10oct - 2013 Modelado en Flotación

11/10/2013
Modelado de flotación –
la importancia de la fase espuma
Dr Pablo Brito Parada
Froth and Foam Research Group
Royal School of Mines,
Department of Earth Science & Engineering,
Imperial College London
Separation by froth flotation
10 cm
0.5 mm
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Flotation: Why it works
Surface chemistry:
• Differences in mineral surface properties make a separation
possible
Froth physics:
• Froth physics determines the efficiency of the separation
Froth Flotation
Conceptually simple:
• Make one mineral hydrophobic using surface chemistry
• Bubble air through the slurry
• Hydrophobic particles stick to the bubbles,
float to the surface and form a froth,
overflow as the concentrate.
• The waste stays in the pulp.
Chemically and physically

complex.
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Flotation processes: Pulp phase

Pulp processes – attachment of hydrophobic particles to bubbles
Flotation: what does the air do?
In the pulp:
• Bubbles form at impeller

• Frother makes them small and stable
• Pick up particles by collision, float, froth
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Physical Aspects: Collection of particles
What are the sub-processes occurring in the pulp phase?
• Collision
• Attachment
• Detachment
All of these processes are affected by particle and bubble

properties
Physical Aspects
How do we float a desired mineral particle?
The desired particle must be:

• Liberated
• The ‘right’ size
• Hydrophobic
The gangue must be hydrophilic
We need to:
• Provide air bubbles
• Contact air bubbles with particles
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Physical Aspects: Particle Properties
chromite
Dissemination of
minerals in ore will
determine how finely the
ore needs to be milled in
order to obtain fully pyrrhotite
chalcopyrite
liberated mineral grains
silicate
Flotation is most effective for particles between 10 and 100 mm
International Journal of Mineral Processing

Volume 8, Issue 4, 1981, PP289-327
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Valuable minerals must be hydrophobic

and gangue minerals must be hydrophilic
Water
bubble
Hydrophobic surface Hydrophilic surface
Hydrophobicity is commonly determined using

contact angle
Chipfunhu et al 2012
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Physical Aspects: Bubble Properties

In order to collect the valuable hydrophobic particle, we need to
provide bubbles and to contact the particles with the bubbles
Bubbles are either generated by shear inside a tank or by

spargers outside the tank
Typical bubble size is around 0.5 to 1 mm
• The bubbles must be small enough to provide

sufficient area for attachment
• But with sufficient buoyancy to float the
particles
10 cm
Nesset et al 2006
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If 2 bubbles of radius 0.5 mm coalesce, the resulting bubble will

have a surface area 20% lower than the original 2 bubbles
Alternatively:
Consider a volume of 1 cm3
1 bubble 9 bubbles
Bubble radius: Bubble radius: 3.0 mm

6.2 mm Total Surface area:
Surface area: 1.06 cm3
0.48 cm3
Navarra et al 2009
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The gas phase parameters considered in flotation are:
• Superficial gas velocity (Jg)
• Bubble size (db or d32)
• Gas hold-up (g)
Parameter Symbol Definition Unit Typical

values
Superficial Jg Air rate/cross cm/s 1-2
gas velocity sectional area
Bubble size db (d32) Bubble diameter mm 1
(Sauter mean
diameter)
Gas hold-up g Volume of % 10-20
air/volume of cell
Pulp bubble size is dependent on:

• Air rate
• Impeller speed
• Slurry viscosity
• Frother addition
Nesset et al 2006 Grau & Heiskanen,

2005
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What are the sub-processes occurring in the pulp phase?
• Collision
• Attachment
• Detachment
All of these processes are affected by particle and bubble properties
The probability that a particle is collected by an air bubble in the

pulp phase can be given by:
P = PcPa(1-Pd)
Yoon, 2000
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Pulp phase: Bubble-particle collision
• Differences in surface properties make some minerals

hydrophobic
• Depends on the bubbles and particles colliding
• Particle & bubble size effects
• Mixing
Physical Aspects: Probability of Collision

