Advanced use of column flotation models for process optimization

Villeneuve, J., Durance, M.-V., Guillaneau, J.-C.,

BRGM - Process Simulation Group
Avenue Claude Guillemin, BP 6009
45060 Orléans CEDEX 2 - FRANCE

Da Silva, R.V.G., Birro, E.

MBR
Avenida de Ligaçáo, 3580
CEP 34000-000 - Nova Lima - MG - BRAZIL

Martins, M.A.S.,
CEMI
Av. José Candido da Silveira, 311 cj. 303
Belo Horizonte - MG- BRAZIL
ABSTRACT

A steady-state model of column flotation has been developed based on a combination of the kinetic and
hydrodynamic approaches. It has been developed within the frame of a European Union project: Improvement
and extension of the use of Flotation columns - Flowsheet optimization (IMPEXFLOTCOL).

The model considers three zones in the column:

• the collection zone where collection is expressed by a first order kinetic equation; the recovery is calculated
considering the transport of particles by axial dispersion; the gas carrying capacity may also be taken into
account,
• the intermediate zone represented by a global recovery at the interface,
• the froth zone where the recovery calculation is based on kinetics of particle detachment caused by the
washing water and the bubble coalescence. A specific sampling system has been developed to measure
this type of variables.

This model has two levels of utilization. At the industrial level, it can be used to simulate different
configurations and optimize a complete process. At the pilot plant level, it can be used to optimize the operating
parameters. The model has been included in the USIM PAC simulator and gets all the advantages of the
flexibility in the definition of the phase model.

This paper presents briefly the theory and a validation with industrial data.
 INTRODUCTION

Column flotation has been widely studied during the last 15 years. Its original aspects compared to
conventional flotation cells are the addition of washing water at the top of the froth, the absence of mechanical
agitation and consequently the presence of a specially designed system for bubble generation. These
characteristics make the flotation process occurring inside the vertical tube a "soft" mechanism where the
phenomenon relies more on the intrinsic properties of the bubbles-solution-particles system than on a forced
"energy-supply" dependent mechanism.
This property of a freely-occurring process is certainly one of the reasons why the column flotation had to be
well controlled before its effective and successful use in production. It is also a reason why numerous
researches were aimed at setting up reliable design procedures. These researches have produced a number of
mathematical models based on the fundamental understanding of phenomena and the empirical expertise of
plant operators and manufacturers. A review of most of these models is given by Tujeda (Tujeda, 1994).
One of the main limit in the practical application of these models is that it is often necessary to refer to the
model-builder expertise to get some practical results for sizing or optimizing column flotation circuits. The
main scope of the application presented here has been to produce an operational model for design and steady-
state optimization usable with the data currently available at pilot or industrial scale. This model has been
included in the USIM PAC 2.1 software and its "operationability" is discussed through an example of
application.

THEORETICAL BACKGROUND

The column is considered to be made of three zones: the collection zone between the air injection point and
the feed point, the intermediate zone between the feed point and the interface, and the froth zone between the
interface and the top (Figure 1).

In each zone, a recovery per mineral and per size class is calculated. The total recovery (Rtot) per mineral is
then computed for the three reactors in series according to the general formula:

R1. R2. R3
Rtot =
1 − R1. (1 − R2) − R1. R2.. (1 − R3)
(1)
where:
R1 : recovery in the collection zone,
R2 : recovery in the intermediate zone,
R3 : recovery in the froth.
 water concentrate

froth First order kinetics of detachment

R3 Plug flow

interface Recovery at interface

R2
feed
First order kinetics of flotation

Axial dispersion
collection
R1 Maximum carrying capacity

air tailings

Figure 1. The three zones of the column and the corresponding phenomena.

Collection zone.

