Week 3 Introduction To Flotation

2/28/2014
MinE 410 Mineral Processing II [3]

Dr. Ishaq Ahmad
• Froth flotation utilises the differences in physico –
Assistant Professor chemical surface properties of various minerals.
Dept. of Mining Engineering • Such differences in surface properties become
University of Engineering and Technology, appearent by the interaction of chemical reagents
with the mineral particles.
Peshawar
• To make the minerals selectively hydrophobic and
[Introduction to Flotation]
to separate it by the adherence of this specific
Spring Semester, 2014 particle to air bubble and then to rise to the
Week 3 surface in the form of froth
MinE 410 Mineral Processing II Dr.Ishaq MinE 410 Mineral Processing II Dr.Ishaq
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Ahmad Ahmad
Introduction • Direct Flotation : Valuable mineral is

• Patended in 1906 transferred to the froth, leaving the
• In earlier practice: gangue in the pulp.
– Tailings grade from various gravity plants were of • Reverse Flotation : Gangue is floated
higher grade than ore treated in many modern while leaving the valuable mineral in
flotation plants the pulp.
• Selective process to separate various ores
• Differential Flotation : In which more
– E.g Pb-Zn or Pb,Zn,Cu or Cu from its impurities
than one valuable is flotation one after
the other.
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FLOTATION
Phases
• Flotation is the most important mineral processing
technique. 3 phases in froth flotation:
Flotation has permitted : 1. Solid phase (fine ore particles)

1. The mining of low grade deposits would have
2. Liquid phase (water)
2. The mining of complex ore bodies been regarded 3. Gaseous phase (air)
as uneconomic
3. Ores that require fine grinding to achieve
liberation
4. To treat greater tonnages.
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Ahmad Ahmad
MinE 410 Mineral Processing II Dr.Ishaq

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2/28/2014
• Having reached the surface:

– the air bubbles, if make a stable froth then can
further support the particles
– Otherwise the bubbles burst and the particle fall
down in the pulp
– To form stable froth, numerous chemicals are
added called the flotation reagents
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Forces on Mineral Surface and

Contact Angle
Flotation
• The activity of a mineral surface in relation to
Principle:
flotation reagent in water depends on the forces
which operate on that surface.
• Contact anlge is the angle formed by a liquid at
• The particles which have been rendered: the three-phase boundary where the liquid, gas,
hydrophobic.(Water repellent : Aerophilic)
and solid meet.
• Hydrophilic (water wetted) particle which leaves in the
pulp.
• Most minerals are naturally hydrophilic.
To achieve a separation by flotation, the surfaces of one
mineral must be selectively rendered
MinE 410 Mineral Processing II Dr.Ishaq hydrophobic. 8 MinE 410 Mineral Processing II Dr.Ishaq
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Ahmad Ahmad
γ are the surface

energies (surface
• The air/gas is provided which converts to tension) between the
bubbles solid air, solid water and
air water.
• These bubbles can only stick to the mineral θ is the contact angle
particles if they can displace water from the between the mineral
mineral surface, which can only happen if the surface and the bubble
mineral is to some extent water repellent or
Hydrophobic.
At equilibrium γ s / a = γ s / w + γ a / w ⋅ cos θ [1]

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Work of Adhesion
PHYSICAL ASPECTS OF FLOTATION
• The force required to break the particle Wetting is the ability of a liquid to maintain contact with a solid surface.
bubble interface and is represented with W s/a It results from intermolecular interactions when the two are brought together.
The degree of wetting (wettability) is determined by a force balance between

• It separates the solid/air interface and ADHESIVE and COHESIVE forces.
produces separate air/water and solid/water COHESIVE FORCES within the liquid cause the drop to ball up and avoid contact
interfaces with the surface.
Cohesive forces are intermolecular forces (such as those from hydrogen bonding and Van der Waals
i.e. [2]
W = γ +γ −γ
s/a a/w s/ w s/a
forces).
These attractive forces exist between molecules of the same substance.
From 1 and 2 It is the mutual tension ( energy of reaction ) between molecules of the same type .
Ws / a = γ a / w (1 − cos θ ) [3] Eg. Water .
Rain falls in droplets, rather than a fineMinE

mist, because water has strong cohesion which pulls its molecules
Eq. 3 is called the Young’s equation
Ahmad
13 tightly together, forming droplets.
410 Mineral Processing II Dr.Ishaq
Ahmad
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• Now it can be observed that greater the contact PHYSICAL ASPECTS OF FLOTATION
angle, the greater is the work of adhesion and
more resistance the system is to disuptive forces. ADHESIVE FORCES are the mutual tension ( energy of reaction )
between two phases ( water and mineral).
If θ = 0 , cos θ = 1 They are the attractive forces between unlike molecules.
Ws/a = 0 When water is poured on clean glass, it tends to spread, forming a thin,
uniform film over the glasses surface.
The adhesive forces between water and glass are strong .

