ToF-SIMS-derived hydrophobicity in DTP flotation of chalcopyrite: Contact angle distributions in flotation streams

Particle hydrophobicity has been derived from Time of Flight Secondary Ion Mass Spectrometry (ToF-SIMS) measurements and its impact on the flotation behaviour of chalcopyrite investigated. Batch flotation tests were performed using a dithiophosphate-type of collector in different concentrations. Three flotation regimes were studied using particle size ranges of 20–38 μm, 75–105 μm and 150–210 μm. The individual particle contact angle, and hence, the distribution of contact angles of chalcopyrite within feed, concentrate and tail flotation samples has been determined using ToF-SIMS secondary ions. The effects of particle size and hydrophobicity on the flotation behaviour have been investigated using this new approach. The hydrodynamic effects of the particle size were highlighted by the different distributions of contact angles obtained for each concentrate size fraction, with fine and coarse sizes requiring higher average contact angles to float. This effect was overtaken by hydrophobicity when a high collector concentration was used. The broad distribution of contact angles observed in all samples, i.e. heterogeneity in hydrophobicity, has significant consequences for interpreting flotation behaviour. The methodology of analysis conducted in this study was applied to real ore and can be used as a quantitative, diagnostic tool for examining surface chemical factors affecting hydrophobicity. This new technique has promise and may advance the understanding of mechanisms, which may lead to better control strategies for improving flotation performance. Furthermore, any mineral–collector system can be targeted, provided appropriate calibration is performed.     

Effects of Particle Size and Chain Length on Flotation and Adsorption of Quaternary Ammonium Salts onto Kaolinite

Effects of particle size and chain length on flotation of quaternary ammonium salts (QAS) onto kaolinite have been investigated by mico-flotation tests. The two kinds of quaternary ammonium salts [RN(CH3)3] with different chain lengths, dodecyltrimethylammonium chloride (DTAC) and cetyltrimethylammonium chloride (CTAC) were used as collectors for kaolinite in different particle size fractions (0.075–0.01 mm, 0.045–0.075 mm, 0–0.045 mm). The anomalous flotation behavior of kaolinite have been further explained based on crystal structure considerations by adsorption tests and molecular dynamics (MD) simulation. The results show that the flotation recovery of kaolinite in all different particle size fractions decreases with an increase in pH when DTAC and CTAC are used as collectors. As the concentration of collectors increases, the flotation recovery increases. The longer the carbon chain of QAS is, the higher the recoveries of coarse kaolinite (0.075–0.01 mm and 0.045–0.075 mm) are. But the flotation recovery of the finest kaolinite (0–0.045 mm) decreases with chain lengths of QAS collectors increasing, which is consistent with the flotation results of unsifted kaolinite (0–0.075 mm). It is explained by the froth stability related to the residual concentration of QAS collector. In lower residual concentration, the froth stability becomes worse. Within the range of flotation collector concentration, it's easy of CTAC to be completely adsorbed by kaolinite in the particle size fraction (0–0.045 mm), which led to lower flotation recovery. Moreover, it is interesting that the particle size of kaolinite is coarser, the flotation recovery is higher. The anomalous flotation behavior of kaolinite is rationalized based on crystal structure considerations. The results of MD simulations show that the (001) kaolinite surface has the strongest interaction with DTAC, compared with the (001), (010) and (110) surfaces. On the other hand, when particle size of kaolinite is altered, the number of basal planes and edge planes is changed. It is observed that the finer kaolinite particles size become, the greater relative surface area of edges is, and the more the number of edges is. It means that fine kaolinite particles have more edges to adsorb less cationic colletors than that of coarse kaolinite particles, which is responsible for the poorer floatability of fine kaolinite.     

Upgrading of calcareous phosphate ores by flotation: Effect of ore characteristics

Sedimentary phosphates contain-besides the phosphate minerals-, various associated gangue minerals such as: clays, silica, calcareous minerals (mainly calcite and dolomite), carbonaceous matter, iron oxides and/or pyrite. The common practiced flow-sheets for concentrating these types of phosphate ores consist of a combination of various mineral processing units such as: crushing and screening, attrition, washing, magnetic separation, and/or flotation. However, none of these combinations was successfully efficient to upgrade the calcareous ores because of the close similarity of the physical properties (density, particle size, particle shape, etc.) as well as the surface physico-chemical properties of the carbonate and phosphate minerals. For the last five decades extensive efforts have been spent to adopt flotation for separating carbonates from phosphate ores. These efforts include thermodynamic analysis, modification of the technique, controlling the pulp environment, and finding new reagents that can specifically differentiate between carbonates and phosphates.This paper reviews some of the published work on the separation of carbonates from phosphate ores by flotation and presents the flotation results of phosphate ore samples different in their physical properties and mineralogical composition. The results obtained reflect the effect of ore nature on the flotation performance and the reagents consumption.     