In the collection zone, the flotation is a first order kinetic phenomenon with limitation of the recovery per
component when gas carrying capacity is exceeded.
The transport is represented by the axial dispersion model, which gives, after integration combined with a first
order transfer phenomenon:
 1 
4.a.exp 
 2. Np 
R1 =
 a   −a 
(1 + a) 2 .exp  − (1 − a) .exp
2

 2. Np   2. Np  (2a)

with:
a = 1 + 4. k.Tp. Np (2b)
where:
k : kinetic constant per mineral and size class (1/s),
Tp : residence time per mineral and size class (s),
Np : vessel dispersion number.

• The particles residence time is calculated according to:

 ul 
Tp = Tl.   (3)
 ul + usp 
where:
Tp : particle residence time (s),
Tl : liquid residence time in the collection zone (s),
ul : liquid superficial velocity in the collection zone (m/s),
usp : particle terminal settling velocity relative to the liquid (m/s).

 Hc. (1 − εg) 
Tl =   (4)
 ul 
where:
 Hc : height of the collection zone (m),
εg : gas fractional holdup in the collection zone (given by the user).

ul = ufl + ubias (5)

where:
ufl : superficial velocity of feed liquid (m/s),
ubias : bias superficial velocity (m/s) (given by the user).

The calculation of terminal particle settling velocity in the liquid is iterative:

g.dp 2 . (ρs − ρl). (1 − Φs) dp. usp. ρs. (1 − Φs)
2.7
usp = ↔ Rep =
(
18. µl. 1 + 0.15. Rep 0.687
) µl (6)

where:
g : acceleration due to gravity (m/s2),
µl : liquid viscosity (kg/m.s),
ρl : liquid density (kg/m3),
ρs : solid density (kg/m3),
Φs : volume fraction of solids in the slurry,
dp : particle diameter (m),
Rep : particle Reynolds number.

• The kinetic constant is defined according to:

3 ug
ki, j = . . Pi, j (7a)
2 db

2 AK   dpi  
1.5
 dp  
Pi , j = α j  i  ⋅  1 −   (7b)
 db   d max j  
 
where:
i : index of size class,
j : index of mineral,
ki,j : flotation rate constant (1/s),
Pi,j : probability of flotation,
ug : gas superficial velocity (m/s),
db : diameter of bubbles (m),
dpi : particle diameter (m),
dmaxj : maximum size of floating particles (m),
αj : adjustment constant.
AK : adjustment for the effect of particle size.

The diameter of bubbles may be specified by the user. If this parameter is not known, the following equations
relating the gas holdup and the gas flowrate are used:

db =
(
18. µl. usb. 1 + 0.15. Reb 0.687 ) ↔ Reb = db. usb. ρl.(1 − εg)
(8)
g. (ρl − ρg). (1 − εg) µl
m-1

ug ul
usb = + (9)
εg 1 − εg
 where:
db : bubbles diameter (cm),
µl : liquid viscosity (g/cm.s),
ρl : liquid density (g/cm3),
ρg : gas density (g/cm3),
g : acceleration due to gravity (cm/s2),
εg : fractional gas holdup,
m : usually equal to 3, (Ref.),
usb : slip velocity between liquid and bubbles (cm/s),
ug : superficial gas velocity (cm/s),
ul : superficial liquid velocity (cm/s).

• The vessel dispersion number is:

a  Dc 
0.63
 ug. (1 − εg) 
Np = .  .  (10)
0.6  Hc   ul 
where:
a : adjustment parameter,
Dc : column diameter (m).

Each mineralogical component is divided into floating and non-floating sub-populations. The floating sub-
population represents the maximum proportion of each mineral which may be recovered.
The recovery R1 is then only applied to the floating sub-population. This allows to take into account a
proportion of unliberated particles which will not be collected (Villeneuve, 1995).

Intermediate zone.

A recovery R2 per component may be specified to account for the effect of the interface. It has been introduced
as another limitation of the flotation due to poorly liberated particles: the particles which are very weakly
attached to the bubbles are not carried into the froth when the bubbles collide the surface of the froth.
This phenomenon is not of clear evidence and its effects may only be measured with an appropriate device,
but some authors (Yianatos, 1988) agree on the fact that "something" happens at the interface and causes
locally a loss of flotation efficiency.