The probability of collision is proportional to the particle size
Firouzi et al, 2011
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Physical Aspects: Attachment of particles
The probability that a particle is collected by an air bubble in the

pulp phase can be given by:
P = PcPa(1-Pd)
Yoon, 2000
Pulp phase: Bubble-particle interactions
• Differences in surface properties make some minerals

hydrophobic
• Hydrophobicity quantified by contact angle; higher, more hydrophobic
• Hydrophobic minerals can attach to air bubbles
• After collision particles must attach to bubbles – a function of the hydrophobicity
of the particle and the turbulence in the cell
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Physical Aspects: Probability of Attachment

The probability of attachment is related to the hydrophobicity,
and often related to measurements of induction time
Verrelli et al (2011), Chem Eng Sci 66(23)

5910-5921
Physical Aspects: Probability of Attachment
The distribution of liberation classes of copper sulfide minerals in 106 × 53 μm fractions of

concentrates and tails as □ highly, moderately and ■ poorly liberated particles.
Liberation:
Attachment time vs SIBX
dosage for concentrates and
tails
(□ Con-1; ○ Con-2; Δ Con-3; ∇
tails).
Albijanic et al, 2012
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Physical Aspects: Probability of Detachment

The probability of detachment is related to the particle size
and hydrophobicity, and also the turbulence in the pulp phase
Goel and Jameson (2012), Min Eng 36-38 324-

330
Physical Aspects: Pulp phase turbulence

Stirred tanks are highly turbulent systems; while this helps
attachment, it can adversely affect detachment
Xia et al (2009), Min Eng 22(11) 880-885
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Quantifying the separation
Recovery of valuable mineral, metal or gangue:

The fraction of the substance in the feed to the process that is
recovered to the concentrate stream:
Recovery = Flowrate of substance in concentrate

Flowrate of substance in feed
..... also used for air and water.
Physical Aspects: Quantifying Collection
Jameson, 2012
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Physical Aspects: Quantifying Collection
The collection of particles in the pulp zone is a balance

between:
• Particle liberation and size
• Bubble size, surface area and buoyancy
• Contact between particles and bubbles, and detachment due
to turbulence
Chemical Aspects of Flotation
For flotation to be effective, we need the mineral(s) we want to be

hydrophobic and the mineral(s) we don’t want to be hydrophilic
For this we need to consider:

• Chemistry of surfaces
• Adsorption of reagents that impart hydrophobicity
• Reagents that will depress the gangue and/or minerals we don’t
want
• Water chemistry and pH
We will also need to produce small bubbles
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Chemical Aspects of Flotation
For flotation to be effective, we need the mineral(s) we want to be

hydrophobic and the mineral(s) we don’t want to be hydrophilic
For this we need to consider:

• Chemistry of surfaces – sulphide or non-sulphide
• Adsorption of reagents that impart hydrophobicity - collectors
• Reagents that will depress the gangue and/or minerals we don’t
want – modifiers (depressants)
• Water chemistry and pH
We will also need to produce small bubbles - frothers
Metal extraction: Performance measures
Recovery:
• The fraction of the metal in the feed to the process that is
recovered to the concentrate stream
Grade:
• The mass fraction of metal in the feed, concentrate or tailings
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The Grade-Recovery Balance
Recovery:
The fraction of the metal in the feed to the process that is
recovered to the concentrate stream:
Recovery = Flowrate of metal in concentrate
Flowrate of metal in feed
Grade:
The mass fraction of metal in the feed, concentrate or tailings:
Grade = Mass metal in stream
Total mass of solids in stream
The Grade-Recovery Relationship

… balancing what you want and don’t want
35
30
25
Cu Grade %
20
15
10
0
70 75 80 85 90 95 100
Cu Recovery %
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Bank of Flotation Cells

TAILS 1 TAILS 2 TAILS n-1
= FEED 2 = FEED 3 = FEED n
FEED 1
FINAL TAILS
CON 1 CON 2 CON 3

CON n
CUMULATIVE CONCENTRATE AFTER 3 STAGES
CUMULATIVE CONCENTRATE AFTER n STAGES
Concentrate grade decreases down the bank

• Mineral recovery is a rate process – C=C0e-kt
• Gangue recovery is a physical process – depends on froth structure
Grade-Recovery curves
• Show competing effects of quantity of metal recovered

and the quality of the separation
• Recovery - % of metal (or mineral) in feed to valuable

stream
• Grade - % of metal (or mineral) as mass fraction of total
.. can also use an upgrade ratio, for example
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The Grade-Recovery Relationship

… balancing what you want and don’t want
35
30
25
Cu Grade %
20
15
10
0
70 75 80 85 90 95 100
Cu Recovery %
Grade-Recovery curves
Can be plotted :
• Steady-state down a bank of cells
• Cumulatively from a batch test
• Calculate the curve down a bank from the mass balance
• Different operating conditions give different curves.