The flotability of very fine particles — A review

The review is in three main sections. First, the observation that overall flotation performance deteriorates for the finest particles is confirmed, but the precise effects of particle size on recovery, grade, and flotation rate are shown to be more complex. In the second section an assessment is made of theories which have been proposed to explain the slower flotation rate of ultrafines, the effects of slime coating, and the flotation of slimes with cationic collectors. The last section of the paper gives a critical evaluation of methods which are claimed to improve the flotation of ultrafine particles.     

New method and equations for determining attachment tenacity and particle size limit in flotation

A new method and simple, yet accurate, equations for determining the tenacity of particle attachment and the particle size limit in flotation were developed by applying the force analysis of the gravity–capillarity coupling phenomena controlling the bubble–particle stability and detachment. Approximate solutions to the Young–Laplace equation were used to develop simple equations for the tenacity of attachment of particles with diameter up to 20 mm. Simple equations for the maximum size of floatable particles were derived as explicit functions of the particle contact angle, the surface tension, the particle density and the mean centrifugal acceleration of turbulent eddies. For the typical particle size and contact angle encountered in flotation, the analysis showed that the bubble size has little effect on the tenacity of particle attachment. The prediction for the largest size of floatable particles is compared with the experimental data and signifies influence of turbulence on the particle detachment.     

The air flow number in flotation machine scale-up

The flotation cell is quantified as a mixing device for one, two, and three phase systems using combinations of water, air, and solids. To do this, power consumption was measured as a function of impeller speed, rate of aeration, and solids concentration. Initial suspension of solids and dispersion of suspended solids throughout the water or water/air system were also studied as influenced by impeller speed, particle size and solids concentration. The power number and air flow number were used to correlate the data.Flotation studies with a zinc ore using three sizes of cells of the same design, showed that aeration had to be controlled in the smaller cells to duplicate the results in the cell of commercial size. For optimum results the flow number range in the smallest cell was less than the critical value for suspension of coarse particles. Operating flow numbers for the three cell sizes under optimum conditions were close; commercial cells of the same size operating elsewhere appear to have two to three times higher flow numbers.The general relationships among air flow, impeller speed, particle suspension and flotation are discussed with particular reference to scale-up problems and coarse particle flotation. Both impeller speed and aeration should be considered as variables requiring systematic study and independent adjustment.     

The effect of bubble size on the rate of flotation of fine particles

Flotation experiments have been carried out in a cell in which bubbles of known size could be generated independently of the turbulence levels, which could be controlled by varying the impeller speed. The mean bubble size ranged from 75 μm to 655 μm.Results are reported for the flotation rates of fine particles, less than 50 μm diameter. The materials floated were polystyrene latex particles, quartz and zircon. These were chosen to give a wide range of specific gravity.It was found that the flotation rate was very strongly affected by the bubble size, there being an increase of up to one hundred-fold when the bubble size was reduced from 655 μm to 75 μm. Effects of particle density and impeller speed are also reported.     

河北丰宁招兵沟铁磷矿浮选选磷影响因素分析

通过对河北丰宁招兵沟铁磷矿浮选选磷工艺7年的生产实践总结,对原矿石性质,浮选粒度、浓度,浮选泡沫层动态,浮选机充气量,浮选温度,浮选水质等影响因素分别进行探讨和研究,找出影响浮选工艺的因素,为选矿厂生产提供依据。     

The entrainment factor in froth flotation: Model for particle size and other operating parameter effects

Accurately estimating entrainment is crucial when predicting flotation performance as it is essential for determining the concentrate grade achieved. It has been found previously that the amount of gangue entrained is proportional to the water recovery; this proportionality is referred to as the entrainment factor. Experimentally it has been found that entrainment is a strong function of particle size, as well as being dependent on other cell operating parameters such as froth depth and air rate.A simplified theoretical model for entrainment is developed which includes the effects of liquid motion and content, particle settling and particle dispersion. First, a detailed one-dimensional differential model for the entrainment factor is developed and solved numerically. Thereafter, a simplified analytical expression for the entrainment factor is produced which is a good approximation to the more detailed one-dimensional model. Both these models are shown to predict closely experimental trends for entrainment as a function of particle size and froth depth.     

