A NEW VARIABLE IN FLOTATION: THE EFFECT OF

PRESSURE/ALTITUDE ON PERFOMANCE
Courtney A. Young
Dept Head and ASARCO Professor
Metallurgical & Materials Engineering
Montana Tech
Butte MT 59701
Background
Butte (Montana Tech)
Basin (Froth Flotation)
Introduction
History
Variables
Objectives
Procedures
Results
Conclusions
Acknowledgements
Butte, Montana
Population 40,000
Heart of the Rocky Mtns
Nearby National Parks
Historical Mining District
Head Frames
Berkeley Pit
Montana Tech
M
o
n
t
a
n
a
Background
Art Chateau
Granite MtnMemorial
Old No. 1 Trolley (HUB)
Berkeley
Pitlake
Stamp Mill Park
Background
Orphan Girl
Head Frame
Lady
of
The
Rockies
Mineral
Museum
World
Museum
of Mining
Background
Background
ELC Building
Background
Main Street
Basin School
Welcome to Basin!
Basin, Montana
25 Miles NW of Butte
Population 255
Historic Mining District
Background
Merry Widow Au, Ag, Cu, Pb, Zn and U
Now, a Radon Health Mine !
Background
Hope/Katy Complex
Jib Mill Ag & Au
Background
Smelter processed
area concentrates
Background
Basin & Atwater Mills are
historically significant
Background
Butte & Superior Copper Company
1909 Leased Basin Mill
50 TPD Zn Gravity Mill
5-8% Zn in tails
1911 Built Atwater Mill
1
st
froth flotation in US
30% Zn concentrate
1
st
rougher-cleaner cells
54% Zn concentrate
1912 Built Butte Mill
1200 TPD of ore at 20% Zn
2
nd
rougher-cleaner cells
49% Zn con (>90% rec)
Among the largest !
Rougher-Cleaner Cells in Atwater Mill
Background
Background
Butte (Montana Tech)
Basin (Froth Flotation)
Introduction
History
Variables
Objectives
Procedures
Results
Conclusions
Acknowledgements
Introduction
History of Flotation (Highlights)
1860 Haynes develops the bulk oil flotation process
1877 Bessel brothers show enhanced separation by boiling
1885 Everson improves selectivity using sulfuric acid
1886 Bessel brothers generate gas by acid/carbonate rxns
1902 Potter and Froment generate gas electrolytically but
were first to attribute separation to buoyant forces
1902 Cattermole uses soap to reduce oil consumption
1904 Elmore enhances bubble formation with a vacuum
1905 Sulman, Pickard and Ballot form bubbles by agitation
1905 Mineral Separations Limited at Broken Hill, Australia
employs their technology on an industrial scale
1909 Sulman, Greenway and Higgins employ frothers
1911 Hyde establishes the first US operation in Basin, MT
1923 Keller uses soluble oils (xanthate collectors) which
sets the stage for froth flotation to develop
Introduction
Today, froth flotation is used to treat ores in excess of
600,000,000 TPY:
Metal sulfides (40%) Industrial minerals (30%)
Metal oxides (20%) Coal (10%)
The technology has expanded outside the mineral industry:
Food Petroleum
Pulp/Paper Recycling
Valuable materials in these primary and secondary industries
Valuable materials in these primary and secondary industries
are separated from waste materials in various ways. To do
are separated from waste materials in various ways. To do
this, some difference in a physical and/or chemical property
this, some difference in a physical and/or chemical property
must be exploited. In froth flotation, the
must be exploited. In froth flotation, the
primary property
primary property
is
is
hydrophobicity
hydrophobicity
.
.
Introduction
A variety of flotation cells have been developed to do this for
all of these industries and include but are not limited to:
Conventional Cell Column Cell
Jameson Cell Air-Sparged Hydrocyclone (ASH)
One design will be preferred over the others depending on
the conditions and, of course, the many secondary process
variables involved in trying to control the hydrophobicity:
commodity types and quantities commodity types and quantities conditioning time conditioning time particle size particle size
collector type and quantity collector type and quantity impellor velocity impellor velocity liberation liberation
frother frother type and quantity type and quantity percent solids percent solids pulp pH pulp pH
modifier type and quantity modifier type and quantity airflow rate airflow rate bubble size bubble size
An examination of the literature will show that pressure has
been used to control the solubility of gases and, in the case
of a vacuum, used to generate bubbles; however, it has been
ignored as a process variable for controlling bubble size.
Introduction
So many variables influence flotation
that it will be long before every one of
them can be investigated and its
influence on the process determined.
Ian W. Wark
Background
Butte (Montana Tech)
Basin (Froth Flotation)
Introduction
History
Variables
Objectives
Procedures
Results
Conclusions
Acknowledgements
Objectives

