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.     

Flotation of galena. Influence of grain size,of pulp deoxygenation,and of cleaning with ammonium acetate

The flotation of < 10, 10–20, and 20–40 μm galena fractions was studied. For uncleaned galena a given collector coverage produced better floatability with increasing grain size. Nitrogen had a detrimental effect only for the < 10 μm fraction, producing at a given collector coverage a recovery smaller than that obtained with air.Galena cleaned with 400 g/l ammonium acetate had very poor floatability, although xanthate abstraction was fairly high; this confirms that strong xanthate adsorption is necessary for flotation. Formation of monothiocarbonate was small in all cases, which points to a very minor influence, if any, of this compound in the flotation process.In blank flotation tests, or for very low residual xanthate concentrations, a peak at 208 nm and a shoulder at 255 nm were observed. The former was assigned to the uncomplexed Pb²⁺ ion, and the latter was tentatively attributed to the PbOH⁺ ion.Lead in solution results from dissolution of the oxidation products of galena, as galena itself has an exceedingly low solubility. The curve for total lead in solution vs. initial xanthate concentration, had a minimum for an initial xanthate concentration of 10^?5M, the further increase in dissolved lead is attributed to formation of complexes such as PbX⁺ (X = xanthate). Dissolved lead concentrations were nearly as high for cleaned as for uncleaned galena, which indicates a high oxidation rate of the mineral.     

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.     

The effect of hydrodynamic conditions on true flotation and entrainment in flotation of a complex sulphide ore

The separation efficiency and selectivity of flotation are directly proportional to recoveries of the mineral species in the feed due to true flotation and entrainment. In this study, effects of the hydrodynamic conditions on true flotation and entrainment were investigated by using a fractional factorial experimental design. A method previously described in the literature was applied to determine the contributions of true flotation and entrainment in flotation of a complex sulphide ore. In order to apply the method, the kinetic flotation tests were conducted under various hydrodynamic conditions defined by some physical variables. Some of these tests were conducted in the presence and absence of a collector to evaluate the self-induced floatability. The selectivity index of the mineral species for entrainment was seen to be suitable evaluation of the non-selectivity and efficiency of the entrainment. Furthermore, the results of the size-by-size analysis of the froth products indicated that the presence of the self-induced hydrophobic particles in the feed is as important as the presence of very fine particles for accurate estimation of true flotation and entrainment in flotation of a complex sulphide ore. In addition, the estimated results for entrainment in flotation of the complex sulphide ore can be misleading. Therefore, a new approach would be necessary to determine the contributions of true flotation and entrainment in flotation of a complex sulphide ore.     

A study on the optimization of the arrangement of flotation circuits

The optimum utilization of available plant capacity has been investigated by simulation of a three-stage flotation circuit. By using simple models of the flotation process a wide variety of cell arrangements has been investigated and the findings tested against a number of operating flotation plants. It is concluded that the efficiency of operation of flotation systems is rather insensitive to circuit arrangement unless the circuit becomes grossly unbalanced. Circuit performance is much more sensitive to the flotation conditions and selectivity in the banks and it is only if a new circuit configuration leads to significantly improved flotation conditions that real improvements are likely. Simulation studies would require detailed modelling of such effects to be useful for circuit optimization studies.     

Interaction of thionocarbamate and thiourea collectors with sulphide minerals: a flotation and adsorption study

The ability of O-isopropyl-N-ethyl thionocarbamate (IPETC), O-isobutyl-N-ethoxycarbonyl thionocarbamate (IBECTC) and butyl ethoxycarbonyl thiourea (BECTU) collectors to increase the flotation of the sulphide minerals, chalcopyrite, galena and pyrite, has been studied. For each collector, the flotation characteristics of these minerals, flotation rate constant and flotation recovery maximum, have been calculated from the flotation data and compared as a function of pH and collector concentration. Overall, the flotation performance of these collectors is stronger for chalcopyrite than for galena and pyrite. Flotation increases with collector concentration and decreasing pH values. For chalcopyrite, the collector performances of BECTU are slightly better than those of IPETC but far superior to those of IBECTC, especially at high pH values or at low collector concentrations. The flotation performance of these collectors has been shown to be in good agreement with the amount of collector adsorbed at the mineral surface. The affinity of BECTU for the various minerals has been calculated using a multilayer adsorption model.     

Species interaction in flotation: A laboratory-scale semi-batch study

Semi-batch flotation tests were performed using different narrow size fractions of three different xanthate-conditioned sulphides floated singly and together in all possible combinations. To ensure proper selective flotation conditions a gangue mineral was included in all tests. Within the reproducibility of the experimentation no significant interaction among the mineral species is indicated, a result which has useful implications in distributed rate coefficient models of flotation kinetics.The conditions under which the present findings may be valid in industrial flotation are discussed, and suggestions are made for further work.     

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.     

