The effect of air flow rate on the kinetics of flotation. Part 2: The transfer of material from the froth over the cell lip

The flotation rate of galena was investigated as a function of air flow rate (AFR) and froth thickness (from 0 to 6 cm) in a batch flotation cell designed to produce a quiescent froth-liquid interface. This cell design limits mechanical breakage of the froth and prevents the hydraulic entrainment of fine particles into the froth phase. The overall transfer rate was characterized by a first-order rate constant, the overall rate constant (ORC). The ORC was found to increase with increasing AFR and with decreasing froth thickness. The transfer rate of material from the slurry to the froth was also determined as a function of AFR, and characterizes by its first-order rate constant, the flotation rate constant (FRC).The froth transport constant (FTC), the first-order constant which characterizes the transport of galena from the froth over the cell lip, was then determined from the ORC and the FRC. The FTC was found to increase with increasing AFR and decreasing froth thickness. For a froth thickness of 5 cm and low-to-intermediate AFR, the FTC was found to be significantly lower than the FRC.The FTC of galena particles of 0–12, 12–32 and 22–40 μm was also determined. At a froth thickness of 5 cm, the FTC decreased with increasing particle size over the full experimental range of AFRs.     

A compartment model for the mass transfer inside a conventional flotation cell

A model is developed by taking into account the simultaneous mechanisms of true flotation and entrainment in a conventional flotation cell. The total volume of the cell is divided into three compartments: pulp collection zone, pulp quiescent zone and froth region, with the mechanisms being modeled as occurring at the same time but originating at different places: true flotation from the collection zone and entrainment from the quiescent one. A particle is referred to as suspended in water or attached to an air bubble, depending upon its original state before crossing the pulp–froth interface (whether or not it remains in that state all the way to the concentrate launder). The model is obtained by solving a set of equations describing the mass conservation of solids and water between adjacent compartments. The principal mass transfer factors are identified as: the flotation rate constant, the mean residence time in the collection zone, the froth recovery of attached particles, the degree of entrainment through the froth and the water recovery from the feed to the concentrate. The development presented here allows the intricate nature of the mass transfer in a flotation cell to be reduced to one single equation, overcoming the need of numerical methods for simulation purposes. Moreover, it is shown that reliable prediction of grade and recovery can be obtained without detailed information on the pulp hydrodynamics or on any froth sub-process either than drainage, bubble bursting and bubble coalescence.     

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.     

Effect of collector, pH and ionic strength on the cationic flotation of kaolinite

The effect of amine collector type, pH, and ionic strength on the flotation behaviour of kaolinite was investigated in a series of laboratory batch flotation tests. In distilled water, ether diamine, a strong collector for silica, does not induce any flotation or only very weak flotation of kaolinite over a wide pH range from pH 3 to pH 10.5. Ether monoamine causes strong flotation of kaolinite in distilled water, especially in acidic solutions, but high dosages of the collector are required. Such observations are in contrast to the flotation behaviour of oxide minerals such as silica for which ether diamine shows stronger collecting power than ether monoamine. The pH dependence of kaolinite flotation is also opposite to that of oxides, with lower flotation recovery obtained at higher pH. In contrast to oxides, the flotation recovery of kaolinite increases with ionic strength. It was demonstrated that the enhanced flotation of kaolinite in NaCl solutions cannot be attributed to the frothing ability of NaCl or the intercalation of kaolinite by alkylamines. It is proposed that the screened zeta potential of kaolinite particles in a high ionic strength environment causes random aggregation of kaolinite particles exposing hydrophobic (001) silica plane in the presence of ether amines.     

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.     