The optimisation of flotation networks

The generalised optimisation of a flotation network is studied by means of using variable connections (structural parameters) and variable enhancement factors which are used instead of a flotation model to describe the separation process. The enhancement factors are functions of variables affecting the flotation process. These functional relationship may be derived by means of using a flotation model. Bounds are placed on the enhancement factors by means of either using a flotation model or by inspection of existing pilot or commercial plant data. These bounds, together with external, system and mass balance constraints and an appropriate objective function, define the general optimisation problem for a flotation network.The optimisation problem above may be solved by non-linear programming methods, however, it is easily transformable into a Linear Programme which is easy to solve. The procedure has been applied to a flotation circuit comprising three banks of cells for which an optimal set of connections and enhancement factors has been computed for varying constraints.A simulation procedure based on a gamma flotation model has been applied to one of the optimal circuits so as to compute the flotation variables.     

Development and implementation of a new flowsheet for the flotation of a low grade nickel ore

Low grade nickel ores containing large amounts of serpentine minerals have historically been difficult to process efficiently. The Mt Keith ore was no exception with recoveries in the first five years of operation averaging just 60%.In this research, the factors limiting performance have been identified and a new process has been devised that raises recovery significantly. The process exploits the particle size dependence of nickel sulphide flotation and the different ways that pH change and pulp density influence the response of coarse and fine particles.Implementation of the new process at Mt Keith has raised nickel recovery by 10%. In turn, nickel production has increased by over 6000 t.p.a. and the net present value (NPV) of the operation has increased by over A$300 m. These outcomes illustrate the large commercial benefits that can be gained by understanding particle size effects in flotation.     

Analysis and optimization of mineral processing and coal-cleaning circuits — Circuit analysis

In mineral processing and coal cleaning operations, there are two classes of unit operations used in the separation processes. The first type — crushing, grinding, pelletizing and settling — modifies the size distribution of the feed. The second type — heavy media, sizing, flotation, magnetic, electrostatic and jigging — separates the particles. In these latter unit operations, the size distribution is not changed; rather, the feed stream is split into a product and waste stream based on subtle physical and physicochemical differences between the different types of feed particles. In separation unit operations, the mathematical functions, representing the behavior of the unit operations, are easy to manipulate. Thus, a number of theorems, useful to both the plant designer, and the plant engineer, can be proven.The work presented in this paper makes the fundamental assumption of linearity as do all current plant design analysis systems. The linearity assumption states that in a separation operation, there is no particle-particle interaction effecting the probability that a particle will be selected for the product or waste stream. In other words, if one doubles or triples the feed rate to a unit operation, the fraction of particles of a given characteristic selected to appear in the product stream remains unchanged. In actuality, this assumption is not true because higher feed rates affect the behavior of separation operations. However, when designing a plant, one can calculate the feed rate to a given unit operation and then select a piece of equipment large enough to handle the computed tonnage. Thus, the designed circuit behaves linearly.     

Dependence of flotation rate on particle size and fractional mineral content

Specific rates of flotation, K, as a function of particle size, d, and fractional mineral content, W, were measured for a quartz-hematite ore in a continuous flotation system using hydroxamate collector. The resulting K-d-W surface is explained in terms of flotation mechanisms and results of previous investigators. A K-d-W relationship will be of value to flotation models.     

Concentration of Utah tar sands by an ambient temperature flotation process

Physical separation of bitumen from low-grade Utah tar sand deposits containing a relatively high viscosity bitumen phase (Sunnyside and Tar Sand Triangle deposits) has been accomplished by traditional size reduction and froth flotation techniques. At appropriate experimental conditions more than 90% of the bitumen can be recovered in a concentrate, containing more than 20 wt. % bitumen, which should be a suitable feed material for subsequent hot water or thermal processing. The efficiency of bitumen recovery depends on the extent of size reduction, as well as promoter and dispersant addition. Rejection of greater than 60% of the sand at ambient temperature and ease of water removal from the concentrate make such a process strategy both energy and cost effective. The energy required to achieve effective separation by the ambient temperature process is significantly less than the energy required for the recently developed hot water process which is being evaluated in a 100-tpd pilot plant this year.The flotation behaviour of the tar sand in this ambient temperature process has been correlated with contact angle measurements and the apparent point-of-zero-charge of the bitumen. The best flotation response at pH 7.8 to 9.0 occurs when the contact angle between the air bubble and bitumen surface is a maximum, corresponding to the apparent point-of-zero-charge of the bitumen as determined by titration.     