Concentrate grade decreases down the bank
• Mineral recovery is a rate process – C=C0e-kt
• Gangue recovery is a physical process – depends on froth structure
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Air Rate and flotation performance
The relationship between the peak in air recovery and flotation bank
performance
Minerals Engineering, Volume 22, Issue 5, April 2009, Pages 451-455
K. Hadler, J.J. Cilliers
Particle size effects

• Experimental data shows high recoveries for intermediate particle
size
• Typical range 20 ≤ dp ≥ 150
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Flotation rates – overall model
Kinetics and flotation rates
dC
 kC First order kinetics...
dt
k
R Mineral recovery from a single tank
k  1 τ is the residence time (tank
volume/flowrate)
Flotation: what does the air do?
• Bubbles form at impeller

• Frother makes them small, (0.5mm) & stable
• Pick up particles by collision, float, froth
• Bubbles come together in the froth and coalesce;

lose >90% of surface area and particle load
• Some burst on surface, the rest overflow with their
particles – about 3% of the total
• The rest of the particles are free to move
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The hydrophobic particles on bubbles
How are particles recovered?
• Particles released from coalescence or bursting move

through the froth
• Some overflow, the “froth recovery”
• Some drain back into the pulp, especially the coarse &
dense
• Gangue is entrained with water that comes into froth
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Foam Structure: The Physics of Foam

Films between bubbles
Plateau borders
A Flowing Froth Model - components
Modelling the Physics of:
• Froth motion
• Liquid flow in the froth
• Solids motion
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Typical Operating Conditions
Depends very much on the system, but...
• Particle size ~100 microns, <250 microns

• 30-40% solids by mass, could be as high as 55%
• Residence time a few minutes per cell
• Air rate about 1cm/s (superficial velocity)
• Rougher froth depths 5-20cm, in cleaners could be much
deeper
• Staged reagent addition; more into scavengers
• Wash water could be added to final stages
Flotation processes and parameters
Phase Process Parameters

Cell dimensions: rcell, Vcell
Feed properties: QF, dp, ρp, ρl, µfl, particle
Pulp Particle attachment
composition, particle floatability
Gas properties: d32, Jg
Transport of attached Slurry properties: dp, ρp, ρl, µfl,
particles Gas properties: d32, dbub, out, Jg, α
Cell properties: rcell, hfroth
Transport of
Feed properties: dp, ρp, ρl, µfl
Froth entrained particles
Gas properties: Jg, α
Cell dimensions: rcell
Transport of liquid Feed properties: ρp, ρl, µfl
Gas properties: dbub, out, Jg, α
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What is the Air Recovery?

Air leaving froth by bursting
• Air leaves a flotation at top surface
cell by bursting on the
top of the froth or
overflowing into the
concentrate.
Air overflowing
the weir as froth
• The AIR RECOVERY is
the fraction of the air
that that overflows (and
does not burst)
Froth
concentrate
Air into the cell
Measuring the air recovery
Air leaving
through Overflowing
bursting froth height
Air flowing
over lip
Air Recovery =
Volumetric flowrate air overflowing
Air flowrate into cell
Volumetric flowrate air overflowing

= overflowing velocity x overflowing
Air In froth height x lip length
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Air Recovery
Why is air recovery important?
• Determines loaded bubbles overflowing

• Sets the upward velocity in the froth and dropback
- RECOVERY
• Controls the water (and entrained gangue)

recovery – GRADE
Air Recovery shows a maximum (PAR)

at a specific air rate
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Why is there a Peak in Air Recovery (PAR)?

Optimum balance
between froth stability
and motion
Air
Recovery
Bubbles heavily loaded Bubbles under-loaded

Stable, but move slowly Unstable, burst quickly
Air Velocity into Flotation Cell
Air Recovery and flotation performance
Air rate that gives highest air recovery also gives highest mineral
recovery
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Why does the Air Recovery affect flotation?