Explore the effect of pressure on flotation

Explore the effect of pressure on flotation
performance. To do this:
performance. To do this:

Conduct tests at various elevations as well as

Conduct tests at various elevations as well as
in the controlled atmosphere of a glove box.
in the controlled atmosphere of a glove box.

Identify and monitor/control, as best as

Identify and monitor/control, as best as
possible, the interdependence of secondary
possible, the interdependence of secondary
variables (in this case, airflow rate and
variables (in this case, airflow rate and
bubble size).
bubble size).
Background
Butte (Montana Tech)
Basin (Froth Flotation)
Introduction
History
Variables
Objectives
Procedures
Results
Conclusions
Acknowledgements
Procedures

Prepare ore samples using traditional means:

Prepare ore samples using traditional means:
receiving receiving obtain 200 pounds of obtain 200 pounds of tetrahedrite tetrahedrite ore from U.S. Silver Corp. ore from U.S. Silver Corp.
crushing crushing crush with lab jaw/roll crushers to 100% crush with lab jaw/roll crushers to 100% - -1/16 inch (1.6 mm), 1/16 inch (1.6 mm),
homogenizing homogenizing use broom/shovel cone & quartering technique, use broom/shovel cone & quartering technique,
sampling sampling prepare 1000 prepare 1000- -g samples with various Jones splitters, and g samples with various Jones splitters, and
grinding grinding dry grind for 45 min with lab ball mill using 94 one dry grind for 45 min with lab ball mill using 94 one- -inch balls inch balls
10
20
30
40
50
60
70
0 10 20 30 40 50
Grinding Time (minutes)
C
u
m

%

P
a
s
s
i
n
g

2
0
0

M
e
s
h
65% Passing
4
5

m
i
n
u
t
e
s
Dry Ground
Copper Ore
U.S. Silver Corp. noted their optimal flotation response occurre U.S. Silver Corp. noted their optimal flotation response occurred near 65% d near 65%
passing 200 Mesh (75 um) which ore microscopy showed to be near passing 200 Mesh (75 um) which ore microscopy showed to be near liberation liberation
10
100
1000
5 10 15 20 25 30 35 40 45 50
Grind Time (minutes)
S
i
z
e

@

6
5
%

P
a
s
s
i
n
g

(
u
m
)
X
65
= 75 um (liberation size)
4
5

m
i
n
Dry Ground
Copper Ore
Procedures

Transport materials to various sites:

Transport materials to various sites:
dry dry- -ground ore ground ore flotation reagents flotation reagents flotation cell flotation cell
pH probe pH probe electrical generator electrical generator timer timer
gas flow meters gas flow meters compressed air compressed air pH buffers pH buffers
water water pressure gage pressure gage sample containers sample containers

Conduct tests at various altitudes:

Conduct tests at various altitudes:
66.9 kPa/9.7 66.9 kPa/9.7 psi psi - - Cooke Pass (elevation 3350 m/11000 ft) Cooke Pass (elevation 3350 m/11000 ft)
82.0 kPa/11.9 82.0 kPa/11.9 psi psi - - Montana Tech (elevation 1735 m/5700 ft) Montana Tech (elevation 1735 m/5700 ft)
91.0 kPa/13.2 91.0 kPa/13.2 psi psi - - Galena Mill (elevation 610 m/2000 ft) Galena Mill (elevation 610 m/2000 ft)
110 kPa/16.1 110 kPa/16.1 psi psi - - Galena Mine (elevation Galena Mine (elevation - -760 m/ 760 m/- -2500 ft) 2500 ft)

