Untitled 5

Chapter 8
BGRIMM Pneumatic Mechanical

Agitation Flotation Machine
With the changes in mineral resource endowments, especially the increasing propor-
tion of low-grade ores, large pneumatic flotation machines have been developed
rapidly and become the most widely applied flotation machines. There are many
kinds of non-ferrous, ferrous and non-metallic minerals in China, but the resource
grades are not high, and the separation is very difficult. Beijing General Research
Institute of Mining & Metallurgy (BGRIMM) started its research on the flotation
equipment technology from 1960. After decades of development, from digestion
and absorption of the A-type flotation machine of the Michael Nobel Research Insti-
tute of the former Soviet Union to independent design of KYF and XCF pneumatic
flotation machines, it has developed the pneumatic flotation machine equipment tech-
nology that meets the requirements of Chinese mineral resources and served more
than 80% of the mines in China [1–3]. Since the 1960s, with OUTOTEC, Mesto
and other companies as representatives, the pneumatic flotation machines have been
developed towards upsizing, and a large pneumatic flotation machine with the single
tank volume of up to 160 m3 emerged at the beginning of the century [4–7]. Based
on years of accumulation of basic theory, Beijing General Research Institute of
Mining & Metallurgy took the lead in realizing the engineering of the world’s largest
pneumatic flotation machine with the volume of 320 m3 at that time by indepen-
dent innovation, and completed the development of the world’s largest pneumatic
flotation machine with the volume of 680 m3 in the last 2 years. At present, there
are numerous specifications of BGRIMM pneumatic mechanical agitation flotation
machine series. From the volume 5L at the laboratory level to the maximum volume
680 m3 industrially applied in the world, they can meet the requirements of research
institutes and concentrators of different scales. The BGRIMM pneumatic mechan-
ical agitation flotation machine with good applicability to different minerals can be
used to separate copper, lead, zinc, nickel, molybdenum, sulphur, iron, gold, bauxite,
apatite, leopoldite and other minerals.
© Metallurgical Industry Press 2021 263

Z. Shen, Principles and Technologies of Flotation Machines, Springer Tracts
in Mechanical Engineering, https://doi.org/10.1007/978-981-16-0332-7_8
264 8 BGRIMM Pneumatic Mechanical Agitation Flotation Machine
8.1 KYF Pneumatic Mechanical Agitation Flotation

Machine
At present, the pneumatic mechanical agitation flotation machine is one of the most
widely applied flotation machine types in China, and it has also been industrially
applied around the world. Thousands of flotation machines have been popularized
worldwide. This type was successfully developed by Beijing General Research Insti-
tute of Mining & Metallurgy on the basis of a large number of researches and
long-term practice accumulation.
8.1.1 Working Principle and Key Structures of KYF Flotation

Machine
The structure diagram of the KYF flotation machine is shown in Fig. 8.1. This
flotation machine mainly consists of rotors, stators, spindles, motors, transmission
Fig. 8.1 KYF flotation machine