Froth zone.

In the froth zone the main phenomenon considered is detachment. From the work of Yianatos, a first order
kinetics of detachment combined with a plug flow behavior of bubbles gives the recovery.
R3 = exp( − kd.Tz) (12)
where:
kd : detachment rate constant (1/s)
Tz : residence time of bubbles in the froth (s).

The residence time Tz is calculated according to:

zf

∫ εg(z).dz
Tz = 0 (13)
ug
where:
εg(z) : fractional gas holdup at level z.
The value of the fractional holdup at the interface (level 0) is given by the user. A normal value of 55 to 60 %
corresponds to a packed bed of spheres. The fractional holdup is supposed to vary according to a parabolic
profile until it reaches the value at the concentrate lip (level zf).
The fractional gas holdup is calculated knowing the superficial velocity of water in the concentrate and its
water content:
ug
eg(zf) =
ulc
ug + (14)
pw
where:
ulc : superficial velocity of water in the concentrate (m/s),
pw : percent water in the concentrate.

The superficial velocity of water in the concentrate is obtained by:

ulc = uw − ubias (15)
where:
uw : superficial velocity of wash water (m/s).

USE OF THE MODEL

Industrial example: flowsheet optimization.

The control of the operation of a plant is often made trough control sheets where the essential information
concern factors related to mechanical constraints, breakdowns prevention, reagents and energy consumption.
The aim of this example is to show that the control of metallurgical performance may be made with very few
data from sampling using simulation.

Brief description of the process.

The installation of the ore treatment of MBR - Pico project has a capacity of 8,400,000 tons of ROM (dry
base) per year. It produces four iron ore specific products: lump ore, hematitinha, sinter feed and pellet feed
fines. These products differ from each other on chemical characteristics and size:
• the product lump ore (LO) is a coarse product meant for direct reduction.
• the hematitinha has characteristics close to lump ore, having narrower range of size (- 1/2 inch + 1/4 inch)
and is sold on the Brazilian internal market for direct reduction.
• the product sinter feed is located approximately below 1/4 inch and above 100 mesh Tyler, and is meant
for sintering.
• the product pellet feed fines is within the range -100 mesh Tyler and + 20 µm approximately.
This last product is obtained through classification/mud removal by cycloning and concentrated in a flotation
circuit in columns in two stages. The other products are obtained through crushing and classification in
vibrating screen and spiral classifiers.
The ROM is carried on trucks and feeds a circuit of primary crushing. The crushed ore is carried on a belt
conveyor and composes an intermediate conic pile with capacity for 180,000 tons, whose function is to
regularize the plant feedrate.
The ore is retaken into the intermediate pile, and follows to primary and secondary screening stages, from
where products L.O. and hematitinha are withdrawn.
The screen undersize is sent to a classification circuit in spiral classifiers, where the underflow is collected as
a sinter feed product and the overflow (<100 mesh) goes to the concentration circuit.
The overflow of the spiral classifier is fed in a mud removal circuit by hydrocyclones in two stages (15 inch
and 6 inch). The cycloning overflow composes the mud scrap. The underflow feeds a thickener 21 m in
diameter where the pulp is thickened until it reaches the ideal solid concentration for flotation.
The flotation circuit is composed of two stages: rougher and cleaner. The rougher scrap is discarded as a final
scrap of flotation. The concentrate cleaner is the final concentrate.
MBR-Pico's flotation operates as a reverse process, the silica which contaminates the ore being floated and
the sunk hematite is mainly the useful material.
The flotation concentrate feeds a filtering circuit, the filter cake being carried and piled up, composing the
product pellet feed fines. The efficiency of silica removal is a key factor for the quality of this product.

Data analysis.
The flotation circuit is represented in figure 2.