• No work is needed to break particle bubble They pull the water molecules out of their spherical formation
interface, because there is no particle bubble They hold them against the surface of the glass.
interface (surface is completely wetted by water) ADHESIVE forces between a liquid and solid cause a liquid drop
to spread across the surface.
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Ahmad Ahmad

If θ = 180 ° THE CONTACT ANGLE(θ)-
If the surface of one phase is plane ( as mineral surface M )
Surface is covered by air. Not valid in

practice
A
• The floatability of a mineral increases
θ W
with the contact angle. M
• Most minerals are NOT naturally
water repellent in their natural state
As the tendency of a drop to spread out over a flat, solid surface increases, the contact angle
and flotation reagents are added to decreases.
the pulp to make the surface of
Thus, the contact angle provides an inverse measure of wettability.
minerals hydrophobic A
i.e., as wettability increases, contact angle decreases. L
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Ahmad θ Ahmad
θ

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MINERALISATION OF AIR BUBBLES.
Water particle on a flat surface, ESEM image
Froth flotation depends on attachment of mineral particles to air bubbles.
The bubble attachment is by
1. COLLISION BETWEEN PARTICLES AND BUBBLE IN THE PULP-

Lot of collisions takes place in a flotation cell in a second.
A definite proportion of theses collisions result in bubble - mineral attachment.
Maximum bubble attachment ( i.e, maximum separation of minerals from the
gangue ) is made possible by controlling the various physical and chemical Bubble radius R
parameters of flotation.
2. FORMATION OF GAS BUBBLES ON THE PARTICLE SURFACE FROM THE

R min
SOLUTION.
Ref. Y.C. Jung, B.J. Bhushan, Microsc. 229, 127 (2008) As the contact angle increases, the formation of gas bubble is easier.
Stage I - The pulp water is oversaturated- no bubbles formed- gas molecules I II III
move to areas where they can easily combine and break the binds in the water Time t
molecules.
Stage II - A large number of gas molecules accumulate in certain areas. They
unite forming bubble molecules.
Stage III - The gas molecules grow due to diffusion of dissolved gases.
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Ahmad Ahmad
PHYSICAL ASPECTS OF FLOTATION PHYSICAL ASPECTS OF FLOTATION
A contact angle less than 90° ( low contact angle ) - V MINERALISATION OF AIR BUBBLES.
wetting of the surface is very favorable,
L
the fluid will spread over a large area of the surface. COMBINED BUBBLE ATTACHMENT TO A MINERAL.
S
Hydrophilic
Contact angles greater than 90° (high contact angle)- The discussed two methods of bubble formation may be combined.
wetting of the surface is unfavorable,
the fluid will minimize contact with the surface and
1. A small bubble forms on a mineral particle-
form a compact liquid droplet.
It activates the mineral surface and
For water, a wettable surface may be termed hydrophilic and improves the attachment to other bubbles.
Hydrophobic
a non-wettable surface hydrophobic.
2. A larger bubble having enough lifting power to carry the
Superhydrophobic surfaces have contact angles greater than 150°, particle into the froth attaches to the first bubble.
showing almost no contact between the liquid drop and the surface.
This is sometimes referred to as the "Lotus effect". 3. These two bubbles coalesce and a still larger bubble is formed.
4. It sticks to the particle.

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WSA = E AW ( 1 - Cos θ ),
For an aq. Solution with surface tension 70 dynes/ cm and θ = 60◦,
WSA = 70 ( 1 – Cos 60 )= 35 ergs/sqcm. FROTH PROPERTIES.
For θ = 90◦, Ω = 70 ergs/sqcm.
i.e, the work for adhesion ( adhesion is the measure of wettability) is
doubled. More work of adhesion needed to make surface wettable.
A contact angle less than
90° ( low contact angle ) –
1.Must retain the mineralised air bubbles.
As θ increases, WSA increases, wettability decreases. wetting of the surface is
very favorable,
2.The gangue materials must get detached in the froth.
Flotation process is made up of the fluid will spread over a
large area of the surface.
1. Artificially increasing the surface energy by introducing many fine
air bubbles in the system and Contact angles greater than 3.The froth should not be highly stable.
2. Causing the bubbles to adhere to each other and to suspend 90° (high contact angle)-
minerals whose contact angle is not ZERO. wetting of the surface is

unfavorable, The froth should breakdown easily on removal from the flotation cell.
OTHER THINGS BEING EQUAL, the fluid will minimize
AN INCREASE IN CONTACT ANGLE RESULTS IN contact with the surface
and
MORE RAPID FLOTATION.
form a compact liquid
droplet.
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IN FROTH FLOTATION FACTORS AFFECTING FLOTATION.