8.1 KYF Pneumatic Mechanical Agitation Flotation Machine 265
components, tank bodies, etc. At present, the structures of tank bodies of flotation
machines include circular tank body and U-shaped tank body, and the transmission
types available now mainly include belt transmission and gear transmission.
8.1.1.1 Working Principle
When the rotor is rotating, the pulp in the tank is sucked into the spaces between
the rotor blades from all sides via the tank bottom by the lower end of the rotor.
Meanwhile, the low-pressure air supplied by the blower enters the air distributor of
the rotor chamber via the air duct, air regulating valve and hollow spindle, and enters
the spaces between the rotor blades through the holes in the air distributor. After being
fully mixed between the rotor blades, the pulp and air bubbles are discharged from
the periphery of the upper part of the rotor. The discharged ore current is inclined
upward and enters the whole tank after current stabilization and orientation by the
stators installed to be inclined upward around the rotor. As mineralized bubbles
ascend to the tank surface, froth is formed and flows into the froth tank through the
scraping plates or automatically, and then the pulp is returned to the rotor area for
recirculation.
8.1.1.2 Key Structures
a. Rotor
According to the design theory of the centrifugal pump, there are three cases of the
mounting angle β of the rotor blade at the outlet, i.e. forward inclined, radial and
backward inclined. For the backward-inclined blade, when the flow rate is high, the
theoretical head is low, the dynamic head component in the gross theoretical head is
accordingly small and the velocity head is low, which is good for stabilizing the pulp
level in accordance with the requirements of fluid dynamics of the flotation machine.
In addition, the adoption of the backward-inclined blade forms complies precisely
with the requirements of fluid dynamics of the flotation machine due to high flow
rate and low power consumption of the backward-inclined blade.
After the blade direction is determined, the rotor shape is to be further determined.
Specific speed is the main basis for determining the rotor shape. For the high specific
speed pump, it has the characteristics of high flow rate and small head. On the
contrary, it has low flow rate and great head. The rotor of the flotation machine
is similar to that of the high specific speed pump. Since the rotor inlet diameter
and outlet width of the high specific speed pump are relatively large and the outlet
diameter and inlet width are relatively small, it is proper to design the rotor of the
flotation machine using a rotor shape similar to that of the high specific speed pump.
Another important function of the rotor is air dispersion. For this reason, an air
distributor is arranged in the rotor chamber. The air distributor can distribute the
air evenly in most areas of the rotor blade in advance, and provide a lot of pulp–
air interfaces, thus greatly improving the air diffusion capability of the rotor and
improving the degree of air dispersion of the flotation machine.
Therefore, the rotor of the pneumatic mechanical agitation flotation machine is
designed into a centrifugal rotor with backward-inclined blades and high specific
speed, with an air distributor provided in the centre of the rotor.
The determination of structural parameters of the rotor is a complicated process. In
addition to theoretical calculations, a lot of experiments must be carried out by making
use of past experiences to obtain reasonable parameters step by step. Figures 8.2 and
8.3 show the main structural parameters of the rotor of the KYF flotation machine.
Generally, a large number of tests should be conducted to determine the relation-
ship between rotor structures, so the tests are usually conducted in a small flotation
machine in the laboratory in order to reduce the testing expenses. After the relation-
ship between rotor structure parameters is determined, the rotor diameter, which is
Fig. 8.2 Rotor of KYF flotation machine
Fig. 8.3 Structure parameters of KYF rotor (d—feed bore; b—blade height; β—blade incidence)
Fig. 8.4 Stator of KYF

flotation machine
the parameter characterizing the rotor structure, is amplified through the amplifica-
tion factor determined through research and tested in an industrial flotation machine,
and finally the desired reasonable parameters are obtained.
b. Stator
The KYF flotation machine is provided with low damping direct suspension stators
and radial short blades. As shown in Fig. 8.4, they are installed above the rotor,
distributed in the periphery and fixed to the tank bottom by support members. This
makes it possible to enlarge the pulp circulation area around the lower area of the
stator, eliminates the unnecessary interference of the lower parts to the pulp, facilitates
pulp flow to the lower area of the rotor, reduces the pulp circulation resistance and
power consumption, and enhances the circulation in the lower circulation area of the
tank body and the suspending capability of the solid particles. The mixture of pulp
and air that is thrown out from the rotor may enter the pulp smoothly to make the air
disperse properly. The key parameter of the stator, i.e. the diameter, can be obtained
by amplification.
c. Tank body
The tank bodies of the flotation machine mainly include the U-shaped tank body and
the circular tank in order to reduce the sand deposit area, facilitate the movement
of coarse mineral particles to the tank centre so as to return to the rotor area for
recirculation and reduce the probability of pulp short circuit. For the KYF flotation
machine with the single tank volume of 70 m3 and below, the tank body of the
flotation machine is designed depending on its configuration mode. When horizontal
configuration is required for the floatation machine operations, the tank body is in
a U-shaped structure, and the froth is scraped out by the scraping plates. For the
step configuration, the tank body is mainly in the structure of a circular tank, and
the self-overflow of the froth is recovered. For the flotation machine with the single
tank volume of greater than 70 m3 , the step configuration shall be adopted for the
floatation machine operations, the base plate is designed into a flat base and the
section of the tank body is designed into the structure of a circular tank body in order
to ensure even dispersion of the pulp.
Large flotation machines have the problems of long froth conveying path, high
probability of target minerals falloff and difficult recovery in time. According to the
requirements of the flotation process, two froth push cones may be provided in areas
near the liquid level of the tank body, wherein the outer froth push cone also serves
as the outer froth tank (Fig. 8.5), so that the froth conveying distance is significantly
reduced, the froth migration velocity is increased and the froth recovery time is
effectively shortened. In addition, due to reduced froth area and increased froth layer
thickness, the secondary enrichment in the froth layer is effectively enhanced, and
the process index of the target minerals is improved. Froth near the edge of the tank
body overflows from the outer froth tank; froth near to the centre overflows from the
inner froth tank; in this way, froth is divided into two parts so that the froth transport
distance is shortened.
The KYF flotation machine has complete specifications and models and the most
mature flotation machine upsizing, and represents the highest level of the research on
flotation machines in China. In 2000, a flotation machine with the single tank volume
of 50 m3 was successfully developed, and nearly 1000 such flotation machines were
quickly promoted worldwide. In 2005, a flotation machine with the single tank
volume of 160 m3 was successfully developed and used in the 34,000 t/d project of
Wunugetushan Cu-Mo deposit of China National Gold Group Co., Ltd.; in early 2008,
a 200 m3 flotation machine was successfully developed and used in the 90,000 t/d
project of Dashan Concentrator of Jiangxi Copper Corporation Limited. In 2008,
a 320 m3 flotation machine was successfully developed, whose enrichment ratio of
copper reaches up to 20.62 for a single flotation machine, enrichment ratio of sulphur
Fig. 8.5 Dual crowder and