Conduct tests in a glove box:

Conduct tests in a glove box:
107.6 kPa/15.6 107.6 kPa/15.6 psi psi ( (- -610 m/ 610 m/- -2000 ft) 2000 ft)
82.0 kPa/11.9 82.0 kPa/11.9 psi psi (1735 m/5700 ft) (1735 m/5700 ft)
31.7 kPa/4.6 31.7 kPa/4.6 psi psi (9144 m/30,000 ft) (9144 m/30,000 ft)
Procedures

Conduct tests with other variables fixed:

Conduct tests with other variables fixed:
Wemco Wemco laboratory flotation machine laboratory flotation machine
5 5- -liter batch cell with automatic paddles liter batch cell with automatic paddles
20% solids 20% solids
1800 rpm impellor speed for conditioning 1800 rpm impellor speed for conditioning
1500 rpm impellor speed for floating 1500 rpm impellor speed for floating
Lime as pH 8 modifier (0.9 kg/MT; 1.8 lbs/ton) Lime as pH 8 modifier (0.9 kg/MT; 1.8 lbs/ton)
K K- -ferrocyanide ferrocyanide as pyrite depressant (0.05 kg/MT; 0.1 lbs/ton) as pyrite depressant (0.05 kg/MT; 0.1 lbs/ton)
Aero 31 as collector (0.25 kg/MT; 0.5 lbs/ton) Aero 31 as collector (0.25 kg/MT; 0.5 lbs/ton)
MIBC as MIBC as frother frother (0.1 kg/MT; 0.2 lbs/ton) (0.1 kg/MT; 0.2 lbs/ton)
Conditioning time of 16 minutes Conditioning time of 16 minutes
Flotation time of 10 minutes Flotation time of 10 minutes
Airflow Rate was ambient (uncontrolled) or 5 liters/min (contr Airflow Rate was ambient (uncontrolled) or 5 liters/min (controlled) olled)

Repeat tests 4 times (statistical confidence)

Repeat tests 4 times (statistical confidence)
Background
Butte (Montana Tech)
Basin (Froth Flotation)
Introduction
History
Variables
Objectives
Procedures
Results
Conclusions
Acknowledgements
Results
75
80
85
90
95
4 6 8 10 12 14 16 18
Pressure (psi)
R
e
c
o
v
e
r
y

(
%
)
Increasi ng Ai r Fl ow
Decreasi ng Bubbl e Si ze
pH 8 (CaO - 1.8 lbs/t on)
K
2
Fe(CN)
6
(0.1 lbs/t on)
Aer o 31 (0.5 lbs/t on)
MIBC (0.2 lbs/t on)
45-min Dr y Gr ind
Pressurized Flotation
Copper Ore
+11,000 ft
+5700 ft
-2500 ft
4
6
8
10
12
14
16
4 6 8 10 12 14 16 18
Pressure (psi)
G
r
a
d
e

(
%
)
Pressurized Flotation
Copper Ore
+11,000 ft
+5700 ft
-2500 ft
pH 8 (CaO - 1.8 lbs/t on)
K
2
Fe(CN)
6
(0.1 lbs/t on)
Aer o 31 (0.5 lbs/t on)
MIBC (0.2 lbs/t on)
45-min Dr y Gr ind
Increasi ng Ai r Fl ow
Decreasi ng Bubbl e Si ze
75
80
85
90
95
4 6 8 10 12 14 16 18
Pressure (psi)
R
e
c
o
v
e
r
y

