Froth Pump Power Estimation According Weir [1]

Froth pumping: Warman Pump Selection

Mineral froth head and efficiency corrections

Example data
Index P: pulp without froth

Pulp flow rate

Qp = 454 m³/h
Pulp head
Hp = 18.3 m
Pulp specific gravity
SP = 1.15 -
Percentage air
PA = 20%
Pump static head
Hstat = 9.14 m

Qp: Pulp flow rate, also design flow, also

compressed flow, or De-aereated flow
QF: Froth flow rate, also uncompressed or
aereated flow

Froth volume factor

Froth volume factor FVF = 1 / ( 1 - PA)
FVF = 1 / ( 1 - PA) PA = 20%
FVF = 1.25
Froth flow rate
Qf = FVF * Qp Volume flow rate with froth
Qf = FVF * Qp
Specifiv gravity with froth FVF = 1.25 -
SF = SP/FVF Qp= 454 m³/h
Qf = 568 m³/h
System curve
Hp = Hstat + C*Qp^2 Specifiv gravity with froth Eq. (8)
SF = SP / FVF
Constant of system curve "C" SP = 1.15
C= (Hp - Hstat ) / Qp^2 FVF = 1.25
 SF = 0.92 -
Head correction factor
HRf = Hf / Hw Constant of system curve "C"
Hp = Hstat + C*Qp^2
Efficiency correction factor C= (Hp - Hstat ) / Qp^2
ERf = Ef / Ew Hp = 18.3 m
Hstat = 9.14 m
Pump power Qp = 454 m³/h
P= Qf * Sf* Hf / (367 * Ef) C= 4.43E-05

Selected pump

Water head
Hw = 79 ft
Hw 23.7 m

Pulp head
with froth
Hf = 75 ft
Hf = 23.4 m

Pup design head

(without froth)
Hp = 60 ft
Hp = 18.3 m
Efficiency on water
Ew = 0.68
and pump speed
Staic head
N = 640 rpm
Hstat = 30 ft
Hstat = 9.14 m

Pulp design flow (without froth)

Qp = 2000 gpm Pulp with froth
Qp = 454 m³/h Qp = 2500 gpm
Qp 568 m³/h

Head of equivalent water Hw Correction factor for the head

Head on pulp
Pump curves have its pressure HR =
expressed in water column ( Hw ). Head on water
Head of equivalent water Hw Correction factor for the head
Head on pulp
Pump curves have its pressure HR =
expressed in water column ( Hw ). Head on water
Thus, to select a pump the head Hp
HR =
needs to be expressed in water Hw
equivalent meters . and
Warman gives following relation
for the water equivalent head a s a
Hp=Hw⋅HR (3 )
function of the pulp head Hp
expressed in meters of pulp Correction factor for the
column (mpc ), and usig a head efficiency
correction factor HR: Efficiency on pulp
Hp ER =
H w= Efficiency on water
HR
Ep
The head correction factor is given ER =
in Figure 2-3, where Ew
HR =f (S p ,Cw , d50) and
S p :Specific gravity of pulp also Ep=Ew⋅ER (4)
designed with index s (slurry )
Microsoft Equation
Microsoft Editor de 3.0
ecuaciones 3.0

Specific gravity of mP 1
pulp with froth ρ F= ⋅
V p FVF
ρ 1
S i= i ρ F=ρ p⋅
ρw FVF
ρF ρp
S F= ρ F=
ρw FVF
ρF
mP S F=
ρ p= ρw
VP ρp
m P +mair FVF
ρ F= S F=
VF ρw
m air ≈0 1
ρ p FVF
m +0 S F=
ρ F= P ρw 1
VF
ρp 1
m S F=
ρ F= P ρ w FVF
VF 1
S F=S p
V F=V p⋅FVF FVF
S
m air ≈0 1
ρ p FVF
m +0 S F=
ρ F= P ρw 1
VF
ρp 1
mP S F=
ρ F= ρ w FVF
VF 1
S F=S p
V F=V p⋅FVF FVF
m Sp
ρ F= P Microsoft Equation S F= Eq .( 8)
3.0 FVF Microsoft Equation

V p⋅FVF 3.0
Froht head for Q = Qf Correction factors
Hf = Hstat + C*Qf^2
Hstat = 9.14 m For the Froth Volume Factor
C= 4.43E-05 FVF = 1.25
Qf = 568 m³/h The Mineral froth corrections for
Hf = 23.4 m.p.c. head (HRF) and efficiency (ERF) are:

Mineral froth corrections HRf = 0.95

ERf = 0.95
Weir froth diagrams

Required water head

Hw = Hf/HRf
Hf = 23.43
HRf = 0.95
 Hw = 24.7

Required water head Pump power

Hw = 24.7 m.w.c. P= Qf * Sf* Hf / (367 * Ef)
Qf = 567.8 m3/h
Required froth head Sf = 0.92 -
Hf = 23.43 m.p.c. Hf = 23.4 m.p.c.
Ef = 0.646 -
Static head P= 51.6 kW
Hstat = 9.14 m.p.c. P= 69.15 hp

From the figure Security factor on power

Efficiency on water Let
Ew = 0.68 SFP = 1.2
Pump speed considering fluctuations in duty due to
N= 640 rpm variations in air content.