dual launder
1-outer launder 2-inner launder and crowder

3-inner crowder
is 71.44 and single unit power consumption is about 200 kW. In 2017, a 680 m3 intel-
ligent supersized flotation machine was successfully studied, which is the flotation
machine with the largest single tank volume for industrial application in the world.
It is applied in the tailing recovery project of Sizhou Concentrator of Jiangxi Copper
Corporation Limited, with reliable mechanical performance that meets the process
index requirements and considerable economic benefits. The technical parameters
of the KYF flotation machine are shown in Table 8.1.
Table 8.1 Technical parameters of KYF flotation machine

Specification Effective Installed Minimum inlet wind Aeration rate/m3
volume/m3 power/kW pressure/kPa (m2 min) −1
KYF-1 1 3 >11 0.05~1.4
KYF-2 2 5.5 >12 0.05~1.4
KYF-3 3 7.5 >14 0.05~1.4
KYF-4 4 11 >15 0.05~1.4
KYF-5 5 11 >15 0.05~1.4
KYF-6 6 11 >17 0.05~1.4
KYF-8 8 15 >19 0.05~1.4
KYF-10 10 22 >20 0.05~1.4
KYF-16 16 30 >23 0.05~1.4
KYF-20 20 37 >25 0.05~1.4
KYF-24 24 37 >27 0.05~1.4
KYF-30 30 45 >31 0.05~1.4
KYF-40 40 55 >32 0.05~1.4
KYF-50 50 75 >33 0.05~1.4
KYF-70 70 90 >41 0.05~1.4
KYF-100 100 132 >46 0.05~1.4
KYF-130 130 160 >50 0.05~1.4
KYF-160 160 160 >52 0.05~1.4
KYF-200 200 220 >56 0.05~1.4
KYF-320 320 280 >64 0.05~1.4
KYF-450 450 355 >65 0.05~1.4
KYF-560 560 400 >65 0.05~1.4
KYF-680 680 500 >70 0.05~1.4
8.1.2 Fluid Dynamics Research in KYF Flotation Machines
8.1.2.1 Flow Field Characteristics of KYF Flotation Machines
The KYF series flotation machines have similar flow field characteristics. By taking
the laboratory KYF-0.2 m3 flotation machine as an example, the flow field charac-
teristics of KYF flotation are introduced, and the overall three-dimensional velocity
vector is shown in Fig. 8.6. In the rotor area, the fluid driven by the rotor has a
very high velocity, and every stator blade has an obvious diversion effect. As the
fluid leaves the rotor–stator area, the fluid velocity gradually decreases, and multiple
strands of upward and downward circulation structures as many as the stator blades
are formed in the tank body. It should be noted that the original flotation theory
points out that there are upper and lower circulating flow field structures in the tank,
but when judging from the overall three-dimensional velocity vector diagram, the
circulating flow field structures are greatly affected by the stator, and a stream of
circulating flow will be formed at each stator blade.
Figure 8.7 shows the details of circulation flow at the longitudinal section in
the KYF flotation machine. Remarkable upper and lower circulating flow fields are
formed in the flow field after the fluid is thrown out by the rotor blades. According
to the design theory of flotation machines, one of the design intents for the special
structure of the rotor is to form the circulating flow field structures to ensure that the
pulp can realize the flotation process efficiently.
Figure 8.8 shows the details of fluid flow at the cross section below the rotor disc.
Due to the counterclockwise rotation of the rotor, the fluid is thrown out of the rotor
area under the action of centrifugal force, hits the blade side towards the pulp and
gets out as jet flow in the direction of the stator blades. In the velocity cloud picture,
Fig. 8.6 Velocity vectors of

the lab-scale KYF-0.2
flotation machine
(a) Velocity vector diagram (b) Velocity cloud picture
Fig. 8.7 Flow pattern of the lab-scale KYF-0.2 flotation machine
Fig. 8.8 Velocity contour on a plan below rotor lid