(
%
)
pH 8 (CaO - 1.8 lbs/t on)
K
2
Fe(CN)
6
(0.1 lbs/t on)
Aer o 31 (0.5 lbs/t on)
MIBC (0.2 lbs/t on)
45-min Dr y Gr ind
- at alt it ude
- glove box
Pressurized Flotation
Copper Ore
Constant Ai r Fl ow
Decreasi ng Bubbl e Si ze
4
6
8
10
12
14
16
4 6 8 10 12 14 16 18
Pressure (psi)
G
r
a
d
e

(
%
)
Pressurized Flotation
Copper Ore
Constant Ai r Fl ow
Decreasi ng Bubbl e Si ze
pH 8 (CaO - 1.8 lbs/t on)
K
2
Fe(CN)
6
(0.1 lbs/t on)
Aer o 31 (0.5 lbs/t on)
MIBC (0.2 lbs/t on)
45-min Dr y Gr ind
- at alt it ude
- glove box
Without Airflow Control
Without Airflow Control
With Airflow Control
With Airflow Control
Results
0
2
4
6
8
10 11 12 13 14 15 16
Pressure (psi)
B
u
b
b
l
e

S
i
z
e

(
m
m
)
Theoreti cal (PV = nRT)
Wi thout Ai rfl ow Control
Wi th Ai rfl ow Control
Increasi ng
Coagul ati on
Results

Implementation
Implementation

To control pressure, the design

To control pressure, the design

must handle slurries under pressure/vacuum:

must handle slurries under pressure/vacuum:

introduction of the feed

introduction of the feed

discharge of the con/tailing products

discharge of the con/tailing products

must provide for:

must provide for:

agitation/aeration control
agitation/aeration control

froth level control

froth level control

maintenance/access
maintenance/access

can be done by:

can be done by:

modifying existing flotation cells (conventional,

modifying existing flotation cells (conventional,
column, ASH, Jameson, etc.)
column, ASH, Jameson, etc.)

pressurizing the room (

pressurizing the room (
hyperballic
hyperballic
chambers)
chambers)

constructing/purchasing new flotation cells

constructing/purchasing new flotation cells
Results

Economic Evaluation
Economic Evaluation

Assume a small mill:

Assume a small mill:

10000 STPD (approximately 9000 MTPD)

10000 STPD (approximately 9000 MTPD)

10 flotation cells
10 flotation cells

8 rougher/scavenger conventional cells

8 rougher/scavenger conventional cells

2 cleaner/
2 cleaner/
recleaner
recleaner
column cells
column cells

modification costs will be ~US$200,000

modification costs will be ~US$200,000

copper con at 75% of current market value of

copper con at 75% of current market value of
US$3.15/pound (US$6.93/kg)
US$3.15/pound (US$6.93/kg)

recovery increases by a mere 2%

recovery increases by a mere 2%

annual profits will increase by US$1.82M

annual profits will increase by US$1.82M

Excluding interest and downtime, the Return

Excluding interest and downtime, the Return
-
-
on
on
-
-
Investment (ROI) will be approximately one month!
Investment (ROI) will be approximately one month!

This does not include increased profits from

This does not include increased profits from
other products and/or credits: Au, Ag,
other products and/or credits: Au, Ag,
Pb
Pb
, Zn, etc.
, Zn, etc.
Results

Other benefits will include:

Other benefits will include:

Decreased environmental concerns

Decreased environmental concerns

Reduced costs for environmental permits

Reduced costs for environmental permits

increased con grades

increased con grades

Improved smelter contracts

Improved smelter contracts

Could be used at high

Could be used at high
-
-
elevation operations:
elevation operations:

Tintaya
Tintaya
-
-
Peru (4200 m/13800 ft
Peru (4200 m/13800 ft
asl
asl
; 63.4 kPa/9.2
; 63.4 kPa/9.2
psi
psi
)
)

Grasberg
Grasberg
-
-
Indonesia (3990 m/13100; 64.8 kPa/9.4
Indonesia (3990 m/13100; 64.8 kPa/9.4
psi
psi
)
)

Antamina
Antamina
-
-
Peru (4300 m/14200 ft
Peru (4300 m/14200 ft
asl
asl
; 62.8 kPa/9.1
; 62.8 kPa/9.1
psi
psi
)
)

Such operations would gain the greatest in

Such operations would gain the greatest in
flotation performance with recoveries and
flotation performance with recoveries and
grades estimated to improve 5% or more.
grades estimated to improve 5% or more.