Mixing and gangue dispersion in flotation machine pulps

Tracer experiments using quartz in sized ranges to simulate gangue minerals provide information on how impeller speed, air rate, and particle size determine the concentration of gangue in the uppermost pulp layers. Tests with and without a froth will contribute towards an understanding of the selective action of the froth column.Results indicate that the laboratory machine-operating conditions required for flotation coincide with a hydrodynamic region which is responsible for fine-gangue transfer from the pulp into the froth column by elutriation and entrainment process acting in the pulp, thus compromising the selective action of the flotation process itself.Topics are suggested requiring further investigation and mention is made of machine design features to which attention should be paid in attempting to reduce gangue transfer from pulp to froth.     

Pre-concentration and residual bitumen removal from Athabasca oilsands froth treatment tailings by a Falcon centrifugal concentrator

Both froth flotation and centrifugal concentration were used to pre-concentrate the oil sands froth treatment tailings prior to the recovery of heavy minerals (titanium and zirconium minerals). Over 90% of the heavy minerals were recovered into a bulk flotation concentrate that was about 50% of the feed mass at 85 °C without any reagents. The same recoveries were obtained at 50 °C with the addition of NaOH and/or sodium oleate. However, the flotation concentrate also recovered over 90% of the residual bitumen and much of the clays/slimes. Subsequent treatment of the flotation concentrate such as dewatering and bitumen removal would be difficult due to these residual bitumen and clays. On the other hand, a SB40 centrifugal concentrator recovered over 85% of the heavy minerals but less than 30% of the residual bitumen. With improved liberation the recovery of the residual bitumen into the concentrate could be further reduced. The particle sizes of the SB40 concentrates were also larger than the flotation concentrates, making subsequent processing much easier.     

Interpretation of interaction effects and optimization of reagent dosages for fine coal flotation

The effect of three most important reagents for coal flotation namely sodium meta silicate, collector (kerosene) and frother (MIBC) was studied using 2³ full factorial design. The regression models were developed using factorial experiment data to quantify the effect of sodium meta silicate, collector and frother and to predict grade and recovery of combustible material for different reagent conditions. The addition of sodium meta silicate increased the recovery without affecting the grade significantly. The MIBC addition reduce the surface tension at the liquid–vapor interface, which results in the production of finer bubble size distribution and thus improves flotation rates and recovery values. However, a finer bubble size distribution also increases water recovery, which results in a greater recovery of entrainable ash bearing particles and thus degradation of the product grade. The interaction between OH group of MIBC and hydrated mineral matter improves flotability of high ash coal particles and degrades the product grade further. The negative effect of kerosene and MIBC interaction on both grade and recovery could be due to the recovery of high ash coal particles in preference to low ash coal particles. The highest possible grade of product is 94.19% combustibles with 25.33% recovery. A product with 91.11% combustibles grade at 95.58% recovery was obtained at 0.1 g/kg sodium silicate, 0.4 g/kg collector and 0.075 g/kg frother from the coal fines tested.     

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.     

Co-adsorption of paraffinic gases in the system quartz-dodecyl ammoniumchloride and its effects on froth flotation

When paraffinic gases (ethane, propane or butane) are used as the gas phase in froth flotation systems, the rate of flotation and recovery are generally increased as compared with air. The mechanism of the effect of paraffinic gases in froth flotation was studied and it was shown that they co-adsorb with the collector on the mineral surface. The adsorption of collector and gas on the surface was studied on the system quartz-dodecyl ammoniumchloride (DACl)-propane and ethane. It is shown that the contact angles in this system are significantly larger than when air is the gas, over a wide range of concentrations of DACl.The extent of adsorption of gas on the solid, for low concentrations of DACl, is of approximately 6.5 mols of propane per mol DACl and 7.3 mols of ethane per mol DACl. Increasing the concentration of DACl caused a decrease in the absorbed gas DACl ratio, which reached a value below 1:1 for the highest concentration tested. The co-adsorption of paraffinic gas and interfacial phenomena are interpreted in terms of effective chain length of the surfactant (DACl).     

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.     