The effect of particle shape and hydrophobicity in flotation

The effect of particle shape on the flotation process has been investigated in laboratory experiments with monosized spherical ballotini and ground ballotini. The particles were treated by partial methylation with trimethylchlorosilane to achieve varying degrees of hydrophobicity. In flotation, the process of film thinning and liquid drainage is critical in the formation of stable bubble–particle attachments and this is affected by the particle shape and surface hydrophobicity. Flotation tests with different particle sizes were conducted in a modified batch Denver cell. Predictions from a computational fluid dynamic model of the flotation cell that incorporates fundamental aspects of bubble–particle attachment were compared with data from flotation tests. Contact angles of the particles were measured using a capillary rise technique to indicate surface hydrophobicity. Ground ballotini generally has higher flotation rates than spherical ballotini; the results are consistent with effects from faster film thinning and rupture at rough surfaces and are well correlated by the sphericity index.     

An appreciation of galena concentration using a steady-state flotation model

A general-purpose computer program has been developed for the steady-state modelling of flotation plants. It permits simulation of flotation banks, made up of any number of cells, interconnected if necessary through a regrind unit. Specification of the fresh feed material in terms of the relative amounts and flotation-rate behaviour of its flotable components is necessary so that the program can then calculate the concentration of these components in all the plant streams.The use of the program for plant investigation is demonstrated using data for a lead concentration plant. The model was fitted to steady-state plant data and then tested by comparing the predictions of the model with actual plant measurements at a second feed condition. Full circuit simulation results are also presented to show how steady-state modelling can be used to give information on the likely response of the plant to other changes in feed material and the benefits which might result from rearrangements of the circuit.     

Proportional sampling — A new philosophy of metallurgical accounting

This paper shortly describes a method making it possible to obtain, as the result of a single sampling operation, a “proportional sample” thanks to which the tonnage of material sampled can be accurately determined, as well as its grade.The tonnage estimation is reported to be more accurate and more reliable than the estimation obtained by means of conventional methods such as belt-scales (solids), flow- and density-meters (pulps), which makes the method very attractive. It was successfully tested at pilot scale and is being implemented in a full-scale flotation plant.By generalizing this sampling method to the various materials fed to or produced by a metallurgical plant (e.g. a flotation plant) a very accurate metallurgical balance can be established. Industrial results will be published as soon as available.     

Characterisation of sphalerite and pyrite flotation samples by XPS and ToF-SIMS

The surface analytical techniques of X-ray Photoelectron Spectroscopy (XPS) and Time of Flight Secondary Ion Mass Spectroscopy (ToF-SIMS) have provided information on the type and concentration of species on the surface of sphalerite and pyrite particles in flotation concentrate and tail samples, but also on their distribution on each particle and across particles of different sizes. From this surface analytical study, a more accurate interpretation of the flotation results of sphalerite and pyrite minerals in a mixed mineral system could be made as a function of the concentrations of copper sulphate activator and xanthate collector, and particle size. In particular, it was found that sphalerite particles reporting to the concentrate are larger in size and contain less iron hydroxide on their surface than particles reporting to the tail. As for the pyrite particles, their lower recovery than the sphalerite particles is the result of a larger proportion of iron hydroxide on their surface inhibiting copper and collector adsorption.     

焦家金矿选厂旋流器溢流产品工艺矿物学分析

焦家金矿选矿厂目前的日处理量达12000吨/天,金回收率92%。选矿厂已将破碎段产品用双螺旋分级机洗矿,洗矿的矿泥产率为7%,矿泥单独浮选,整体工艺初步实现了泥砂分选。为进一步提高选金回收率,流程改造拟将磨矿-浮选系统的旋流器溢流产品二次分级,分级的次生矿泥与洗矿矿泥进入矿泥浮选系统一并浮选,为了掌握旋流器溢流产品的性质,本文采用偏光反光两用显微镜、扫描电镜、X射线衍射仪、红外光谱和差热分析等手段进行研究。研究结果表明矿物种类主要是金属硫化物和脉石矿物,金属硫化物约占4%,脉石约占96%,金属硫化物主要是黄铁矿(70.17%)和黄铜矿(16.27%),脉石主要是石英(47.12%)和长石(15.90%)。黄铁矿和石英是重要的载金矿物,黄铁矿含金65%,石英含金20%。颗粒越细,单体颗粒含量越高,连生体颗粒含量越少;颗粒越细,黄铁矿含量越高,Au、Ag分布率越高,-0.037 mm粒级中黄铁矿含量达到73.58%,Au、Ag占到47.99%和56.60%,金分配率与黄铁矿含量成正相关;粗粒级中未发现金颗粒,中等粒级中次显微金约占30%,细粒级中次显微金约40%,金粒径在2~10μm范围内;金形状有三角形、棱角状、小粒状、不规则状等。红外光谱与差热曲线研究发现颗粒越细矿物成分趋于复杂。研究结论为磨矿分级产生的次生矿泥浮选调控提供了依据,对矿泥浮选的药剂制度调控、浮选流程确定等具有重要实际意义。