Pump efficiency on froth Thus, the power requirement will be

The pump efficiency on froth is Preq = SFP * P
Ef = ERf * Ew SFP = 1.2
ERf = 0.95 P= 51.6 kW
Ew = 0.68 Preq = 61.9 kW
Ef = 0.646
The next comercial size [3]
Pmotor = 75 kW

Pump power
Replacing equation ( 4a) into
From equation
Ql ⋅S p⋅TDH m. p .c.
Ql ⋅S p⋅Hw m . w. c .⋅HR
s
PkW =
s
(1) PkW = (5)
1 . 02⋅η
Pump power
Replacing equation ( 4a) into
From equation
Ql ⋅S p⋅TDH m. p .c.
Ql ⋅S p⋅Hw m . w. c .⋅HR
s
PkW =
s
(1) PkW = (5)
1 .02⋅η % 1 . 02⋅η %
Applying the correction factor HR one gets
to the pulp TDH ( TDH=Hp) Ql ⋅S p⋅Hw m . w. c .⋅HR
TDH m. p . c .=Hwm .w . c .⋅HR (3a) PkW = s
(6 )
1 . 02⋅η w _%⋅ER
Replacing equation (3a) into Considering that
equation (1 ) one gets HR=ER
Ql ⋅S p⋅Hw m. w. c .⋅HR Ql ⋅S p⋅Hw m . w. c .
s
PkW = (5) PkW =
s
(7 )
1 .02⋅η % 1 . 02⋅η w _%
Similarly, the efficiency on
pulp Ep will be less than When selecting the motor, the
efficiency on water Ew, efficiency of the transmition
according equation must be considered
Ep=Ew⋅ER (4) η=η w:%⋅η transm
or
η% =ηw _%⋅ER (4a) Microsoft Editor de
ecuaciones 3.0

Specific gravity of pulp with froth

Sp
S F= Eq .( 8)
FVF
 Rev. cjc. 15.06.2016
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ume Factor
-
corrections for
efficiency (ERF) are:

m.p.c
 m.w.c.

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(5)
o

(5)

(6 )

7)

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ecuaciones 3.0

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Pump power Q m ³⋅TDH Pa
s
Ql ⋅S p⋅TDH m . p .
PW = g s
η[ − ] PkW =
Q m ³⋅TDH Pa Q m ³⋅g⋅TDH mm. w . c . 1000 η[ −]
s
s
PW =
η[ − ] g 1
P= =
1000 102
η[ − ] Q m ³⋅g⋅1000⋅TDH m . w .c .

3 3
PW =
s
η[ − ]
Ql ⋅S p⋅TDH m . p . c .
m m N s
⋅Pa= ⋅ PkW =
s s m² Q m ³⋅g⋅1000⋅S p⋅TDH m . p .c . 102⋅η[ − ]
m3
s
N⋅m PW =
η[ − ] Ql ⋅S p⋅TDH m . p . c .
⋅Pa=
s s Q m ³⋅g⋅1000⋅S p⋅TDH m . p .c .
PkW = s
1
m3 J PkW =
s
1000 η[− ]
102⋅η[ − ]
⋅Pa= Q m ³⋅g⋅S p⋅TDH m . p. c . Ql ⋅S p⋅TDH m . p . c .
s s s
PkW = s
m3 η[ − ] PkW =
η
⋅Pa=W
s
1
1000 ls
Q ⋅g⋅S p⋅TDH m . p . c . 102⋅ %
PkW =
100
Q m ³⋅TDH Pa η[ − ] Ql ⋅S p⋅TDH m . p . c .
s Ql ⋅S p⋅TDH m . p . c .
PW = g s PkW =
s
η[ − ] PkW =
1000 η[− ] 1 . 02⋅η %

Microsoft Editor de Microsoft Editor de

ecuaciones 3.0
ecuaciones 3.0

Head of equivalent water Hw

Correction factor for the head
Pump curves have its pressure Head on pulp
expressed in water column ( Hw). HR =
Head on water
Thus, to select a pump the head
Hp
needs to be expressed in water HR =
equivalent meters . Hw
Warman gives following relation and
for the water equivalent head a s a Hp=Hw⋅HR (3 )
function of the pulp head Hp
expressed in meters of pulp
column (mpc ), and usig a head Correction factor for the
correction factor HR: efficiency
Hp Efficiency on pulp
H w= ER =
HR Efficiency on water
The head correction factor is given Ep
function of the pulp head Hp
expressed in meters of pulp
column (mpc ), and usig a head Correction factor for the
correction factor HR: efficiency
Hp Efficiency on pulp
H w= ER =
HR Efficiency on water
The head correction factor is given Ep
in Figure 2-3, where ER =
Ew
HR =f (S p ,Cw , d50)
and
S p :Specific gravity of pulp also Microsoft Equation

