Flotation of copper ore
in a pneumatic flotation cell
Li Changgen and A. Bahr
Abstract-The adaptability ofpneumaticflotation cells for
the flotation of sulfde ore and the conditions for- sul$de ore
flotation in pneumatic cells were investigated. The advantages
of pneumatic flotation cells over mechanical flotation cells, as
well as flotation columns,for the flotation of sul$de ore were
demonstrated. Test results indicated that the Cu grade and
recovery for concentrates obtained when using the pneumatic
flotation cell were I % to 2% and 4%, respectively, higher than
those obtained when using the mechanicalflotation machine.
Introduction
The flotation process can be divided into three steps:
Conditioning of pulp.
Aeration of pulp and adhesion of the solid particles to the
air bubbles, forming stable aggregates.
Separation of solid particles-air bubble aggregates as
froth from the pulp.
Conditioning of feed pulp takes place in an individual
conditioning vessel. Aeration (the dispersion of air to form
microbubbles followed by their attachment to ultra-fine solid
particles) is most effective under high energy input through
mechanical agitators for breakdown of hydrophilic hydration
film on mineral surfaces. However, laminar flow conditions
free of turbulence are necessary to increase flotation separation
accuracy.
In conventional flotation cells with mechanical agitators,
aeration and separation of froth from pulp occur in the same
vessel. Hence, it is impossible to provide optimum conditions
for both steps. Ejector or injector flotation cells, as well as
flotation columns, also cannot ensure optimum conditions for
flotation(AlizadehandSimonis,1985;Schubert, 1988;Jameson,
1988).
For this reason, Bahr advanced a novel pneumatic flotation
cell design based on detailed investigation of pulp aeration and
air bubble forming mechanisms (Bahr, Ludke and Mehrhoff,
1982; Bahr and Ludke, 198 1; Stich and Bahr, 1979). Bahr's cell
differs essentially from mechanical and from other pneumatic
flotation cells. The pneumatic flotation cell consists of a
separation vessel and aerators (reactors) isolated from the sepa-
ration vessel. The dispersion of air and formation of aggregates
between air bubbles and mineral particles in the feed take place
in a layer of limited extent over a shert flow distance. The
aeration of pulp and separation of froth from the pulp proceed in
the aerator and the separation vessel, respectively. Thus, opti-
mum conditions for both processes can be realized simulta-
..----- J.
The cross-current aerator, pipe aerator,
aerator, Hosch-
Auto-air-aeratOr and A1lflot 'ystem were used in pneumatic
flotation cells (Bahr, Ludke and Mehrhoff, 1982; Bahr, Legner,
Ludke and Mehrhoff, 1987; Bahr and Ludke, 1981; Imhof and
Bahr, 1985; Imhof and Hoffman, 1984; Imhof and Stahl, 1986;
MINERALS 8 METALLURGICAL PROCESSING
Jungmann and Reilard, 1988). The pulp level in the separation
vessel was successfully controlled automatically (Bahr, Ludke
and Mehrhoff, 1982; Bahr, Legner, Liidke and Mehrhoff, 1987;
Imhof, 1988).
After carrying out development and research on a bench-
scale plant at the Steinkohlenbeegbauverein,Essen, and in the
preparation plant at the Bergwerk Westerholt, the results were
evaluated, and a pilot plant with a capacity of 50 m3/h pulp was
constructed.
Pneumatic flotation cells with maximum throughputs of 550
m3/h and 800 m3/h pulp were operated with satisfactory results
in 1980 and 1984, respectively (Bahr, Liidke and Mehrhoff,
1982; Bahr, Legner, Ludke and Mehrhoff, 1987).
Summaries of results from some commercial operations
follow:
During the treatment of gravity and magnetic iron
concentrates at the Bong Mining Co., Liberia, the Fe grade
and Fe recoveries in superconcentrates obtained with single-
stage pneumatic flotation cells were higher than those ob-
tained withconventional mechanical flotation cells in double-
stage (Bahr, Imhof and Ludke, 1985; Bahr, Klingbiel and
Priesemann, 1984).
In dressing magnesite ore from Spain, magnesite recov-
ery into concentrate obtained in a pneumatic cell with through-
put of 10 to 15 m3/h in single-stage increased by 8.6% as
compared with recovery in a three-stage conventional flotation
plant (Bahr, Imhof and Liidke, 1985; Imhof and Heep, 1986).
Results for apatite ore flotation in a pneumatic flotation
cell with a throughput of 100 m3/h indicated that a single-stage
pneumatic cell was capable of replacing one rougher, two
scavengers and a double purification stage (Bahr, Imhof and
Ludke, 1985).
Pneumatic flotation cells also have been used to remove
carbon particles from fly ash used as raw material for cement
and mortar (Imhof, 1986). However, to date the cells have
been primarily used to float nonmetallic ores (for example,
coal, apatite, magnesite, fluorite and so on).
Pneumatic flotation of lead-zinc ore was also tested, but
only to treat ultra-fine lead and zinc sulfide particles (below
10 ym) in the extra-dilute overflow from a thickener (12
g/L solids). The lead and zinc recoveries were only 30% and
45%, respectively (Bahr, Imhof and Ludke, 1985).
The objectives of the work reported here were to demonstrate
the adaptability of pneumatic flotation cells for flotation of
sulfide ore and to define the optimum conditions for pneumatic
Li Changgen is senior engineer with Beiiing General Flesearch
Instituteof Mining and Metallurgy, Peoples Republic of China. A. Bahr
is professor Dr.-lng. with lnstitut fiir Aufbereitung und Veredelung, TU
Clausthal, Germany. SME nonmeeting paper 91-612, Manuscript
March 25. 1991. Discussion of this ,oaoer , must be submitted. in
duplicate, prior to June 1,1992.
FEBRUARY 1992 7
flotation cells, as well as comparison of the pneumatic flotation There are two aerators in a pneumatic flotation cell, a pipe
cells with mechanical flotation machines and flotation columns. aerator and a ring aerator:

Experimental materials, equipment and method The pipe aerator consists of an inner porous tube made
01.esun~plos of polyethylene and an outer tube made of metal. The pulp
passes through the porous tube, while the air flows into the outer
Samples of copper ore were taken from a copper porphyry tube and then through the porous tube wall inwards to form
mine in China. The chemical and the mineral phase analyses of microbubbles. The mineral particles and air bubbles react with
the ore samples are given in Table I and Table 2. respectively. eachother in the pipeaerator,thus forming themineralized froth.
The ore contains pyrite. chalcopyrite, molybdenite, quartz.
sericite and chlorite. The ring aerator is made of a porous ring pipe. Air
flow is added into the ring pipe to form air bubbles. The
Table 1-Chemical analysis of crude ore mineral particles and air bubbles contact each other in the
pulp in the separation vessel. The mechanism of the miner-
Element 7'0 Element 7'0 alized froth formation with the ring aerator is similar to that
in a flotation column.
Cu 0.52 Zn 0.01
Mo 0.009 Fe 4.5
Ti0 MgO 1.35
The pulp level can be adjusted by means of a pulp level
0.76
CaO 1.OO K20 4.10 adjustor.
Si02 65.60 Alpo, 15.40
Method
Table 2-Mineral phase analysis of crude ore The ore samples and tap water in a given mass were intro-
duced into a laboratory rod mill and ground to a given fineness.
Copper mineral phase Cu content, % Cu distribution, % The ground pulp was poured into the mechanical flotation cell
or the agitator and then agitated for I min. The collectors (butyl
Oxide 0.01 1.83 and ethyl xanthate mixture, 1 to 1 ) were added and agitated for
Secondary sulfide 0.065 11.93 3 min. Ore flotation was startedafterfrother(pineoil) was added
Primary sulfide 0.47 86.24 and agitated for 2 min.
Total 0.545 100.00
Experimental results