Fig. 8.9 Velocity vectors between rotor blades
the obvious jet flow effect of the fluid along the stator blade sides towards the pulp
indicates that the stator has good current diversion and stabilization effects.
Figure 8.9 further reveals the flow characteristics between the rotor blades. It
should be noted that a clockwise eddy obviously opposite to the rotation direction is
formed at the rotor blades near the leeward side of the pulp. The maximum velocity
region in the whole field appears near the leeward side of the pulp, which is even
higher than the blade tip velocity.
8.1.2.2 Research on the Rotor of KYF Flotation Machine
The rotor of the KYF flotation machine is designed with backward-inclined blades,
and a backward inclination angle β = 30 is formed in the relative rotation direction
(the rotor of the flotation machine rotates in the clockwise direction) of the blades,
as shown in Fig. 8.10. A research was carried out by selecting a backward-inclined
rotor, a radial rotor and a forward inclined rotor in order to master the dynamic
performance of the rotor at a backward inclination angle. Figure 8.11 gives the tests
of three kinds of rotors and the comparison of PIV power consumption. The results
show that the backward-inclined rotor has the lowest power consumption among
the three kinds of rotors, which verifies the advantage of the flotation machine with
backward-inclined rotors in energy consumption.
Backward inclined rotor Radial rotor Forward inclined rotor
Fig. 8.10 Feature of KYF flotation machine rotor (top view)
(a) Test (b) CFD
Fig. 8.11 Power consumption comparison of the three rotors
The rotors with different backward inclination angles (β = 0°, 15°, 30°, 45°,
60°, 69°, 75°) (Fig. 8.12) also have great influences on the performance of flota-
tion machines. Figure 8.13 gives the relationship between the power consumption
315 rpm and the backward inclination angle. With the increase of the backward
inclination angle, there is a law that the power consumption of the flotation machine
decreases first and then increases, and the flotation machine with the rotor that
is inclined backward at 69° has the smallest power consumption, and a point of
inflection appears.
8.1.2.3 Research on the Stator of KYF Flotation Machine
The size of the stator of the flotation machine is enlarged with the continuous enlarge-
ment of the volume of the flotation machine, but the structure type does not change
much. The continuously growing height of the stator blades causes the increase in
the impact of the pulp on the stator blades, and the deformed potential at the upper
end of the stator blades is bound to increase. From the mechanical point of view, a
Fig. 8.12 Rotor blades with different inclined angles
Fig. 8.13 Power consumption versus blade inclination angle at 315 rpm
(a) Standard stator (b) Stator with an annular reinforcing ring
(c) Stator with a vertical reinforcing ring (d) Stator with a 45° vertical reinforcing ring
Fig. 8.14 Different stator designs
reinforcing ring needs to be added to the upper part of the stator blades of a supersized
flotation machine to ensure the mechanical reliability. However, the introduction of
the reinforcing ring will affect the flow field structure. Therefore, the influences of
different reinforcing rings on the flow field are studied, as shown in Fig. 8.14.
Figure 8.15 shows the influences of the stator structure on the flow field. The results
show that the fluid flow pattern distributions of four kinds of flotation machines with
stators are slightly different. The stator with an annular reinforcing ring has more
obvious horizontal jet flow, and high velocity areas appear in the rotor area and the
stator horizontal jet flow area. The vertical reinforcing ring results in the trend of
upward flow of part of the fluid from the inside of the reinforcing ring. Therefore, a
high velocity area of the fluid also appears in the upper area inside the stator. Due to
the existence of the annular reinforcing ring, the original upward inclined jet flow is
not very obvious, and the fluid blocked flows out of the stator area horizontally. The
velocity is high at this point, and the annular reinforcing ring is impacted. On the
other hand, whether this will cause the mineralized particles in the rotor area to fall off
will also cause a waste of energy. Due to the existence of the vertical reinforcing ring,
the original upward inclined jet flow is blocked and thrown upward, and the current
stabilization and guiding effects of the stator are weakened, which is equivalent to
(a) Standard stator (b) Stator with an annular reinforcing ring
(c) Stator with a vertical reinforcing ring (d) Stator with a 45° vertical reinforcing ring
Fig. 8.15 Flow patterns of different stator designs
the fact that only part of the stator blades work, a high velocity area appears at the
upper part of the stator and the horizontal jet effect is obviously worsened. The 45°
vertical reinforcing ring acts as a guide for the fluid which is thrown out in the upward
inclined direction. To sum up, the addition of the reinforcing ring also plays a guiding
role for the fluid, leading to changes in the flow field.
8.1.3 Performance and Application of the KYF Flotation