The effect of slime coatings of the serpentine minerals,chrysotile and lizardite,on pentlandite flotation

Serpentine minerals in the gangue often interfere with the concentration of nickel sulfide ores. The influence of slime coatings of the serpentine minerals chrysotile and lizardite on the flotation of unoxidized pentlandite has been studied. In addition to microflotation testing at pH 9 with potassium amyl xanthate collector, electrophoresis and scanning electron microscopy have been used. The formation of a slime coating was found to be directly related to the surface charges on the slime and the sulfide mineral. Chemical additives which modified the slime surface charge, such as carboxy methyl cellulose, dextrin, sodium pyrophosphate and sodium silicate, were shown to be effective in reducing the adverse influence of the slime on the flotation of pentlandite.     

Oxidation-Reduction effects in the flotation of chalcocite and cuprite

A laboratory study of the batch flotation of chalcocite from chalcocite-quartz mixtures and of cuprite from cuprite-quartz mixtures with potassium ethyl xanthate as collector has shown that the oxidation-reduction state of the flotation pulp can have a pronounced influence on mineral floatabilities. At pH 11 chalcocite floated over a relatively narrow Eh range of about 300 mV; pH had no influence on the potential of the lower flotation boundary in reducing conditions but had a significant effect on the potential of the upper boundary in oxidizing conditions. Below this upper limit, the floatability was reversible with respect to Eh. Provided the Eh was in correct region chalcocite could be floated in the absence of measurable concentrations of dissolved oxygen.Cuprite displayed a high level of floatability with ethyl xanthate for which, by contrast with chalcocite, no flotation limit in reducing conditions was found; over a small range of potentials close to zero, its behaviour was strongly pH dependent.An attempt to account for the floatabilities of chalcocite and cuprite in terms of the formation of cuprous ethyl xanthate on their surfaces did not lead to correlations with the observed behaviour in reducing conditions but provided a rough correlation with the upper flotation potential limit. It is believed that more detailed and properly controlled comparative flotation studies of the chalcocite-xanthate and cuprite-xanthate systems could help to resolve some of the uncertainties associated with the effects of Eh, pH and oxygen concentration in sulphide mineral flotation.     

The effect of dextrin on surface properties and the flotation of molybdenite

The effect of dextrin on molybdenite surface properties has been investigated experimentally through measurements of zeta potentials, adsorption densities, contact angles, Hallimond tube flotation and oil flotation response. These studies indicate that the adsorption of dextrin on molybdenite occurs through physical interaction with the surface, possibly due to hydrophobic bonding. The hydrophobic bonding mechanism is in accord with the magnitude of the adsorption free energy, which was estimated to be—5.4 kcal per mole of dextrin monomers. Dextrin was found to be a very effective depressant for the air flotation of molybdenite in the absence of a collector, whereas it does not effectively depress molybdenite in an oil flotation process using iso-octane. This has been discussed qualitatively from the contributions of electrical double layer repulsion, van der Waals' attraction, and hydration effects.     

Hallimond tube flotation of scheelite and calcite with amines

Hallimond tube flotation experiments have been carried out on the two calcium minerals scheelite and calcite using dodecylammonium chloride as collector. The main variables studied were the calcium ion concentration and the pH.In the case of scheelite, addition of calcium chloride markedly lowered the flotation recovery. Recovery was also lowered when the pH was reduced below about 10. Since it is known that the zeta potential of scheelite is almost independent of pH this confirms that co-adsorption of un-ionized amine is necessary for good flotation. Other un-ionized long-chain molecules can replace the amine; thus it was shown that excellent flotation can be obtained event at about pH 7 by adding dodecanol together with dodecylammonium chloride. With the completely ionic trimethyldodecylammonium chloride recoveries were poor and were independent of pH.In the case of calcite, calcium chloride had no immediate effect on flotation recovery, but at low collector concentrations marked depression occurred after many hours standing in the presence of calcium ions. The effect of pH on flotation of calcite was anomalous and there appear to be two pH regions in which recoveries are high.The results are discussed and attention is drawn to the need for more thorough studies of the calcium carbonate/water interface.     

Relation between the relative density of composite coaly grains and their flotation recovery

Batch flotation tests on low- and high-rank Australian coals showed that it was difficult to reduce the original ash yield substantially whilst maintaining high recovery. The ash yield of the flotation concentrates was found to be mainly the result of the recovery of composite coaly grains containing both carbonaceous matter and mineral matter. Even 50 μm grains were composite in nature, the mineral matter being very finely disseminated. Separation of the flotation products using the heavy-liquid density-gradient technique showed that flotation recovery of coaly grains of a given size decreased with increasing relative density of the grains. The effect was much greater for coal of low rank. The fall in recovery correlated with an increase in the proportion of hydrophilic mineral matter in the composite grains, rather than with the changing proportions of the macerals vitrinite and inertinite.     

Investigation of mechanism of ultrasound on coal flotation

Coal flotation studies were carried out in ultrasonically assisted flotation cells. Representative hard coal slime samples from Prosper-Haniel Coal Preparation Plant located in Bottrop, Ruhr Region of Germany were used for this purpose. A Wemco type flotation cell was fitted with transducers and tests were carried out at variable frequency and power. The reagent for coal flotation was Ekofol-440 with variable dosages during conventional and ultrasonic flotation experiments. The results showed that ultrasonic coal flotation yields more combustible recovery and lower ash values in concentrates than conventional flotation by using similar reagent dosages. These results are explained on the basis of efficient surface cleaning of the coal particles.     