Butyl and ethyl xanthates and pine oil were kindly provided
by Hoechst AK.
The following reagents. all of analytical grade, were used in
the tests: NaOH, HCl and CuS04.
Flotation equipme111
All flotation tests were carried out in a laboratory me-
chanical air-blowing flotation cell (volume 0.5 L) and a
laboratory pneumatic flotation cell (volume 3.0 L and D x H
= 100 x 400 mm) which were made in the lnstitut fiir
Aufbereitung und Veredelung, TU Clausthal. The equip-
ment flowsheet is shown on Fig. 1.
Ring aerator
railings
Feed pulp
Fig. 1-The equipment flowsheet for the pneumatic flotation tests.
Figures 2 and 3 show the effects of air flow rate and pulp flow
rate on flotation results with a pneumatic flotation cell.
As seen from Fig. 2, for a given pulp flow rate, as the air
flow rate increased, the Cu recovery first increased, then
reached a maximum, and finally decreased. On the other
hand, for a given air flow rate, as the pulp flow rate changed.
the Cu recovery only changed slightly.
For a given pulp flow rate, as air tlow rate increased, the Cu
grade in the concentrate decreased. When the air tlow rate was
given, as pulp flow rate increased, the Cu grade in the concen-
trate increased slightly.
As shown in Figs. 4 and 5. fineness of grind had little
influence on recovery when using mechanical and pneumatic
flotation cells. As the percentage of -200 mesh material in-
creased in flotation feed, the Cu grade in the concentrate
obtained with a mechanical cell decreased, whereas the Cu
grade in the concentrate'obtained with a pneumatic cell in-
creased slightly.
It can be observed that the pulp density had little influence
on the Cu grade and recovery in the concentrate obtained with
a mechanical cell or on the Cu grade in the concentrate obtained
with the pneumatic cell. As the pulp density increased in the
pneumatic cell, the Cu recovery increased (Fig. 6).
Fig. 7 shows that when the pulp density increased to 300
g/L solids, the desired collector dosage with a pneumatic cell
decreased to the same level as with a mechanical cell.
The effect of aeration method on flotation results with a
pneumatic cell is given in Fig. 8. When the air flow rate of the
pipe aerator is set at 0.4 L/min, the Cu recovery only changes
slightly. Whereas, when the air flow rate of the ring aerator
increases, the Cu grade in concentrate decreases. Using a ring
aerator alone, the Cu recovery decreases by 6.95% as compared
with pipe aerator alone.

8 FEBRUARY 1992 MINERALS 8 METALLURGICAL PROCESSING

 Y-
Fig. 2-Effect of air flow rate and pulp flow rate on Cu recovery.
(Flotationconditions:pulpdensity,100glLsolids;grindfineness, 65% Fig. 3-Effect of air flow rate and pulp flow rate on Cu grade in
-200 mesh; frother, 70 g/t; collector, 80 glt; pH of flotation, 8.15). concentrate. (Flotation conditions were the same as those of Fig. 2).

Cu Recovery Cu grade, % Cu Recovery Cu grade, %

85 I 8
90 I 8

-200 mesh: 65% 87% 95% -200 mesh: 65% 87% 95%
Recovery, mechanical cell 0 82 69 81 72 82.96 Recovery. mechanical cell 0 81.78 83.39 83.21
Recovery, pneumatic cell 83.03 83.30 83.10 Recovery. pneumatic cell 87.35 86.88 87.34
Grade, mechanical cell 6.08 5.29 5.07 Grade, mechanical cell 6.29 4.95 4.13
Grade, pneumatic cell 1 6.24 6.80 6.88 Grade, pneumatic cell 1 7.04 7.10 7.32

Grinding fineness Grinding fineness

Fig. 4--Effect of grind size on pneumatic cell flotation results at pulp Fig. %Effect of grind fineness on pneumatic cell flotation results at
density of 100 g/L solids. (Flotation conditions: pulp flow rate, 2.63 pulpdensity of 300 glLsolids. (Flotation conditions: pulp flow rate, 2.63
Umin; air flow rate, 1.54 Umin). Urnin; air flow rate, 1.54 Umin).