Machines
8.1.3.1 Performance of the KYF-50 Flotation Machine
The KYF-50 flotation machine is the first large flotation machine independently
developed by Beijing General Research Institute of Mining & Metallurgy. Indus-
trial tests were carried out in 2000, and the product was rapidly put into industrial
application. At present, it has been widely applied in large and medium-sized mining
enterprises at home and abroad.
A. Dynamic performance
To investigate the performance of the KYF-50 flotation machine, the dynamic param-
eters of the flotation machine were measured under the clean water condition, mainly
including the suction rate, the degree of air dispersion, power, air holdup, bubble
diameter, etc. The test results are shown in Table 8.2.
Table 8.2 Dynamics test results of KYF-50 flotation machine

Speed of flotation machine Average aeration rate Air dispersion Current of flotation
/r min−1 /m3 (m2 min) −1 machine
/A
136 1.22 1.63 93
131 1.17 2.07 97
126 1.15 1.71 84
The degree of air dispersion of the KYF-50 flotation machine is greater than 2.0 at
131 r/min, which meets the requirement of air dispersion. The aeration rate reaches
1.17 m3 /(m2 .min), which meets the aeration rate required for conventional mineral
separation.
B. Pulp suspension capacity
Four points were measured downward from the liquid level of the overflow weir
of the flotation machine, i.e. samples were taken at four pulp layers at depths of
1 m, 1.5 m, 2 m and 2.5 m for hydraulic analysis and grade analysis. The results
of detection and analysis show that the distribution of particle sizes in the pulp in
the tank body of the KYF-50 flotation machine is uniform, without stratification of
coarse and fine particle sizes, which indicates that the flotation machine has strong
agitation force, good air dispersion and no turbulence in the ore current.
C. Process index
The industrial test of the KYF-50 flotation machines was carried out in a nickel
mine in Jinchuan. Two KYF-50 flotation machines were used to replace the five
16 m3 flotation machines and one 20 m3 agitation tank before primary rougher in the
original production process and the five 16 m3 flotation machines before secondary
scavenger in the original production process. Under the same process conditions, the
cumulative indexes in the primary rougher stage of the KYF-50 flotation machine
are shown in Table 8.3, and the cumulative indexes in the secondary scavenger are
shown in Table 8.4.
Compared with the indexes of the 16 m3 flotation machine with 5 tanks before the
primary stage of the original process, the indexes of the KYF-50 flotation machine,
i.e. the grades of nickel and copper in the concentrate, are improved by 2.322% and
1.408%, respectively, the content of magnesium oxide in the concentrate decreases
by 4.181%, the operational recovery rate of nickel is as high as 0.108% and the
operational recovery rate of copper is as high as 2.363% in the case that the nickel
grade in the run-of-mine is 0.045% higher and the copper grades are equivalent. This
indicates that the KYF-50 flotation machine has certain effects on improving the
concentrate grades of nickel and copper, reducing the content of magnesium oxide
in concentrate and improving the recovery rate of copper.
From Table 8.4, it is seen that the concentrate grade of nickel is improved by
0.06%, the concentrate grade of copper is improved by 0.06% and the concentrate
Table 8.3 Cumulative indexes in the primary rougher stage of the industrial test on KYF-50 flotation
machine (%)
Item Raw ore grade Concentrate grade Tailings grade Recovery
Ni Cu Ni Cu Ni Cu Ni Cu
50 m3
for 1.499 0.848 8.963 4.881 0.646 0.387 61.343 59.043
primary
rougher
16 m3 for 1.454 0.850 6.646 3.473 0.655 0.456 61.235 56.680
primary
rougher
Difference 0.045 −0.002 2.499 1.408 −0.009 −0.069 0.108 2.363
Table 8.4 Cumulative indexes in the secondary scavenger stage of the industrial test on KYF-50
flotation machine (%)
Item Raw ore grade Concentrate grade Tailings grade Recovery
Ni Cu Ni Cu Ni ara> Cu Ni Cu
50 m3
for 0.38 0.34 1.17 0.73 0.26 0.30 40.36 29.36
secondary
scavenger
16 m3 for 0.35 0.34 1.11 0.67 0.29 0.31 25.58 17.06
secondary
scavenger
Difference 0.03 0 0.06 0.06 −0.03 −0.01 14.78 12.3
grade of magnesium oxide is improved by 1.16% with a higher grade of selected