Particle size distribution and dissolution properties of metals in cyclone fly ash

The particles in the examined cyclone fly ash were all smaller than 0.25 mm. in diameter, and particles smaller than 0.075 mm. in diameter accounted for 88.4 % of the ash weight. This result indicates that cyclone fly ash consists of particles with a small diameter. The metals in the cyclone fly ash were enriched in small particles. The highest concentrations for zinc, copper, lead, cadmium and molybdenum in the cyclone fly ash were found in the smallest particle size fraction (< 0.075 mm.) and for Barium, chromium, nickel, Vanadium and Cobalt in the second to smallest particle size fraction (0.075-0.125 mm.). From an environmental and toxicological standpoint, the smallest particles are of the greatest concern when ash is handed at landfill disposal sites (transport and disposal especially in stormy weather conditions), and some studies have reported risks to workers from prolonged exposure to ash. The results of the comparison of various dissolution methods for metals showed that the digestion procedures with nitric acid alone (USEPA 3051) or with a mixture of nitric acid + hydrogen peroxide (USEPA 3050B) slightly underestimated the metal concentrations in the cyclone fly ash. Although the use of hydrofluoric acid is often necessary for the determination of a number of elements associated with siliceous minerals, its use can result in loss of trace elements during dissolution.     

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.     

Removal of lead minerals from copper industrial flotation concentrates by xanthate flotation in the presence of dextrin

Potato starch and dextrins resulting from thermolysis of potato starch in the absence of reagents and presence of -amino acids are promising depressants for separation of lead and copper minerals present in the Polish industrial copper concentrates. The polysaccharides were used for differential xanthate flotation of the final industrial concentrates produced by flotation with sulfhydryl collectors in the absence of depressants. The polysaccharides depressed galena and provided froth concentrate rich in chalcocite and other copper minerals as well as cell product containing lead minerals. The best results of separation were obtained in the presence of plain dextrin prepared by a thermal degradation of potato starch. The industrial concentrate containing 18.5% Cu and 5.5% Pb was divided into a froth product containing 38.1% Cu with 77% recovery of copper and a cell product assaying 7.3% Pb with 83% recovery of lead. It was accomplished using 2500 g/t of dextrin, 50g/t of potassium ethyl xanthate, and 50 g/t of frother (α-terpineol). The pH of flotation was 8.0–8.2.     

大位移剪切下钙质砂破碎演化特性

为了揭示钙质砂在大位移剪切作用下的破碎及形状演化规律,对南海钙质砂进行了系列不同剪切位移下的环剪试验。首先,利用筛分和激光粒度分析获取试验后的颗粒粒径分布,分析颗粒分布变化情况;其次,通过粒径分布对破碎进行定量分析;最后,运用图像处理技术计算颗粒圆度和扁平度,分析了颗粒形状的变化情况。试验结果表明,在不同的竖向压力下,颗粒会达到不同的稳定级配,但达到稳定所需的剪切位移相同;经历大位移剪切后,出现粒径为0.01～0.075 mm钙质砂破碎严重的现象;随剪切位移的增加,颗粒的圆度和扁平度减小。针对细小颗粒破碎严重的现象,修正了相对破碎率;修正后的相对破碎率能考虑粒径为0.01～0.075 mm颗粒发生的破碎。剪切后的钙质砂颗粒更为规则,整体轮廓趋于圆形、表面更光滑。     

Effects of surfactant adsorption and surface forces on thinning and rupture of foam liquid films

The properties of thin liquid films (TLF) are of paramount significance for colloidal disperse systems, and a number of industrial processes, including froth flotation. In flotation, the bubble–particle attachment is controlled by the thinning and rupture of the intervening liquid film between an air bubble and a mineral particle. The froth evolution and its transient stability are also a function of the drainage and rupture of liquid films between air bubbles. Surface-active substances (surfactants) are used as flotation reagents to control the behavior of the liquid films. This paper presents a review of our research in the area of surfactant adsorption, surface forces and liquid films. It mainly focuses on the validation, application and extension of the Stefan–Reynolds theory on the liquid drainage. The extension of the Stefan–Reynolds theory comprises surface forces (disjoining pressure), surface tension variation, caused by the adsorption and diffusion of surfactants. Both the experimental and theoretical results are mostly related to the free (foam) films formed between two bubbles but can be principally extended to emulsion films between two oil drops and wetting films between an air bubble and a solid surface.     

