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.

The effect of residence time and aeration on coal recovery within the high density zone of a flotation machine

The high intensity zone within the Jameson Cell is the downcomer. It is largely external and separated from the flotation tank. This, together with operation of the downcomer under vacuum, rather than at elevated pressure and the absence of moving parts, allows ready access to the high intensity zone for measurement and analysis. Experimentation was conducted allowing measurements of recovery for residence times of between 20 milliseconds and ten seconds within the downcomer of a Jameson Cell. The affect of aeration rate on the recovery of different particle sizes was also studied.

Applications of the Jameson cell at the head of base metal flotation circuits

The Jameson Cell is a high intensity flotation device, which utilises induced air from the atmosphere. It was developed jointly by Mount Isa Mines and Professor Graeme Jameson of the University of Newcastle in the 1980s. It is proven to generate fine bubbles, in the order of 300 to 500 µm, in a high intensity, high shear and compact zone contained in the downcomer. This aerated mixture exits the downcomer into the pulp zone, which is the quiescent mineral and gangue separation zone. A number of Australian base metal flotation circuits feature a reverse flotation stage at the head of the circuit. Testwork and plant operating data has shown that the use of a Jameson Cell in the prefloat cleaner application has further improved prefloat gangue recovery and selectivity. Operation of a Jameson Cell in a carbonaceous/pyrite prefloat cleaner duty at the Mt Isa copper concentrator increased copper recovery and reduced pyrite in the copper concentrate. Testwork at Zinifex Century Zinc Mine showed a decrease in zinc losses by the utilisation of Jameson Cell prefloat cleaner. Appraisal of a Jameson Cell in a scalping role within the Mt Isa Copper Concentrator indicated significant benefits could be achieved.

JKSimFloat V6.1 Plus: Improving flotation circuit performance by simulation

Analyzing, optimizing and designing flotation circuits using models and simulators have improved significantly over the last 15 years. Mineral flotation is now generally better understood through major advances in measuring and modeling the sub-processes within the flotation system. In addition, new and better methods have been derived to represent the floatability of particles as they move around a flotation circuit. A simulator has been developed that combines the effects of all of these sub-processes to predict the metallurgical performance of a flotation circuit. This paper presents an overview of the simulator, JKSimFloat V6.1PLUS, and its use in improving the industrial flotation plant performance. The application of the simulator at various operations is discussed with particular emphasis on the use of JKSimFloat V6.1PLUS in improving the flotation circuit performance.

JKSimFloat V6: Improving flotation circuit performance and understanding

Methods of analysing and optimising flotation circuits have improved significantly over the last 15 years. Mineral flotation is now generally better understood through major advances in measuring and modelling the sub-processes within the flotation system. JKSimFloat V6 is a user-friendly Windows-based software package incorporating simulation, mass balancing, and, currently under development, liberation data viewing and model fitting. This paper presents an overview of the development of the program up to its current status, and the plans established for the future. The application of the simulator, in particular, at various operations is also discussed with emphasis on the use of the program in improving flotation circuit performance.