These estimates are dependent on differences in

These estimates are dependent on differences in
minerals being concentrated as compared to
minerals being concentrated as compared to
the
the
tetrahedrite
tetrahedrite
examined in this study on ore
examined in this study on ore
from the Galena Mine of US Silver Corp.
from the Galena Mine of US Silver Corp.
Background
Butte (Montana Tech)
Basin (Froth Flotation)
Introduction
History
Variables
Objectives
Procedures
Results
Conclusions
Acknowledgements
Conclusions

Flotation is used to process ores and concentrates around

Flotation is used to process ores and concentrates around
the world at a variety of elevations but the effect of pressure
the world at a variety of elevations but the effect of pressure
on its performance, as usually determined by recovery and
on its performance, as usually determined by recovery and
grade, has been ignored.
grade, has been ignored.

Based on the results in this study, operations can improve

Based on the results in this study, operations can improve
both recovery and grade by as much as 5%
both recovery and grade by as much as 5%
pending the
pending the
characteristics of the ores and
characteristics of the ores and
mineral(s
mineral(s
) being separated
) being separated
.
.

Pressure was also found to influence flotation results by

Pressure was also found to influence flotation results by
affecting bubble size (and coagulation) as well as frothing
affecting bubble size (and coagulation) as well as frothing
action thus making airflow rate an important interrelated
action thus making airflow rate an important interrelated
variable to consider.
variable to consider.

Economics should be extremely favorable because capital

Economics should be extremely favorable because capital
and operating costs to control pressure will be greatly offset
and operating costs to control pressure will be greatly offset
by improved profits.
by improved profits.

However, further studies are needed to fully examine the

However, further studies are needed to fully examine the
economics, effects of bubble size/airflow rates, and design of
economics, effects of bubble size/airflow rates, and design of
pressurized flotation cells and systems.
pressurized flotation cells and systems.
Background
Butte (Montana Tech)
Basin (Froth Flotation)
Introduction
History
Variables
Objectives
Procedures
Results
Conclusions
Acknowledgements
Acknowledgements

National Science Foundation for funding the

National Science Foundation for funding the
Undergraduate Research Program at Montana Tech.
Undergraduate Research Program at Montana Tech.

Undergraduate students who worked on this project:

Undergraduate students who worked on this project:
Tyler Anderson, Adam House, Hubert
Tyler Anderson, Adam House, Hubert
Schimann
Schimann
, Darby
, Darby
Stacey, Amy Stepan, Randy Hamilton and Dave Douglas.
Stacey, Amy Stepan, Randy Hamilton and Dave Douglas.

US Silver Corporation for sending the ore samples,

US Silver Corporation for sending the ore samples,
conducting most of the analyses, and allowing the
conducting most of the analyses, and allowing the
students to conduct flotation tests at the surface and
students to conduct flotation tests at the surface and
depth of their Galena Mine in Idaho.
depth of their Galena Mine in Idaho.

Mr. Bill Huestis, Lab Director, whose patience and

Mr. Bill Huestis, Lab Director, whose patience and
experience helped this project succeed.
experience helped this project succeed.

The Technical Papers Committee and Organizers for

The Technical Papers Committee and Organizers for
the 28
the 28
th th
Mining Convention of Peru and
Mining Convention of Peru and
Extemin
Extemin
2007.
2007.

Gustavo & Ana Maria Plenge and Tatiana Castro.

Gustavo & Ana Maria Plenge and Tatiana Castro.

Miriam Young, my beloved wife, who made the trip!

Miriam Young, my beloved wife, who made the trip!