Optimum balance between froth
stability and motion
High recovery and grade
Metallurgical
Air
Recovery  Recovery
INCREASE AIR REDUCE AIR
Reduce grade Increase grade
Increase recovery Increase recovery

Bubbles heavily loaded Bubbles under-loaded

Stable, but move slowly Unstable, burst quickly
Air Velocity into Flotation Cell
Air recovery: Key concepts

Optimum balance
between froth
stability and motion
High recovery and
Metallurgical
Air Recovery
grade

Recovery
Bubble under-loaded
Froth flows fast but
bubbles burst quickly
Lower recovery, low
grade

Bubbles heavily loaded
Froth flows too slowly
Burst before overflow
Lowest recovery, high
grade
Air Velocity into Flotation Cell, Jg
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Air Recovery Application
• Measuring air recovery

• Air rate effect and flotation performance
• Bank air profiling using air recovery
Froth Flotation and Froth Physics
The surface chemistry determines whether

the minerals can be separated
The froth physics determines how well the

separation happens
Requires a froth-phase model describing the

physics
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Flotation rates – previously

Kinetics and flotation rates – without the froth
dC
dt
k  Pf Sb Flotation rate constant
6J g
Sb  Bubble surface area flux
db
k Mineral recovery from a single tank

R
volume/flowrate)
Flotation rates – previously

Kinetics and flotation rates – without the froth
dC
dt
k
R Mineral recovery from a single tank
volume/flowrate)
This does not give a full mass balance:

Water? Hydrophilic gangue?
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The gangue and entrainment mechanism
Primarily:
Gangue is entrained with the water, and
Hydrophobic valuable minerals are floated from the

pulp and recovered by the froth
This approach allows us to separate the mechanisms
Modelling flotation: How are particles recovered?

Flotation and Entrainment
Model for overall recovery of each solids class i
 kRf 
Recovery     Entrainmen t 
kRf  1
Floated particles Entrained particles
Primarily
gangue is
entrained and
hydrophobic
valuable
minerals are
floated
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Mass balance modelling of GANGUE recovery
Model for recovery of gangue (waste) minerals
 kRf 
Recovery     Entrained  particles 
kR f  1 
Froth phase: Water recovery and entrainment
Recovery of different sizes

of silica gangue as a
function of water recovery
This gives us a way of

modelling entrainment:
Gangue recovery is
proportional to water
recovery
Engelbrecht and Woodburn, 1975
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Modelling flotation:
Flotation and Entrainment
 kRf   QW ,C  
Recovery       Ent 

kRf  1  QW , F  
Entrainment
Model for overall recovery of each solid type
Froth phase entrained particle recovery
Experimental results show solids recovered via
entrainment is proportional to water recovery and
size (e .g. Engelbrecht and Woodburn, 1975)
So first we need a water model...
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Modelling flotation: Froth phase liquid recovery
Model for water overflow rate, based on froth

physics
Model includes cell dimensions, gas rate, overflowing bubble size,
air recovery and slurry rheology (Neethling et al.)
6.81Acell J g2 Note :   1
QW ,C  2
1    2
k1d bub,out For α>0.5 the equation changes
and the α terms drop out
g fl Acell – Cell area

k1 
3C PB m fl Jg – superficial gas velocity
dbub, out – bubble size overflowing
α - air recovery (fraction)
CPB ~ 50
Froth phase: Overflowing water rate into Concentrate, QW,C
AcolumnJ g2
QW ,C   (1   )
0.25
Simplification by Smith et al. Minerals Engineering 21 (2008) 973–
981
 kRf   QW ,C  
Recovery       Ent 

kR f  1   QW , F  
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Froth phase: Gangue entrainment factor (Neethling, 2008)
 v1settling
.5
h froth  Note :   1

Ent  exp 
2
 D J g (1   )  For α>0.5 the equation
  changes and the α

terms drop out
1 g (  s   )d p
2
hfroth is the total froth
vsettling  D  J 1g.5
3 18m depth (~10-30cm)
 kRf   QW ,C  
Recovery       Ent 

kRf  1  QW , F  
Froth phase: Water recovery and entrainment

Experimental relationship between the
entrainment factor and particle size
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Mass balance modelling of flotation recovery