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.     

The anomalous behavior of kaolinite flotation with dodecyl amine collector as explained from crystal structure considerations

The electrokinetics and flotation behavior of kaolinite have been investigated through flotation experiments, zeta potential measurements, and FTIR spectral analysis. These results have been explained based on crystal structure considerations and quantum mechanical calculations. It has been shown that the PZC of kaolinite is at pH 4.2. Kaolinite exhibits good floatability in weakly acidic solution with dodecyl amine (DDA) collector. The negative zeta potential of kaolinite increases with an increase in pH, and hence the adsorption of DDA on kaolinite increases. However, the flotation of kaolinite decreases with an increase in pH and an increase in DDA adsorption. This anomalous flotation behavior is rationalized based on crystal structure considerations and particle aggregation phenomena. It is considered that the silica (001) and the alumina (001¯) basal planes of kaolinite are negatively charged. From quantum chemistry calculations, the interaction between DDA and the (001) plane was found to be stronger than at the (001¯) alumina plane due to the difference in the structure at the (001) and (001¯) planes. The self-aggregation between (001¯) faces and the edge planes and the adsorption of DDA at the silica (001) plane make the kaolinite aggregates hydrophobic, and good floatability is achieved in acidic solution. In alkaline solution, the kaolinite particles are dispersed. In the presence of DDA, hydrophobic aggregation appears to occur in alkaline solution between the (001) planes due to adsorbed DDA, and thus the hydrophilic (001¯) faces are exposed and flotation is not achieved.     

Roughing and cleaning flotation behaviour and the realistic simulation of complete plant performance

Data are presented which illustrate a range of flotation behaviour observed for roughing and cleaning operations in industrial plants. Differences are observed in the size by size recoveries in cleaner flotation from those measured in the roughers.The implications of these differences to flotation modelling are discussed, and the importance of conducting confirmatory laboratory batch flotation tests is emphasized.Batch flotation tests have indicated that for certain minerals the flotation characteristics in the cleaner tests are substantially different from those in rougher tests conducted under the same conditions of pulp level, impeller speed, aeration rate and froth removal. The differences are most pronounced for the coarse particles.Computer simulations of a rougher-cleaner circuit have been done to illustrate the effects of these differences on predicted circuit performance. The differences are significant and arise mainly from differences in the behaviour of coarse particles.     

Modelling transport phenomena in a flotation de-inking column: Focus on gas flow,pulp and froth retention time

A laboratory flotation column using Venturi aerators and a vacuum system to remove froth was used to investigate the contribution of gas flow, pulp flow, cell volume and froth retention time on the ink removal efficiency and on cellulose fibres and mineral fillers loss. The increase in the gas flow from 4 to 8 L/min gave a general rise of particle transport from the pulp slurry to the froth with an ensuing strong increase in ink removal, from 75% to 85%, and water and total loss, from 10% to 40% and 15% to 30%, respectively. Whereas, the increase of the cell volume from 14 to 24 L improved ink removal from 72% to 80% without considerably affecting flotation loss. The rise of the froth retention time in the flotation cell from 5 to 20 s before removal gave a general decrease in the flotation loss from 20% to 11% without a corresponding decrease in ink removal. This trend was interpreted as reflecting poor ink drainage through the froth. The increase of both pulp and froth retention time in the flotation cell appeared as the most favourable way to improve ink flotation selectivity. A mathematical model, describing particle removal during flotation in terms of true flotation, entrainment and drainage, was proposed and used to fit experimental data.