Cu Recovery Cu grade, %
Cu recovery Cu grade, %
90 10

Solid: 100 glL 200 glL 300 g/L

Recovery, mechanical cell 0 82.78 82.03 83.06 . -
40 (Mech. cell) 27 (Pneu. cell) 40 (Pneu. cell) 80 (Pneu. cell)
Recovery, pneumatic cell 83.17 85.86 87.03
87.02 87.17
82.51
Grade, mechanical cell 6.47 6.24 6.58 7.35 7.21 7.25
Grade, pneumatic cell 1 7.21 7.12 7.09

Pulp dens$y Collector dosage, g/t

Fig. 6-Effect of pulp density on pneumatic cell flotation results. Fig. 7-Effect of collector dosage on flotation results. (Flotation
(Flotation conditions: pulp flow rate, 2.63 Umin; air flow rate, 0.44 conditions: grind, 65% -200 mesh; pulp density, 300 glL solids.
Llmin). Pneumatic cell: pulp flow rate, 2.63 Umin; air flow rate, 0.44 Umin).

MINERALS 8 METALLURGICAL PROCESSING FEBRUARY 1992 9

 Cu recovery, %
Recovery, 100 g1L
Recovery, 300 g1L
Grade, 100 glL
Grade, 300 glL
2.63 Umin; air flow rate, 0.44 Llmin).
-
0
Pipe 0.4, ring 0 Pipe 0.4, ring 0.1 Pipe 0.4, ring 0.2 Pipe 0, ring 0.4
83.41
86.84
7.67
7.19
85.25
87.33
7.43
6.82
Air rates of different aerators, Llmin
Fig. &Effect of aeration method on pneumatic cell flotation results. (Flotation cond~t~ons:
Results for Cu grade and Cu recovery in different size
fractions of concentrate are given in Fig. 9.
The Cu grade and recovery in the coarse size fractions in the
concentrate obtained with mechanical cell and pneumatic cell
are close. The Cu grade and recovery in the fine fractions in
concentrate with the pneumatic cell increaseincomparisonwith
the mechanical cell.
Grade distribution along the pulp level is given in Fig. 10.
As can be seen, the Cu grade at the level of the feed point is
lower than the feed grade (0.5% Cu). Only at the level of 100
mm will the Cu grade be the same as the Cu grade of the feed.
Then, the Cu grade increases as the pulp level increases, with
the Cu grade of the froth product increasing rapidly to
7.02%.
Results and discussions
The investigation results indicated that not only the air
flow rate but also the pulp flow rate influenced flotation
results in a pneumatic cell. For a given pulp flow rate, the
lower the air flow rate, the smaller and more evenly formed
were the bubbles. However, if air flow rate was too low, though
the air bubbles were smaller and more even, the Cu recovery of
concentrate was still not high enough because of the decreasing
total surface area of the froth. For example, the Cu recovery
was about 74 % at the air flow rate of 0.19 L/min.
If air flow rate was too high, the formed bubbles had a
larger size and lower specific surface area, as well as a
turbulent pulp surface, so both the Cu recovery and grade
decreased. For the same reason, for a given air flow rate,
the greater the pulp flow rate, the smaller and more even
were the air bubbles formed, to a certain extent.
If pulp flow rate was too low, the formed bubbles had
great size and small specific surface. As a result the Cu
recovery was lower, for example, 69.26% to 78.56% at the
pulp flow rate of 2.07 Llmin.
A satisfactory flotation result must correspond with the
