed for methyl iso butyl carbinol (MIBC) based on the Komarowsky reaction, has been extended to a wide range of common mineral flotation frothers. The procedure, which is briefly described, is shown suited to on-site determinations in a campaign at Kennecott Utah Copper Copperton Concentrator (Rio Tinto). Some observations are described, including: frother (MIBC) concentration evolution down a bank, frother distribution between pulp and froth phases, and loss of frother over time due to adsorption on certain minerals. A possible interference with a fuel oil addition was overcome. MIBC in recycle water was also measured. The ability to monitor frother easily will help interpret gas dispersion behaviour and should permit further optimisation of flotation cell hydrodynamics and chemistry. The capability to directly measure should help optimise the type, amount and location of frother addition, and to assess frother recycled with reclaim process water.

Jan 1, 2005

By Frank Cappuccitti, James A. Finch, Stéphanie Gélinas

"A colorimetric technique, originally developed for methyl iso butyl carbinol (MIBC) based on the Komarowsky reaction, has been extended to a wide range of common mineral flotation frothers. The procedure, which is briefly described, is shown suited to on-site determinations in a campaign at Kennecott Utah Copper Copperton Concentrator (Rio Tinto). Some observations are described, including: frother (MIBC) concentration evolution down a bank, frother distribution between pulp and froth phases, and loss of frother over time due to adsorption on certain minerals. A possible interference with a fuel oil addition was overcome. MIBC in recycle water was also measured.The ability to monitor frother easily will help interpret gas dispersion behaviour and should permit further optimization of flotation cell hydrodynamics and chemistry. The capability to directly measure should help optimize the type, amount and location of frother addition, and to assess frother recycled with reclaim process water.INTRODUCTIONOwing to the lack of analytical methods, the task of determining frother concentration in plant flotation circuits is not routinely performed. Industrial sites seldom outsource analyses that are both costly and inconvenient, due to the necessity of shipping freeze-dried samples to remote testing facilities. A more direct colorimetric method has recently been demonstrated for the laboratory characterization of common industrial frothers (Gélinas and Finch, 2004). The approach, based on the Komarowsky reaction (Penniman et al., 1936; Coles et al., 1942; Duke, 1947), was previously described by Parkhomovski et al. (1976) for methyl iso butyl carbinol (MIBC). The reaction involves the interaction of the OH group of a higher alcohol, concentrated sulphuric acid, and salicylaldehyde, to yield coloured solutions with intensities that can be analyzed by UV-visible spectrophotometry."

Jan 1, 2005

By James A. Finch, Stéphanie Gélinas

"A colorimetric technique, originally developed for methyl iso butyl carbinol (MIBC) based on the Komarowsky reaction, has been extended to a wide range of common mineral flotation frothers. The procedure, which is briefly described, is shown suited to on-site determination in a series of industrial campaigns. Some frother observations are described, including: concentration evolution down a bank, distribution between pulp and froth phases, and a mass balance around a circuit. Minute amounts of frother in recycle water were also measured.The contribution of frother and alcohol by-products in the analysis was generally additive for plants using aliphatic alcohol type frothers and decoupled for systems using glycols. Typically, U250C (polyglycol) was used at higher concentration (>10 ppm) than MIBC (aliphatic alcohol) (<10 ppm) or F-150 (polyglycol) (<3ppm).The ability to monitor frother easily will help interpret gas dispersion behaviour and should permit further optimization of flotation cell hydrodynamics and chemistry. The capability to directly measure should help optimize the type, amount and location of frother addition, and to assess frother recycled with reclaim process water.INTRODUCTIONOwing to the lack of analytical methods, the task of determining frother concentration in plant flotation circuits is not routinely performed. Industrial sites seldom outsource analyses that are both costly and inconvenient, due to the necessity of shipping freeze-dried samples to remote testing facilities. A more direct colorimetric method has recently been demonstrated for the laboratory characterization of common industrial frothers (Gélinas and Finch, 2004). The approach, based on the Komarowsky reaction (Penniman et al., 1936; Coles et al., 1942; Duke, 1947), was previously described by Parkhomovski et al. (1976) for methyl iso butyl carbinol (MIBC). The reaction involves the interaction of the OH group of a higher alcohol, concentrated sulphuric acid, and salicylaldehyde, to yield coloured solutions with intensities that can be analyzed by UV-visible spectrophotometry."

Jan 1, 2007

By J. E. Nesset

Significant progress has been made over the past few years on characterizing and understanding the hydrodynamic properties of frothers and collectors and their effect on flotation performance. This new understanding of the relationship between chemistry and hydrodynamics has dramatic implications for how flotation circuits should be controlled and optimized. Previous work has shown that choosing a frother of the right &apos;strength&apos; is critical to the optimization process, and the work and discussion presented here serve to strengthen the argument. In addition, we know that collector chemistry may also influence hydrodynamic properties and needs to be taken into consideration. To achieve the desired outcome, the overall system of reagents and operating parameters must be considered. This paper describes and discusses some of the findings from recent research on frother and collector chemistry effects (on hydrodynamics), and how this knowledge can be used to improve flotation performance. Examples from plant experience are discussed.

Jan 1, 2009

By J. E. Nesset

"Significant progress has been made over the past few years on characterizing and understanding the hydrodynamic properties of frothers and collectors and their effect on flotation performance. This new understanding of the relationship between chemistry and hydrodynamics has dramatic implications for how flotation circuits should be controlled and optimized. Previous work has shown that choosing a frother of the right ‘strength’ is critical to the optimization process, and the work and discussion presented here serve to strengthen the argument. In addition, we know that collector chemistry will also influence hydrodynamic properties and needs to be taken into consideration. To achieve the desired outcome, the overall system of reagents and operating parameters must be considered. This paper describes and discusses some of the findings from recent research on frother and collector chemistry effects (on hydrodynamics), and how this knowledge can be used to improve flotation performance. Examples from plant experience are discussed.INTRODUCTIONFrothers perform various functions in flotation but the primary ones are control of bubble size in the pulp zone and stabilization of the froth zone. Laskowski (2003) was among the first to try to capture both roles in characterizing frothers in order to provide a basis for frother selection for a given duty, as well as to explore the link between function and frother chemistry (structure). The method he used requires bubble size data and a frothing index; the procedure has been simplified by Cappuccitti and Finch (2008) using gas hold-up to substitute for bubble size, and froth height (without overflow) as the froth stability metric. The gas hold-up/froth height relationship will be referred to as ‘hydrodynamic characterization’. Essentially, the gas hold-up parameter reflects the sum of the hydrodynamic conditions in the pulp phase (water in this case), i.e. the effect of bubble size plus the apparent impact of the water surrounding the bubble due to the frother (Finch, Nesset and Acuna, 2008). Similarly, the stable froth height parameter reflects the sum of hydrodynamic conditions in the froth, i.e. the effect of bubble size undergoing coalescence plus the influence of the water in the lamellae and Plateau borders between bubbles. It could be argued that the gas hold-up/froth height relationship is a superior one to simple bubble size/froth index for discerning differences in frother behaviour"

Jan 1, 2010