Model for recovery for either valuable or gangue minerals
 kRf   QW ,C  
Recovery       Ent 

kRf  1  QW , F  
Pulp Froth
Floated and entrained particle recovery
 kRf   QW ,C  
Recovery       Ent 

kRf  1  QW , F  
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Floated and entrained particle recovery
 kRf   QW ,C  
Recovery       Ent 

kRf  1  QW , F  

Model for recovery of valuable mineral by flotation from a mixed tank, and
taking into account the role of the froth
This includes the Froth Recovery, Rf

Physically, it is the % of attached particles coming into the froth that make it
over the lip
 kRf 
Recovery   
kR f  1 
The froth recovery allows us to take into account the effect of froth
structure and bursting
Froth recovery generally quite low – 5% to 25%
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Model for recovery of valuable mineral by flotation from a mixed tank,

and taking into account the role of the froth
What affects the RATE CONSTANT k ?
 kRf 
kR f  1 
Must depend on particle properties eg size & hydrophobicity
Must also depend on operating conditions – air rate &
bubble size
How do we incorporate the air rate & bubble size?
• Increasing air rate gives more bubble surface area

• Smaller bubbles in pulp (d32) increases surface area
• Quantify through the total bubble surface area / cell area
BUBBLE SURFACE AREA FLUX, SB

6J g
SB 
d 32
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Pulp phase bubble-particle interactions
• Relationship
between
experimental rate
constants and SB
• e.g. Gorain et al., 1997
• Rate depends on SB,

but constant ratio
• Ratio of k and SB is
the mineral
floatability, P
• P is a particle
property
k  PS B

Model for recovery of valuable mineral by
flotation from a mixed tank, and taking into
account the role of the froth
What affects the RATE CONSTANT k

(or PSB) ?
  ( PS B ) R f 
 ( PS B ) R f  1 
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6J g
Modelling flotation: SB 
Pulp phase bubble size (d32) variation with Jg d 32
To increase SB and thus k and mineral recovery either:

Decrease d32 chemically (at constant Jg) or increase Jg (at almost constant
d32)
Frother (surfactant) addition reduces Experimental measurements of pulp

pulp bubble size (d32) (e.g. Nesset et al., 2008) bubble size (d32) and gas rate (Jg)
shows limited effect of Jg on d32 (e.g.
Nesset et al., 2006)
Froth phase floated particle recovery – THE FROTH
• How much coming into the froth overflows the tank?

• Include this as a modification to the rate constant, Rf
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This includes the Froth Recovery, Rf

Physically, it is the % of attached particles coming into the
froth that make it over the lip
 kRf 
kR f  1 
The froth recovery allows us to take into account the effect of
froth structure and bursting
Froth recovery generally quite low – 5% to 25%
Froth phase floated particle recovery
• Froth recovery defined as:
“the fraction of particles entering the froth attached to bubble
films which report to the concentrate”
• Model for froth recovery, Rf, based on froth physics (Neethling, 2008)
• Model includes the gas velocity, bubble size entering froth and leaving
froth over the lip, the fraction of bubbles which overflow and physical
particle data
• Can probably assume bubble size ratio constant (if unknown)
• f is fraction of particles which drop off bubble films when bubbles coalesce;
0.5 to1?
f f Note :   1
 J g  2  rbub, pulp  2
R f     
r     fl gd p2
 set 
v  bub, out  vset 
p
54m fl
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Air recovery (α) variation with Jg
• Air recovery shows a peak with Jg (e.g. Barbian et al., 2006)
• Air recovery curve sets range of Jg to examine (e.g. Neethling and Cilliers, 2008)
– At Jg where α ≤ 0 no froth is overflowing, therefore no solids or liquid are recovered
0.4
0.35
f f 0.3
 J g  2  rbub, pulp  0.25

R f     
  0.2
 vset   rbub, out  0.15
0.1
Increasing α and Jg will

0.05
0
increase Rf and mineral 0 0.5 1
Jg
1.5 2
recovery
α Jg*α Jg*a*(1-a) Jg*Jg*α*(1-α)

All terms have now been covered, both for floated and entrained material.
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Modelling flotation: Concentrate grade
• Recovery of each solids is modelled individually

• Modelled mass flow rate of all solids in concentrate is
summed to yield total solids rate in concentrate
• This can then be used to calculate the concentrate grade of each solids
class
i n
M CTOT   M F ,i * Recovery i
i 0
M C ,i
Concentrate grade i 
M CTOT
The Physics of the Froth