nickel when the indexes of the KYF-50 flotation machine are compared with those
of the 16 m3 flotation machine with five tanks before secondary scavenger in the
original process. The operational recovery rates of nickel and copper are increased
by 14.78% and 12.3%, respectively.
During the industrial tests, the current of the flotation machine under different
concentration working conditions was measured, and the results are shown in Table
8.5. The current of the flotation machine under the normal concentration condition
is close to that measured in the clean water test.
Table 8.5 Measured currents of KYF-50 flotation machine at different pulp concentrations
Pulp concentration/% 52 48 36 32
Measured current/A 100.6 96 91 90
To investigate the performance of the KYF-160 flotation machine, the dynamic

parameters of the flotation machine were measured under the clean water condition,
mainly including the suction rate, the degree of air dispersion, power, air holdup,
bubble diameter, etc. The flotation dynamic test results are shown in Table 8.6.
Through the above tests, we have basically determined the clean water test
condition of KYF-160 and relevant laws, as shown in Figs. 8.16, 8.17, 8.18 and
8.19.
The air dispersion is relatively uniform at the speed of 111 r/min. At the speed
of 111 r/min, the aeration rate is 0.79 m3 /(m2 min), the maximum motor power is
123.85 kW, the aeration rate is 1.6 m3 /(m2 min) and the minimum motor power is
99.37 kW. At the speed of 111 r/min, the maximum air holdup is 0.149% and the
minimum air holdup is 0.085%. At the same liquid level, the changes in the air holdup
with the aeration rate are the most obvious at the speed of 111 r/min. At the speed
of 111 r/min, the maximum bubble diameter is 1.5 mm and the minimum bubble
diameter is 1.23 mm. At the speed of 111 r/min, the range of bubble diameter distri-
bution is also relatively large, which meets the requirements of flotation. Therefore,
we can determine that the pulp test speed of the flotation machine is 111 r/min, which
conforms to the design requirement.
B. Pulp suspension capacity
To investigate the pulp suspension capacity, the distribution of mineral particles at

different depths in the flotation machine was measured, i.e. hydraulic analysis and
grade analysis were carried out by sampling at six pulp levels as deep as 1.2 m,
1.8 m, 2.4 m, 3.0 m, 3.6 m and 4.2 m from the lower part of the overflow weir. The
results of detection and analysis show that the distribution of partial sizes in the pulp
in the tank body of the KYF-160 flotation machine is uniform, without stratification
of coarse and fine particle sizes, which indicates that the flotation machine has good
suspension capacity that meets the design requirements.
C. Process index
The pulp of the KYF-160 flotation machine is tested in order to further verify the
performance of the KYF-160 flotation machine. The following tests are mainly
carried out: research on the method for comparison of process indexes, comparison
of pulp test indexes, on-load start test, current measurement of flotation machine,
distribution detection of mineral particles at different depths in the flotation machine,
automatic control of liquid level, automatic control of aeration rate, primary rougher
of original process as well as particle size distribution detection of run-of-mine, and
concentrates and tailings of the KYF-160 flotation machine.
280
Table 8.6 Test data of flotation dynamics tests

Speed/r min−1 104 111 117
Aeration rate/m3 (m2 min) −1 0.86 0.93 1.1 1.43 0.79 1.05 1.27 1.6 0.68 1.03 1.23 1.96
Air dispersion 1.37 2.63 1.81 1.89 2.50 2.64 2.85 2.33 1.21 2.18 3.34 1.83
Motor power/kW 106.57 104.17 99.37 93.61 123.85 114.73 108.97 99.37 144.01 131.53 123.85 112.81
Air holdup/% 0.1 0.11 0.12 0.133 0.085 0.096 0.122 0.149 0.105 0.118 0.13 0.154
Mean bubble diameter/mm 1.10 1.12 1.06 1.17 1.5 1.39 1.37 1.23 1.03 1.11 1.19
8 BGRIMM Pneumatic Mechanical Agitation Flotation Machine
Fig. 8.16 Aeration rate

versus air dispersion

versus power consumption
The pulp test of the KYF-160 flotation machine was carried out in a nickel mine in
Jinchuan. Ten KYF-16 flotation machines in primary rougher of the original produc-
tion process were replaced with one KYF-160 flotation machine, and an agitation tank
with the diameter of 3000 was deleted from the pulp test process of the 160 flotation
machine as compared with the original process. Under the same process conditions,
the cumulative indexes and comparable cumulative indexes in the primary rougher
stage of the pulp test of the KYF-160 flotation machine are shown in Table 8.7, and
the comparison of total indexes of the system is shown in Table 8.8.
As seen from the table above, when the cumulative total index of the KYF-160
flotation machine is compared with the comparable cumulative index, with the run-of-
mine grade improved by 0.04%, the Ni concentrate grade is improved by 0.14%, the