optimum ratio between air flow rate and pulp flow rate. Bahr
confirmed that the optimum air and pulp ratio ranged from
1.3 to 1.5 during coal flotation with a pneumatic cell. The
quantity of sulfide minerals floated into the froth product
from sulfide ore was much less than from coal. So that the
10 FEBRUARY 1992
Cu grade, %
87.55
87.07
6.43
5.88
77.81
79.89
7.26
7.10
grind fineness, 65% -200 mesh; pulp flow rate.
optimum air:pulp ratio for the flotation of sulfide ore with a
pneumatic cell was much lower (0.15:0.48) (Figs. 2 and 3).
The test results of the aeration method indicated advantages
of the aerator developed by Bahr over conventional aerators. In
reality, this aerator is a reactor for mineral particles and air
bubbles. In the aerator, mineral particles obtain a great energy
input to promote breakdown of hydrated film on mineral surface
and an increasing probability of collision between mineral
particles and bubbles because of a great energy input.
The aerator is proved to be suitable for flotation of fine
mineral particles. For example, as compared to the mechanical
flotation machine, the Cu recovery from the 32 to 20 pm size
fraction with the pneumatic cell increased by 4.44% and from
the -20 pm size fraction by 6.07 % (Fig. 9).
The adhesion of air bubbles to mineral particles with the ring
aerator used in the aeration method tests is similar to adhesion
in a flotation column. That is, while mineral particles are falling
down and air bubbles are floating up in the pulp, they contact
each other. Though the collision probability between mineral
particles and bubbles may be great,the Cu recovery into the new
size fraction in concentrate with the ring aerator will be lower
than with the pipe aerator (reactor).For example, as compared
with ring aerator alone, the Cu recovery in concentrate with the
pipe aerator alone increased by 5.60% to 6.95% (Fig. 8),
whereas the Cu grade of concentrate basically did not change.
Using a conventional aerator, for example a ring aerator, the
bubble forming frequency and bubble size were determined to
be a function of air flow rate, air pressure drop and orifice size
of aerator. On the other hand, using the pipe aerator, besides
above-mentionedparameters, the pulp flow rate passing through
the aerator can control the bubble size. Therefore, the bubble
size and bubble number could be changed readily by means of
modification of both air flow rate and pulp flow rate to form
more even microbubbles.
In the 1960s, a great number of large-volume flotation
columns were used in Chinese concentrators to treat copper,
molybdenum, lead, zinc and iron ores. Some failures of the
flotation columns occurred due to the plugging of aerators by
mineral particles and scale formed on aerator surfaces, espe-
cially when using lime as a flotation reagent. There was also a
problem in restarting after occasional breakdowns because of
the great quantity of mineral particles deposited on the aerators.
MINERALS 8 METALLURGICAL PROCESSING
 Cu recovery, % Cu grade, %
100 12