Ep=Ew⋅ER (4) 3.0

designed with index s (slurry ) Microsoft Editor de

ecuaciones 3.0
 Rev. cjc. 14.06.2016

Ql ⋅S p⋅TDH m . p . c . Ql ⋅S p⋅TDH m . p . c .
s s
Q l⋅S p⋅TDH m . p. c .
PkW = (1 ) s
000 η[ − ] 1 . 02⋅η % PkW = (1 )
1 . 02⋅η%
1 1000⋅Qm ³ ⋅S p⋅TDH m . p. c .
102 PkW =
s
1 . 02⋅η % Q m ³⋅S p⋅TDH m . p .c .
l ⋅S p⋅TDH m . p . c . h
s 1000 PkW = (2)
⋅Q ⋅S ⋅TDH m . p .c . 3 . 67⋅η %
02⋅η[ − ] 3600 mh ³ p
PkW =
l ⋅S p⋅TDH m . p . c . 1 . 02⋅η %
s
Q m ³⋅S p⋅TDH m . p . c .
02⋅η[ − ] h
PkW =
l ⋅S p⋅TDH m . p . c . 3600
⋅1 . 02⋅η%
s 1000
η 3600
02⋅ % ⋅1 . 02=3 . 67
100 1000
l ⋅S p⋅TDH m . p . c . Q m ³⋅S p⋅TDH m . p . c .
s h
(1 ) PkW = (2)
. 02⋅η % 3 . 67⋅η%

Microsoft Editor de Microsoft Editor de

ecuaciones 3.0 ecuaciones 3.0

Pump power Replacing equation ( 4a ) into

From equation Ql ⋅S p⋅Hw m . w. c .⋅HR
Ql ⋅S p⋅TDH m . p . c. s
s PkW = (5)
PkW = (1) 1 . 02⋅η %
1 . 02⋅η %
Applying the correction factor HR one gets
to the pulp TDH ( TDH=Hp) Ql ⋅S p⋅Hw m . w. c .⋅HR
TDH m . p . c.=Hwm .w . c.⋅HR s
(3a ) PkW = (6 )
1 . 02⋅η w _%⋅ER
Replacing equation (3a ) into Considering that
equation (1) one gets HR=ER
Ql ⋅S p⋅Hw m. w.c .⋅HR Ql ⋅S p⋅Hw m . w. c .
s s
PkW = (5) PkW = (7 )
1 . 02⋅η % 1 . 02⋅η w _%

Similarly, the efficiency on

When selecting the motor, the
 Replacing equation (3a ) into Considering that
equation (1) one gets HR=ER
Ql ⋅S p⋅Hw m. w.c .⋅HR Ql ⋅S p⋅Hw m . w. c .
s s
PkW = (5) PkW = (7 )
1 . 02⋅η % 1 . 02⋅η w _%

Similarly, the efficiency on

When selecting the motor, the
pulp Ep will be less than
efficiency on water Ew,
efficiency of the transmition
according equation must be considered
Microsoft Equation Ep=Ew⋅ER ( 4) η=η w:%⋅η transm
3.0

or
Microsoft Editor de
η% =ηw _%⋅ER (4a) ecuaciones 3.0 Microsoft Editor de
ecuaciones 3.0

7
 Rev. cjc. 14.06.2016
Page 1 of 2

H m . p. c .
(1 )
%

H m . p .c .
(2)
η%

Page 2 of 2
 http://calgarypumpsymposium.ca/archives/Presentations/2007/Froth-Presentation.pdf
[1] http://www.calgarypumpsymposium.ca/Froth-Presentation.pdf

[2] Warman Technical Bulletin No 28, version 2

http://www.weirminerals.com/pdf/Technical%20Bulletin%2028v.2%20-%20082109.pdf

[3] Standard motors

http://oee.nrcan.gc.ca/regulations/products/14297
 Microsoft Editor de
ecuaciones 3.0

082109.pdf
Microsoft Editor de
ecuaciones 3.0
Qp: Pulp flow rate, also design flow, also compressed
flow, also De-aereated flow
QF: Froth flow rate, also uncompressed or aereated flow

Qf = FVF * QS
 1 gpm = 0.227125 m³/h

Design flow (de-aireated)

Qp = 2000 gpm
Qp = 454 m³/h

Design head
H= 60 ft
H= 18.3 m

Pulp specific gravity (de-aireated)