versus air holdup

versus bubble diameter
tailings grades are equal and the recovery rate is improved by 0.67%. When the total
cumulative index of the KYF-160 flotation machine is compared with the cumulative
index of primary rougher in the original process, the grade of Ni concentrate obtained
after primary rougher is improved by 0.06%, with the run-of-mine grade reduced by
0.08%. The grade of Ni tailings is 0.08% higher than that of Ni tailings of primary
rougher in the original process. The KYF-160 flotation machine realizes the efficient
separation of minerals.
As seen from the table above, the system grade of Ni concentrate obtained through
the separation in the process of the 160 flotation machine is 8.88% with the run-of-
mine grade of 1.35%, while the system grade of Ni concentrate obtained through the
separation in the original process is 8.63% with the run-of-mine grade of 1.43%, and
the concentrate grade obtained by the KYF-160 flotation machine is 0.25% higher
Table 8.7 Comparison of primary rougher indexes of the system (%)
Comparison index Raw ore grade Concentrate grade Tailings grade Operational recovery rate
Ni Cu Ni Cu MgO Ni Cu Ni Cu
Debugging stage 1.40 0.85 4.51 2.60 20.79 0.51 0.39 72.29 64.49
Production stage 1.34 0.87 4.11 2.35 20.29 0.50 0.40 71.78 66.11
Cumulative index of 160 1.35 0.87 4.19 2.40 20.35 0.50 0.40 71.88 65.75
flotation machine
Comparable cumulative index 1.31 0.82 4.05 2.42 18.53 0.49 0.36 71.21 65.90
Comparable index error 0.04 0.05 0.14 −0.02 1.82 0.01 0.04 0.67 −0.15
Cumulative index of primary 1.43 0.83 4.13 2.03 19.08 0.42 0.36 78.43 68.87
8.1 KYF Pneumatic Mechanical Agitation Flotation Machine
rougher in the original process

Cumulative index error of −0.08 0.04 0.06 0.37 1.27 0.08 0.04 −6.55 −3.12
primary rougher
283
284
Table 8.8 Comparison of total system indexes (%)

Item Raw ore grade Concentrate grade of the system Total tailing grade of the system System recovery
Ni Cu Ni Cu MgO Ni Cu Ni Cu
Total cumulative index of 1.35 0.87 8.88 4.75 6.34 0.22 0.29 85.68 71.07
the 160 flotation machine
system
Total index of the original 1.43 0.85 8.63 4.10 6.45 0.24 0.31 85.73 68.86
process system
System index error −0.08 0.02 0.25 0.65 −0.11 −0.02 −0.02 −0.05 2.21
than that obtained in the original process; The tailings grade of the Ni system in the
process of the KYF-160 flotation machine is 0.02% lower than that of the original
process, while the recovery rate of the system is reduced by 0.05%. It shows that
the KYF-160 flotation machine is helpful to improve the total concentrate grade of
Ni to some extent, and also reduces the tailings grade. In addition, the grade of Cu
concentrate is increased by 0.65%, the recovery rate is increased by 2.21%, and the
grade of MgO is reduced. From these data we can see that the KYF-160 flotation
machine has good separation performance, and the equipment performance meets
the design requirements.
a. On-load start test
The on-load start of a large flotation machine is very important for large concentrators
because it can save the mineral resources and reduce the labour intensity. During
the tests, the start status of the pulp in the whole tank of the flotation machine was
investigated, stop and start tests were conducted, stop tests for 8, 24, 48 and 144 h were
conducted successively and the flotation machine was started successfully without
any problem, which indicates that the equipment can be started normally in the case
of long-term deposition after stop with the tank full of pulp.
b. Determination of power consumption of the flotation machine
The power consumption of the flotation machine is an important index to investigate

the performance of the flotation machine. During the tests, the current (power) was
measured under different aeration rates when the pulp concentration was 36%. The
data is shown in Table 8.9, and the results are shown in Fig. 8.20.
20.6
y = 106 + x−0.97 (8.1)
1+e 0.113
where
y motor power;
x aeration rate.
Throughout the test, since the pulp concentration was controlled at 36 ± 2%
and the aeration rate was generally adjusted between 1.1 and 1.2, the host power
consumption was 113 ~ 107 kW, the aeration power consumption was about 34 ~
38 kW and the unit total power consumption of the flotation machine was 147 ~
145 kW and less than 150 kW.
Table 8.9 Aeration rates and current change values