-20 20-32 32-40 40-60 50-63 63-80 80-100 100-125 125-160 160+
Recovery,mechanicalI 79.9 91.49 88.99 90.08 83.74 84.2 82.45 77.48 77.08 7376
Recovery, pneumatic 85.97 95.93 91.97 93 52 91.61 89.1 83.49 80 68 80.11 74.19
Grade, mechan~cal 3.78 8.08 7.56 7.13 6.9 6.13 6.03 5.88 5.02 4.34
Grade, pneumatic 6.82 10.61 9.8 8.62 7.44 6.9 5.29 5.16 4.67 4.09

Size class, prn

Fig. 9--Cu grade and Cu recovery into different size fractions of concentrate with a mechanical and pneumatic cell. (Flotation conditions: grind
fineness, 65% -200 mesh; pulp density, 300 g/L solids; pulp flow rate, 2.63Umin; air flow rate, 0.44 Umin).

Pulp level, mm

Froth
A Pulp level of
feed plant, 0 1 2 3 4 5 6 7 8
Tailings
Cu grade, %
Fig. 10-Distribution of Cu grade along pulp level. (Flotation conditions: pulp flow rate, 2.63 Umin; air flow rate, 0.44 Umin; pulp density,
300 g/L solids).

MINERALS 8 METALLURGICAL PROCESSING FEBRUARY 1992 11

The installation of aerators outside the separation vessel of
pneumatic cells might overcome the second difficulty. The feed
pulp passing through the tube of an aerator in pneumatic
flotation cells rubs against the surface of porous material of the
aerator and prevents formation of scale on the porous material.
This contributes to the solution of the problem of aerator
plugging.
With flotation columns, to increase the grade of concentrate,
the required froth depth was usually about 900 mm. Therefore,
the height of a flotation column was 5 to 15 m (Jameson, 1988;
Schubert. 1988). Several disadvantages resulted, including an
increased requirement for floor space, increased cost for pump-
ing the feed up to the required injection level and increased air
pressure drop. For coal, a froth height of 300 to 400 mm was
enough with a pneumatic cell (Bahr, Liidke and Mehrhoff,
1982). The separation vessel of a pneumatic cell with height of
4 m obtained satisfactory results in coal flotation. Thus, it can
be seen that the substitution of pneumatic flotation cells for
flotation columns has broad prospects.
The result5 prove that pneumatic flotation cells can treat both
dilute and denserpulps. The Cu recovery of concentrate obtained in
the pulp density of 300 g/L solids was 3.86% higher than that with
100 g/L solids (Fig 61, which was attributed to the easier adhesion
of mineral particles to bubbles and acceleration ofmineralized froth
floating up in denser pulp. It's really a pity that the flotation tests at
the pulp density of more than 300g/L solids could not be carriedout
because of deficiency of sufficient sample.
In the flotationof sulfideore with the pneumatic cell, as solids
content in the feed pulp increased, the dosage of flotation
reagents decreased rapidly. As seen from Fig 7, the reagent
dosage in the flotation with apneumatic cell was the same as that
with a mechanical flotation machine at the same pulp density
(for example, 300 g/L solids).
Comparison of the pneumatic cell with the mechanical
flotation machine is given in Table 3.
Table 3 - C o n c e n t r a t e s obtained with pneumatic cell and
mechanical f l o t a t i o n machine
Stage Solid Weight Cu
glL % Yo Yo
Mechanical machine
Single 300 6.60-8.62 4.13-6.88 82.10-83.39
Double 300 12.13-12.21 3.82-3.87 90.15-90.37
Pneumatic cell
Single 100 5.79-6.73 6.24-7.67 83.41-83.03
Double 300 6.20-6.34 7.04-7.21 86.84-87.35
As seen from Table 3, as compared with the mechanical
machine in single-stage, the Cu grade and recovery of concen-
trate obtained with the pneumatic cell at the pulp density of 300
g/L solid increased by 1% to 2% and 4%, respectively. That is
the reason why the Cu recovery into the fine size fractions of
concentrate increasesand the mechanical entrainmentofthe fine
gangue particles by froth decreases. Because of the lack of ore
samples, the double-stage flotation tests with a pneumatic cell
and comparison of the flotation results of pneumatic cell with
mechanical flotation machine in double-stage could not be
canied out.
12 FEBRUARY 1992
Conclusions
As with mechanical flotation machines, pneumatic flotation
cells can treat successfully both nonmetallic and metallic ores.
During the flotation of Chinese copper ore. the Cu grade and
recovery of the concentrate obtained with pneumatic cell in-
crease by 1% to 2% and 4%, respectively. as compared with the
mechanical flotation machine because of more effective recov-
ery of fine valuable mineral particles and reduction of mechani-
cal entrainment of fine gangue particles by froth in the pneu-
matic cell.
Substitution of pneumatic flotation cells for flotation columns
canovercomethe difficultiesofboththe pluggingof porousmaterial
in aerators by mineral particles and scale, as well as troubles in
shutdown and restarting. Furthennore, early indications are that
more effective flotation of fine mineral particles is obtained in a
pneumatic cell than in a flotation column.
The flotation reagent dosage and flotation pulp density with
pneumatic cells rarely differ from those with mechanical flota-
tion machines. The airpulp ratio during pneumatic flotation of
sulfide ore is found to be lower (0.15 to 0.48: 1 ).
Pneumatic flotation cells are applicable to the flotation of
ores with fine dissemination size because of effective recovery
of valuable fine mineral particles. The grade of the concentrate
obtained with pneumatic cells has proven to be usually much
higher than with mechanical flotation machines. Therefore,
pneumatic cells are preferred in the cleaning operation.
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MINERALS 8 METALLURGICALPROCESSING