MBR - PICO mines Flotation circuit

Washing Water

Tailings 7 6
3 5

1
Feed
1 2 2
4
Concentrate
Figure 2. Two stages flotation for silica removal.

Three sampling campaigns have been made to get the chemical analysis per size of all the streams of this
circuit. The feed flowrate (stream 1) is well known but the other flowrates are only rough estimates.

The first operation to valorize the measurements is to determine a reliable material balance for each campaign.
This has been done in two steps: firstly, the approximate flowrates of all the streams have been calculated
using the "split curve concept", and secondly, the entire sets of data have been made coherent using the
"statistically coherent material balance" algorithm included in USIM PAC.

The split curve is an engineering tool based on the conservation of total and partial flowrates. In our example,
we have the following relations:
Q3
X4 - X1 = (X1- X3)
Q4
Q5
X4 - X2 = (X2 - X5)
Q4 (16)
where:
Qi : flowrate of stream i.
Xi : grade per size in stream i.

The plot in figure 3 allows to have an idea of the ratio Q3/Q4 (slope of the linear regression), and knowing
Q1, to have the values of these flowrates.
The plot in figure 4 allows to have an idea of the ratio Q5/Q4, and knowing Q4, to have the values of the
flowrates in streams 2 and 5.
It should be noted that the dispersion of the measured fractions and grades gives an idea of the incoherence of
the data. All the data should normally be on the straight line. The incoherence is caused by sampling errors,
sieving and analysis errors, non stationarity of the circuit. It may be reduced, but always exists when getting
data from an industrial operation.
 Split curve Split curve
10 10

5 5
Second output (%)

Second output (%)

0 0

-5 -5
21.11 (Input: 1, First output: 3, Second output: 4) Split of components and size fractions 21.11 (Input: 2, First output: 5, Second output: 4) Split in the second column
Linear regression Linear regression

-10 -10
-10 -5 0 5 10 -10 -5 0 5 10
First output (%) First output (%)

Figure 3. Split curve of the circuit. Figure 4. Split curve of the cleaning column.

Once the flowrates have been estimated as described above, a complete material balance is available.
Unfortunately, the data are still incoherent.
The reconciliation of the data is performed by a specific algorithm. Its principles have been explained by
numerous researchers (Hodouin, 1984; Fletcher, 1987). It provides estimates of the initial values, as close as
possible to these initial values, which are coherent, that is, which guaranty the material conservation in each
column. The measured grade per size data will be used in conjunction with the flowrate estimates obtained
with the split curves, and these estimations will be greatly improved.

Adjustment of the models.

One of the basic hypothesis of the models for steady state simulation is that all partial flowrates of minerals
per size class are conserved. So even if the estimates are not the "true" values, they are inside the tolerance
limits given by the degree of incoherence of the initial data, and will be used to adjust the flotation column
models.
There are not enough data here to consider the three zones of the column. The calibration of the models will
be aimed at providing a description of the selectivity of the separation resulting from differential collection
rates of the minerals.

The experimental separation is shown on the partition curves of figures 5 and 6.

It is interesting to note the "bell shaped" partition in the rougher column which tend to show that the definition
of the influence of size in the collection probability (equation 7b) is well adapted. It appears on the curves that
the maximum size of floating particles (dmax) is approximately 350 µm. The "level" of the separation will
depend on the parameter α and the shape of the bell on the parameter AK.
 Partition curve Partition curve
100 100
21.11 Rougher/Hematite 21.11 Cleaner/Hematite
21.11 Rougher/Silica 21.11 Cleaner/Silica
21.11 Rougher/Gangue 21.11 Cleaner/Gangue
80 80

60 60
(%)

(%)
40 40

20 20

1 10 100 1000 1 10 100 1000

Particle size (µm) Particle size (µm)

Figure 5. Data of the 21st: Partition of size classes per mineral in rougher and cleaner.

Partition curve Partition curve

100
31.10 Rougher/Hematite
31.10 Rougher/Silica
31.10 Rougher/Gangue
80
100
31.10 Cleaner/Hematite
31.10 Cleaner/Silica
31.10 Cleaner/Gangue
80

60 60
(%)

(%)

40 40

20 20

1 10 100 1000 1 10 100 1000

Particle size (µm) Particle size (µm)

Figure 6. Data of the 31st: Partition of size classes per mineral in rougher and cleaner.