1. The particles are made hydrophobic ( non wettable ) . 1. Size and shape of mineral particles –
2. They are brought in contact with gas bubbles . Optimum particle size depends on its surface property , specific gravity .
3. The bubbles attached to the particle surface.
2. Pulp Density-
4. The bubbles carry the particles to the surface. Flotation efficiency increases with pulp density.
5. If the bubbles and surfaces never come in contact, Usual pulp density – 15- 40% solids .
then no flotation can occur.
3. Pulp Temperature.
THREE IMPORTANT POINTS IN FROTH FLOTATION- Temperature influences the speed of reactions.
1. EFFECT OF PARTICLE SIZE. Rise in temperature improves flotation but reduces selectivity.
Particle/bubble collision is affected by the relative sizes of the particles.
4. Composition of process water.
If the bubbles are large relative to the particles, Ions present in the water affect the flotation process.
They may react with flotation reagents ( collectors, modifiers etc) .
the fluid flowing around the bubbles carries the particles
without coming in contact. 5. Reagent feed –reagent type, sequence of addition, time of contact between pulp and
reagent.
Best results if The sequence of addition- regulator to alter pH of medium, depressants to depress certain
THE BUBBLE DIAMETER IS COMPARABLE TO THE PARTICLE DIAMETER constituent, collector and frother.
IN ORDER TO ENSURE GOOD PARTICLE/BUBBLE CONTACT.
6. Particle agglomeration in the pulp.
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FACTORS AFFECTING FLOTATION.
2. COLLECTION IN THE FROTH LAYER 7. Slimes –
They are fine , sticky particles ( 3-10 micron size).

Once a particle and bubble have come in contact,
the bubble must be large enough for its buoyancy to lift the particle to the They
surface.
The particle and bubble must remain attached while they move up into the froth layer at the contaminate the froth,
top of the cell. increase the reagent consumption,
decrease the flotation speed.
The FROTH LAYER MUST PERSIST LONG ENOUGH TO EITHER
FLOW OVER THE DISCHARGE LIP OF THE CELL BY GRAVITY The negative impact of the slime can be reduced by
OR
1. Adding suitable reagents,
TO BE REMOVED BY MECHANICAL FROTH SCRAPERS. 2. Using dilute pulp,
3. Separating slime before flotation.
If the froth is unstable, the bubbles will break and drop the hydrophobic particles back into
the slurry prematurely.
But the froth should not be so stable as to become persistent foam, as a foam is difficult to
convey and pump through the plant.
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Ahmad Ahmad
3. THE SURFACE AREA OF THE BUBBLES IN THE FROTH .
Copper Flotation
LARGER THIS SURFACE AREA, MORE RAPID IS THE FLOTATION RATE OF PARTICLES.
But increased surface area also carries more water into the froth.
Video
Fine particles ( Gangue ) that are not attached to air bubbles will be unselectively
carried into the froth along with the water (entrainment).
MORE WATER IN THE FROTH RESULT S IN CONTAMINATION OF THE PRODUCT WITH GANGUE
MINERALS.
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Ahmad Ahmad

Ahmad 5

Week 3 Introduction To Flotation

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2/28/2014

MinE 410 Mineral Processing II [3]

Introduction • Direct Flotation : Valuable mineral is

Flotation has permitted : 1. Solid phase (fine ore particles)

MinE 410 Mineral Processing II Dr.Ishaq

• Having reached the surface:

Forces on Mineral Surface and

γ are the surface

At equilibrium γ s / a = γ s / w + γ a / w ⋅ cos θ [1]

MinE 410 Mineral Processing II Dr.Ishaq

The degree of wetting (wettability) is determined by a force balance between

These attractive forces exist between molecules of the same substance.

Ws / a = γ a / w (1 − cos θ ) [3] Eg. Water .

Rain falls in droplets, rather than a fineMinE

If θ = 0 , cos θ = 1 They are the attractive forces between unlike molecules.

The adhesive forces between water and glass are strong .

PHYSICAL ASPECTS OF FLOTATION

Surface is covered by air. Not valid in

i.e., as wettability increases, contact angle decreases. L

MinE 410 Mineral Processing II Dr.Ishaq

PHYSICAL ASPECTS OF FLOTATION

The bubble attachment is by

1. COLLISION BETWEEN PARTICLES AND BUBBLE IN THE PULP-

2. FORMATION OF GAS BUBBLES ON THE PARTICLE SURFACE FROM THE

PHYSICAL ASPECTS OF FLOTATION PHYSICAL ASPECTS OF FLOTATION

4. It sticks to the particle.

PHYSICAL ASPECTS OF FLOTATION PHYSICAL ASPECTS OF FLOTATION

minerals whose contact angle is not ZERO. wetting of the surface is

MinE 410 Mineral Processing II Dr.Ishaq

PHYSICAL ASPECTS OF FLOTATION PHYSICAL ASPECTS OF FLOTATION

IN FROTH FLOTATION FACTORS AFFECTING FLOTATION.

PHYSICAL ASPECTS OF FLOTATION PHYSICAL ASPECTS OF FLOTATION

They are fine , sticky particles ( 3-10 micron size).

PHYSICAL ASPECTS OF FLOTATION

3. THE SURFACE AREA OF THE BUBBLES IN THE FROTH .

MinE 410 Mineral Processing II Dr.Ishaq

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