Sp = 1.15 -

Oercentage air
PA = 0.2 -

Static head
Hsdtat = 9.14 m
Static head
Hstat = 30 ft
Weir technical bulletin Nº 28. Ver. 3
http://www.weirminerals.com/pdf/Technical%20Bulletin%2028v.2%20-%20082109.pdf
082109.pdf
Kevin Burges
Warman Pump Thechnology Centre
Artarmon
Australia

2.- HRf & ERf also include effects of fine solids (Wath about heterogeneous flows?)
REf. 2

Warman horizontal froth pump selection procedure

1.- Determine type of froth

Brittle 1.1 <0 FVF <= 1.25
Tenaciuos 1.5 <0 FVF <= 1.8
Medium 1.25 <0 FVF <= 1.5

2.- Qs = De-aereated slurry flow (L/s)

Use maximum reated design flow
Check for maximum duty slurry flow

3.- Qf = Aereated froth flow

Qf = FVF * Qs (L/s)

4.- Calculated froth system head Hf (m)

at aereated flow (Qf) for concentration of
solids in slurry, disregarding froth.
Keep dischatge pipe dismeters large

5.- Hw = Hf/HRf

6.- Select froth pump with duty point is

to the left of BEP. Q >= 25% QBEP
NPSHreq >= 3.5 m

7.- At the duty point, select the pump

speed Nf /rpm) and the water efficiency
Ew (%). Ef = Ew * ERf

8.- Slurry density Sf = Sm / FVF

9.- Calculate froth power

Pf (kW) = Qf * Hf * Sf * 0.98 / EF

10.- Check power

11.- Select motor size with 20% margin

Vertical pump type

Use mainly for brittle type frothd eg copper

Use 2.0 <= FVF <= 2.5

Select a duty flowrate 30% to 85% of maximum

flow shown on vertical froth pump curve

Use HR = ER = 0.9 (Conical hooper)

Select head and spedd as for horizontal froth pump

Ensure a good vortex in the hopper

http://oee.nrcan.gc.ca/regulations/products/14297

Corresponds to Table 2 in the CAN/CSA C390-1

Energy Efficiency Standard (Percentage)
Item Power (HP) Power (kW) Open
2 Pole 4 Pole 6 Pole 8 Pole
1 1 0.75 75.5 82.5 80 74
2 1.5 1.1 82.5 84 84 75.5
3 2 1.5 84 84 85.5 85.5
4 3 2.2 84 86.5 86.5 86.5
5 4 3 84 86.5 86.5 86.5
6 5 3.7 85.5 87.5 87.5 87.5
7 5.5 4 85.5 87.5 87.5 87.5
8 7.5 5.5 87.5 88.5 88.5 88.5
9 10 7.5 88.5 89.5 90.2 89.5
10 15 11 89.5 91 90.2 89.5
11 20 15 90.2 91 91 90.2
12 25 19 91 91.7 91.7 90.2
13 30 22 91 92.4 92.4 91
14 40 30 91.7 93 93 91
15 50 37 92.4 93 93 91.7
16 60 45 93 93.6 93.6 92.4
17 75 55 93 94.1 93.6 93.6
18 100 75 93 94.1 94.1 93.6
19 125 90 93.6 94.5 94.1 93.6
20 150 110 93.6 95 94.5 93.6
21 175 132 94.5 95 94.5 93.6
22 200 150 94.5 95 94.5 93.6
23 250 185 94.5 95.4 95.4 94.5
24 300 225 95 95.4 95.4  -
25 350 260 95 95.4 95.4  -
26 400 300 95.4 95.4  -  -
27 450 335 95.8 95.8  -  -
28 500 375 95.8 95.8  -  -
AN/CSA C390-1
fficiency Standard (Percentage)
Enclosed
2 Pole 4 Pole 6 Pole 8 Pole
75.5 82.5 80 74
82.5 84 85.5 77
84 84 86.5 82.5
85.5 87.5 87.5 84
85.5 87.5 87.5 84
87.5 87.5 87.5 85.5
87.5 87.5 87.5 85.5
88.5 89.5 89.5 85.5
89.5 89.5 89.5 88.5
90.2 91 90.2 88.5
90.2 91 90.2 89.5
91 92.4 91.7 89.5
91 92.4 91.7 91
91.7 93 93 91
92.4 93 93 91.7
93 93.6 93.6 91.7
93 94.1 93.6 93
93.6 94.5 94.1 93
94.5 94.5 94.1 93.6
94.5 95 95 93.6
95 95 95 94.1
95 95 95 94.1
95.4 95 95 94.5
95.4 95.4 95  -
95.4 95.4 95  -
95.4 95.4  -  -
95.4 95.4  -  -
95.4 95.8  -  -