Modelling of froth transportation in industrial flotation cells: Part I. Development of froth transportation models for attached particles

Modelling of froth transportation, as part of modelling of froth recovery, provides a scale-up procedure for flotation cell design. It can also assist in improving control of flotation operation. Mathematical models of froth velocity on the surface and froth residence time distribution in a cylindrical tank flotation cell are proposed, based on mass balance principle of the air entering the froth. The models take into account factors such as cell size, concentrate launder configuration, use of a froth crowder, cell operating conditions including froth height and air rate, and bubble bursting on the surface. (C) 2004 Elsevier Ltd. All rights reserved.

Modelling of entrainment in industrial flotation cells: the effect of solids suspension

Solids concentration and particle size distribution gradually change in the vertical dimension of industrial flotation cells, subject primarily to the flotation cell size and design and the cell operating conditions. As entrainment is a two-step process and involves only the suspended solids in the top pulp region near the pulp-froth interface, the solids suspension characteristics have a significant impact on the overall entrainment. In this paper, a classification function is proposed to describe the state of solids suspension in flotation cells, similar to the definition of degree of entrainment for classification in the froth phase found in the literature. A mathematical model for solids suspension is also developed, in which the classification function is expressed as an exponential function of the particle size. Experimental data collected from three different Outokumpu tank flotation cells in three different concentrators are well fitted by the proposed exponential model. Under the prevailing experimental conditions, it was found that the solids content in the top region was relatively independent of cell operating conditions such as froth height and air rate but dependent on the cell size. Moreover, the results obtained from the total solids tend to be similar to those from a particular gangue mineral and hence may be applied to all minerals in entrainment calculation. (C) 2004 Elsevier Ltd. All rights reserved.

Gas dispersion measurements in industrial flotation cells

For nearly 100 years, the flotation plant metallurgist has often wondered what is happening 'beneath the froth'. To assist in unravelling this mystery, new technology has been developed as part of the Australian Mineral Industries Research Association (AMIRA) P9 project, to measure gas dispersion characteristics (such as gas hold-up, superficial gas velocity and bubble size) in industrial flotation cells. These measurements have been conducted in a large number of cells of different types and sizes by researchers from the Julius Kruttschnitt Mineral Research Centre (JKMRC) and JKTech. A large database has been developed and the contents of this database are described in this paper. Typical cell characterization measurements show a wide spread in values, even in the same cell types and sizes performing similar duties. In conventional flotation cells, the typical gas hold-up values range from 3% to 20%, bubble sizes range between I and 2 mm, and superficial gas velocity ranges from 1 to 2.5 cm/s. The ranges of cell characterization measurements given in this paper will enable plant personnel to compare their operation to other similar types of operations from around Australia and the rest of the world, giving opportunities for further improvement to flotation plant operations. (C) 2005 Elsevier Ltd. All rights reserved.

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

Entrainment in flotation can be considered as a two-step process, including the transfer of the suspended solids in the top of the pulp region just below the pulp-froth interface to the froth phase and the transfer of the entrained particles in the froth phase to the concentrate. Both steps have a strong classification characteristic. The degree of entrainment describes the classification effect of the drainage process in the froth phase. This paper briefly reviews two existing models of degree of entrainment. Experimental data were collected from an Outokumpu 3 m(3) tank cell in the Xstrata Mt. Isa Mines copper concentrator. The data are fitted to the models and the effect of cell operating conditions including air rate and froth height on the degree of entrainment is examined on a size-by-size basis. It is found that there is a strong correlation between the entrainment and the water recovery, which is close to lineal. for the fines. The degree of entrainment decreases with increase in particle size. Within the normal range of cell operating conditions, few particles coarser than 50 mu m are recovered by entrainment. In general, the degree of entrainment increases with increase in the ail rate and decreases with increase in the froth height. Air rate and froth height strongly interact with each other and affect the entrainment process mainly via changes in the froth retention time, the froth structure and froth properties. As a result, other mechanisms such as entrapment may become important in recovering the coarse entrained particles. (c) 2005 Elsevier Ltd. All rights reserved.

Gas dispersion measurements in industrial flotation cells

For nearly 100 years, the flotation plant metallurgist has often wondered what is happening ‘beneath the froth’. To assist in unravelling this mystery, new technology has been developed as part of the Australian Mineral Industries Research Association (AMIRA) P9 project, to measure gas dispersion characteristics (such as gas hold-up, superficial gas velocity and bubble size) in industrial flotation cells. These measurements have been conducted in a large number of cells of different types and sizes by researchers from the Julius Kruttschnitt Mineral Research Centre (JKMRC) and JKTech. A large database has been developed and the contents of this database are described in this paper. Typical cell characterisation measurements show a wide spread in values, even in the same cell types and sizes performing similar duties. In conventional flotation cells, the typical gas hold-up values range from 3 - 20 per cent, bubble sizes range between 1 and 2 mm, and superficial gas velocity ranges from 1 to 2.5 cm/s. The ranges of cell characterisation measurements given in this paper will enable plant personnel to compare their operation to other similar types of operations from around Australia and the rest of the world, giving opportunities for further improvement to flotation plant operations.

Bubble load measurement in the pulp zone of industrial flotation machines - a new device for determining the froth recovery of attached particles

A new device has been developed to directly measure the bubble loading of particle-bubble aggregates in industrial flotation machines, both mechanical flotation cells as well as flotation column cells. The bubble loading of aggregates allows for in-depth analysis of the operating performance of a flotation machine in terms of both pulp/collection zone and froth zone performance. This paper presents the methodology along with an example showing the excellent reproducibility of the device and an analysis of different operating conditions of the device itself. (C) 2004 Elsevier B.V All rights reserved.

Selective transport of attached particles across the pulp-froth interface

A technique for determining the recovery of attached particles across the froth phase in flotation that relies on measuring the rate at which bubble-particle aggregates enter the froth is used to investigate the selectivity of attached particles across the froth phase. Combining these measurements with those of other techniques for determining the froth recovery of attached particles provides an insight into the different sub-processes of particle rejection in the froth phase. The results of experiments conducted in a 3 m(3) Outokumpu tank cell show that the detachment of particles from aggregates in the froth phase occurs largely at the pulp-froth interface. In particular it is shown that the pulp-froth interface selectively detaches particles from aggregates according to their physical attributes. (C) 2005 Elsevier Ltd. All rights reserved.

Selective transport of attached particles across the pulp-froth interface

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