Films between bubbles
Plateau borders
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Froth motion from pulp to concentrate
Laplace equation
gives velocity
Boundary conditions:
1. Shape of tank and
launders
2. Air entering the froth that
overflows:
AIR RECOVERY (%)
Froth motion model

Froth flow:
Key parameter for the drainage modelling since other aspects
depend on it.
Can be represented in terms of a velocity potential:
and must satisfy Laplace's equation:
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Froth flow boundary conditions
Based on the air flowrate, the cell

geometry and the air recovery.
Froth phase
Solid walls:
Pulp-froth
interface:
Top of Pulp phase

the froth:
Overflow:
Froth flow velocity
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Froth Flow in Radial Equipment Designs
Liquid drainage model
Force balance on the Plateau borders (PB’s):
• Fundamentally based
• Gravity, capillarity and viscous dissipation.
• PB’s cross sectional area, A, and liquid velocity, u.
Highly non-linear and capillary boundary layer is present.
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Liquid drainage model
Continuity and EOS:

Liquid content, , and PB’s length per unit volume, .
BOUNDARY CONDITIONS
Liquid Velocity
At the solid walls and at the top of the froth: no-normal flow
Liquid Content
At the pulp/froth interface:
Liquid Motion and Content
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Solids Motion
1. Attached Solids
Particles attached to bubbles
move with the froth
Most particles are detached due
to coalescence (>95%)
2. Unattached Solids:
Particles move in the Plateau
borders
Follow the liquid, settle and
disperse
Overflow into concentrate
Mineral and Waste Particles

Example of motion in Plateau borders
Valuable Mineral
Gangue Minerals
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Mineral grade in froth
Froth Launder Design:

Effect of forcing froth to flow inwards or outwards
INTERNAL CHANNEL 1 CHANNEL 2

CHANNEL
Internal Launder Two Launders
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Foam structure and drainage
• Understanding froth through foams

• Complex structure and processes involved
• Accurate solution of liquid behaviour is required
FEM modelling of froths: Structured vs Unstructured

meshes
• Representation of the domain

• Distribution of grid points
• Isotropy
Structured Unstructured Unstructured

Provided stability and convergence criteria are met, the finer the
mesh, the closer the numerical solution will be to the exact solution.
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Unstructured anisotropic meshes
Anisotropy:
• Spacing between the points can vary to accommodate for
strong gradients of the field
• Particularly useful for boundary layers
Unstructured - Anisotropic
2D Case study: Parameters
Analytical solution for

1D liquid drainage
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2D Case study: Mesh types
Liquid content profiles for three different meshes

L=0.1m
Isotropic -coarse Isotropic-fine Anisotropic-adapted

(L/10) (L/160)
2D Case study: Liquid content profiles
Liquid content profiles for three different meshes

L=0.1m
Isotropic -coarse Isotropic-fine Anisotropic-adapted
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2D Case study: Liquid content variation
Analytical and numerical results for liquid

content through the foam for different meshes
2D Case study: Nodes and computational cost
The error is evaluated in the

L2 norm:
With adaptivity, it is only one

order of magnitude bigger
than with the fine mesh, at a
fraction of the cost!
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2D Case study: Nodes in the adaptive mesh
3D Case study: Wash water addition
Pulse of liquid and liquid addition at the top of the foam

0.1m
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3D Case study: Adaptive remeshing
3D Case study: Change in number of nodes
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3D Case study: Transient liquid content isosurfaces
FEM modelling of froths
Unstructured anisotropic adaptive meshes have been used to model

the drainage of liquid in foams, showing results similar to those
obtained on a fine uniformly sized mesh, and at higher
computational efficiency.
A transient 3D simulation of a pulse of liquid draining through a

foam, using adaptive remeshing, was carried out to showcase the
capabilities of the model.
Mesh adaptivity techniques can provide an adequate grid resolution

whilst significantly reducing the computational cost of performing
the simulations. This technique will be exploited to accurately model
liquid drainage in complex flotation cell simulations.
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Finite Element pairs
P0 P1 P1_DG P2 P2_DG
115
Drainage model verification
P0 P1 P1_DG P2 P2_DG
116
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Numerical model
Foam flow
Brito-Parada et al. , Chem. Eng. Sci., In Press
Numerical model
Foam flow
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Numerical model
Liquid drainage
•Gravity
•Capillarity
•Viscous dissipation
Brito-Parada et al. Miner. Eng, In Press
Numerical model
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Numerical model
Laboratory foam system
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2 3
overflows overflows
2 3
overflo overflo
ws ws
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Air recovery measurements
Air flowing
over lip
Air Air reporting to concentrate