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.     

Effect of surface oxide/hydroxide products on the collectorless flotation of copper-activated sphalerite

The change in collectorless flotation of sphalerite with pH and Cu(II) concentration was correlated with the type and proportion of species present on the sphalerite surface. The solution and surface species were determined using a combination of analytical techniques including zeta potential measurement and X-ray photoelectron spectroscopy. An optimum copper concentration for maximum sphalerite flotation was identified, beyond which flotation decreased. This decrease in flotation coincided with the precipitation of copper hydroxide in neutral to mildly alkaline pH conditions. The hydrophobic polysulfide and hydrophilic copper hydroxide species were the main surface species influencing sphalerite flotation.     

Flotation of calcareous Mussorie phosphate ore

Separation of Mussorie rock phosphate (P₂O₅ = 20%) from Uttar Pradesh, India, containing pyrite, calcite and other carbonaceous impurities by flotation has been successfully attempted to upgrade the phosphate values. Based on Hallimond cell flotation results of single and synthetic mineral mixtures of calcite and apatite using oleic acid and potassium phosphate, conditions were obtained for the separation of calcite from apatite which is considered to be the most difficult step in the beneficiation of calcareous phosphates. Further studies using 250 g of the mineral (?60 +150 and ?150 mesh fractions, deslimed) in laboratory size Fagergren subaeration machine employed a stagewise flotation viz. carbonaceous materials using terpineol, pyrite using potassium-ethyl xanthate and calcite using oleic acid respectively. Separation was, however, found to be unsatisfactory in the absence of a depressant.Among starch, hydrofluosilicic acid and dipotassium hydrogen phosphate, which were tried as depressants for apatite in the final flotation stage, dipotassium hydrogen phosphate proved to be superior to others. However, the tests with the above fractions did not yield the required grade. This was possibly due to insufficient liberation of the phosphate mineral from the ore body and different experimental conditions due to scale up operations. Experiments conducted using ?200 mesh deslimed fractions has yielded an acceptable grade of 27.6% P₂O₅ with a recovery of about 60%. The results have been explained in terms of the specific adsorption characteristics of phosphate ions on apatite and the liberation size of the mineral.     

Influence of shape characteristics of talc mineral on the column flotation behavior

Column flotation, which is a very effective process in mineral processing especially for easily floatable minerals, is one of the most important new developments to emerge in mineral processing technology in the last years. In this study, the flotation behavior of talc products having different particle shapes produced by different grinding mills (ball and rod mill) was determined by using column flotation process. Shape characteristics of the particles were investigated by the two dimensional measuring technique based on the particle projections obtained from the SEM microphotographs using a COREL Draw 10.0 program. The results showed that particles possessing higher elongation and flatness properties were recovered better during column flotation, whilst roundness and relative width had a negative effect on the flotation behavior of the talc mineral studied. Consequently, as the shape of the particles produced by the mill deviated from the ideal sphere, their floatability was increased.     

Potential use of model predictive control for optimizing the column flotation process

A constrained model predictive control (MPC) strategy is proposed to deal with the problem of optimizing flotation column operation using secondary variables. Froth depth, collection zone gas hold-up and bias rate are selected as secondary variables to be controlled whereas tailing, wash-water and gas flow rate are used as manipulated variables. The control problem was formulated in order to minimize the tracking error of the gas hold-up and bias rate by maintaining gas flow rate, wash-water flow rate and bias rate within their operational limits. In particular, a strategy was conceived to optimize the column flotation process based on establishing an unreachable high set point for the gas hold-up (which is equivalent to maximizing the bubble surface area available for particle collection at a given flotation reagent dosage and thus recovery), while simultaneously satisfying operational constraints (such as ensuring a positive bias rate to prevent gangue entrainment and therefore concentrate grade deterioration). Several other operational constraints on wash-water, gas rate, gas hold-up and bias rate were considered, their use being justified from a processing point of view. Since this study deals with the hydrodynamic characteristics of flotation columns, a pilot flotation column working with a two-phase system is sufficient to demonstrate the advantages of using predictive control for this process optimization.     

The effect of air flow rate on the kinetics of flotation. Part 1: The transfer of material from the slurry to the froth

Bubble size distributions and flotation rates were determined as a function of air flow rate and frother concentration using a specially designed batch flotation cell. This cell permitted the unambiguous determination of the flotation rate from the slurry to the froth.Flotation rate constants were determined for different size classes of silica and galena. The flotation rate constants increased to a maximum and then decreased as air flow rate was increased. This maximum was predicted by a model which considered the effect of bubble size on both the total bubble surface area and the bubble-particle collision efficiency. This work shows that collision efficiency effects, shown to exist in single-bubble/single-particle systems, are also present in flotation systems where many bubbles and particles interact.A second model for hindered flotation is proposed which assumes that the particle-capturing bubble surface differs from the particle-retaining surface. This model predicts a sharp transition from hindered to free flotation. Experimental results are presented which agree well with those derived from the model.