The two models have been calibrated with the data of the 21st. The results of the simulation are shown in table
1 and figure 7.

CONV.INI 2111.INI CONV.INI 2111.INI CONV.INI 2111.INI

Stream Global mass Global mass Grade of Grade of Grade of Grade of
definition: flowrate of flowrate of Hematite in Hematite in Silica in phase Silica in phase
phase Iron phase Iron phase Iron phase Iron Iron Ore (%) Iron Ore (%)
Ore (t/h) Ore (t/h) Ore (%) Ore (%)
Stream 1 400 400 93 93 5.87 5.87
Stream 2 296 299 95.8 95.8 2.85 2.75
Stream 3 137 136 86.4 86.2 13 13.4
Stream 4 263 264 96.4 96.5 2.14 2
Stream 5 33.4 35.5 91.3 90.8 8.42 8.36
Table 1. Flowrates and grades in the simulated and the coherent data files.
 Size distribution curve
100

Distribution of Silica in tailings - simulated

Distribution of Silica in tailings - coherent data
80 Distribution of Silica in concentrate - coherent data
Cumulative Passing (%) Distribution of Silica in concentrate - simulated

60

40

20

0
1 10 100 1000
Particle size (µm)

Figure 7. Results of the adjustment of the models on the first set of data.

It is to be noted that, even if these results appear satisfying, they represent a "fit" of a kinetic equation on only
one working point. The kinetic parameters obtained are presumably not correct, but at least they allow a
representation of the operation of the plant, and most of all, they give an idea of the differential flotation
kinetics between the minerals.
The simulator obtained here is only the first "calibrated" simulator. Before been used, it needs to be
"validated". We will use the data of the 31st, which are different enough from the data used for calibration.

Validation of the simulator.

The first run of the simulation with the "calibrated simulator" does not give so good results: table 2 gives these
results.

CONV.INI 3110.INI CONV.INI 3110.INI CONV.INI 3110.INI

Stream Global mass Global mass Grade of Grade of Grade of Grade of
definition: flowrate of flowrate of Hematite in Hematite in Silica in phase Silica in phase
phase Iron phase Iron phase Iron phase Iron Iron Ore (%) Iron Ore (%)
Ore (t/h) Ore (t/h) Ore (%) Ore (%)
Stream 1 342 342 93 93 5.05 5.05
Stream 2 248 287 95.4 94 2.32 4.39
Stream 3 124 108 88 85.7 11 10.9
Stream 4 218 234 95.8 96.3 1.67 2.36
Stream 5 30.1 52.6 92.5 83.7 7 13.4
Table 2. First set of flowrates and grades for the validation point.

The calibration should be improved by fitting the models with the data of the 31st. This is not the aim here.
What is interesting to note is that for the cost of one sampling campaign and a few days of data treatment, it is
possible to obtain a simulator which predicts the operation at a flowrate of -15% from the calibration point
with a mean precision of 20%.
The use of this simulator for the optimisation of the industrial circuit should consider this order of magnitude
of its precision. If the objective does not suffer this precision, the quality of the simulator can be improved by
using more data sets obtained in different operating conditions or also more precise data, particularly
concerning the flowrates.

CONCLUSION

This paper has given the equations of a general model of column flotation. It has been designed to be used
with different kinds of data: pilot plant data or industrial data. It is shown how it can be used to simulate an
industrial operation starting with relatively few and partial data.
The method to estimate the flowrates, reconciliate the data, calibrate the models and check the simulator has
been explained. The quality of the simulator obtained depends on three main factors: the quality of the data,
the ability of the model to represent the data and the validation on at least another operating point.

ACKNOWLEDGEMENTS

This paper is the BRGM contribution n° 96018 for which the work was in part financed by a BRGM research
project.

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