=
Recovery Air flowrate to the tank
- Lip length
- Overflow height
Air in - Overflow velocity
Experimental - Air recovery

Air recovery (%)
3
overflows
2
overflows
Air rate (lpm)
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Experimental - Liquid recovery
Qw (lpm)
3
overflows
2
overflows
Air rate (lpm)
Numerical - Foam velocity

2 overflows 3 overflows
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Numerical – Stagnant zones

Numerical – Foam velocity isosurfaces

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Numerical – Liquid content
The fraction of liquid at every

point in a 3D foam is difficult to
measure during experiments
Impact of configuration on
distribution of liquid
2 overflows
Internal launder
Internal
launder
3 overflows
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Internal launder
Internal
launder
3 overflows
Internal launder
Air recovery (%)
Qw (lpm)
Air rate (lpm) Air rate (lpm)
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Internal launder
Conclusions
A lab scale flotation system that mimics a flotation froth can be used to
test the effect of different cell configurations.
The configurations have an impact on operating parameters. Stagnant

zones, in particular, have been found to play an important role.
Our model is capable of reproducing experimental results, and can

also provide information otherwise not available from experiments.
Liquid fraction and velocity profiles through the foam can now be
investigated, using 3D simulations to evaluate flotation cells and
increase the understanding of the effect of changes in design.
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Modelado de flotación –
la importancia de la fase espuma
Dr Pablo Brito Parada
Froth and Foam Research Group
Royal School of Mines,
Department of Earth Science & Engineering,
Imperial College London
137
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11/10/2013

Separation by froth flotation

Flotation: Why it works

Chemically and physically

Flotation processes: Pulp phase

Flotation: what does the air do?

• Bubbles form at impeller

Physical Aspects: Collection of particles

What are the sub-processes occurring in the pulp phase?

All of these processes are affected by particle and bubble

How do we float a desired mineral particle?

The desired particle must be:

The gangue must be hydrophilic

Physical Aspects: Particle Properties

Physical Aspects: Particle Properties

Flotation is most effective for particles between 10 and 100 mm

International Journal of Mineral Processing

Physical Aspects: Particle Properties

Valuable minerals must be hydrophobic

Hydrophobic surface Hydrophilic surface

Physical Aspects: Particle Properties

Hydrophobicity is commonly determined using

Physical Aspects: Bubble Properties

Bubbles are either generated by shear inside a tank or by

Physical Aspects: Bubble Properties

Typical bubble size is around 0.5 to 1 mm

• The bubbles must be small enough to provide

Physical Aspects: Bubble Properties

If 2 bubbles of radius 0.5 mm coalesce, the resulting bubble will

Bubble radius: Bubble radius: 3.0 mm

Physical Aspects: Bubble Properties

Physical Aspects: Bubble Properties

Parameter Symbol Definition Unit Typical

Physical Aspects: Bubble Properties

Pulp bubble size is dependent on:

Nesset et al 2006 Grau & Heiskanen,

Physical Aspects: Collection of particles

What are the sub-processes occurring in the pulp phase?

All of these processes are affected by particle and bubble properties

Physical Aspects: Collection of particles

The probability that a particle is collected by an air bubble in the

Pulp phase: Bubble-particle collision

• Differences in surface properties make some minerals

Physical Aspects: Probability of Collision

Firouzi et al, 2011

Physical Aspects: Attachment of particles

The probability that a particle is collected by an air bubble in the

Pulp phase: Bubble-particle interactions

• Differences in surface properties make some minerals

Physical Aspects: Probability of Attachment

Verrelli et al (2011), Chem Eng Sci 66(23)

Physical Aspects: Probability of Attachment

The distribution of liberation classes of copper sulfide minerals in 106 × 53 μm fractions of

Albijanic et al, 2012

Physical Aspects: Probability of Detachment

Goel and Jameson (2012), Min Eng 36-38 324-

Physical Aspects: Pulp phase turbulence