Aeration rate/m3 0.67 0.85 0.92 1.00 1.04 1.10 1.30 1.40 1.48
(m2 min) −1
Power/kW 132.41 126.65 122.81 117.05 113.21 112.25 105.53 104.57 104.09
Fig. 8.20 The relationship between the aeration rate and the power can be obtained by fitting
A. Dynamic test
To investigate the performance of the KYF-200 flotation machine, the dynamic

parameters of the flotation machine were measured under the clean water condi-
tion, mainly including the suction rate, the degree of air dispersion, power, air
holdup, bubble diameter, etc. The results of the dynamic test of the KYF-200 flotation
machine are shown in Table 8.10 and Figs. 8.21, 8.22, 8.23 and 8.24.
At the speed of 109 r/min, the maximum degree of air dispersion is 3.17 and the
minimum degree of air dispersion is 2.63. It can be seen that at the speed of 109 r/min,
all the degrees of air dispersion are above 2.5, which are not very different from each
other, and all of them are ideal with uniform changes. At the speed of 109 r/min, the
aeration rate is 0.80 m3 /m2 .min−1 , the current is 325A, the aeration rate is 1.8 m3 /m2
min−1 and the current is 252A. At the speed of 109 r/min, the maximum air holdup
is 0.13% and the minimum air holdup is 0.10%. At the speed of 109 r/min, the
maximum bubble diameter is 1.76 mm and the minimum bubble diameter is 1.29 mm.
Therefore, the speed of the flotation machine is determined as 109 r/min on the basis
of quantitative data in the above four aspects combined with the overall phenomena
in the test.
B. Pulp tests
To investigate the separation performance of the two KYF-200 flotation machines,

the run-of-mine, concentrate and tailings of the test system and the contrast system
were sampled and tested during the test. After the laboratory test, the elements were
Table 8.10 Data of dynamic test with clean water

Rotor Aeration rate/m3 Air dispersion Current/A Air holdup Mean bubble
speed/r (m2 min) −1 diameter/mm
min−1
101 0.4 4.0 300 0.08
0.69 1.32 275 0.11
0.94 3.49 255 0.12
1.22 2.24 250 0.14
105 0.43 2.53 340 0.10
0.67 2.63 315 0.11 2.68
0.88 3.08 310 0.11 1.0
1.15 2.80 270 0.12 1.19
1.6 2.99 260 0.13 0.98
109 0.80 3.17 325 0.10 1.29
1.07 2.89 280 0.13 1.63
1.13 2.67 270 0.11 1.76
1.8 2.63 252 0.11 1.47
113 0.8 2.72 340 0.10 0.98
0.99 2.2 330 0.11 1.61
1.23 3.27 320 0.12 1.60
1.49 2.32 280 0.09
Fig. 8.21 Air dispersion versus aeration rate
Cu and S for both. Samples were taken every 0.5 h and sent for the laboratory test
once per shift.
The 10-day debugging stage of the pulp test was carried out on the flotation
machines, and the cumulative indexes are shown in Table 8.11.
Fig. 8.22 Power consumption versus aeration rate
Fig. 8.23 Air holdup versus aeration rate
Fig. 8.24 Bubble size versus aeration rate

Table 8.11 Comparison of copper indexes in the commissioning stage (%)

Item Raw ore Concentrate Tailings Coarse 1 Flotation System
grade grade grade work efficiency recovery
recovery
rate
Test process 0.405 8.69 0.134 68.31 65.26 85.51
indicator
Compared 0.409 10.34 0.140 66.59 64.36 84.38
process
indicator
Difference −0.004 −1.65 −0.006 1.72 0.9 1.13
The indexes fluctuate greatly in the debugging stage, for example, the highest
grade of copper is 14.75% and the lowest grade of copper is 5.79%. The main
reason is that the liquid level is poorly controlled. The liquid level is controlled
manually in the debugging stage, resulting in failure to give immediate feedback for
the fluctuation of the pulp volume. The installation precision of the overflow weir of
the equipment is also one of the reasons affecting the index fluctuation. The optimal
production conditions, including the thickness of froth layer, the aeration rate and
the liquid level, were explored through the debugging stage, to provide the basis for
the technical conditions in the production stage.
The 17-day indexes in the production stage of the pulp test were counted, and the
cumulative indexes are shown in Table 8.12.
The statistical indexes of the production stage show that the recovery rate is 6.95
percentage points higher when the run-of-mine grade is reduced by 0.001%, which
is far beyond the index of the contrast process, and all the economic indexes of this
type of flotation machine meet the design requirements.
C. On-load start test
The full-load stop must be realized for supersized flotation machines in order to
reduce the economic losses caused by full-load stop of the supersized flotation
Table 8.12 Comparison of copper indexes in the industrial test stage (%)
Item Raw ore Concentrate Tailings Coarse 1 Flotation System
grade grade grade work efficiency recovery
recovery
rate
Test process 0.518 10.88 0.168 68.33 65.94 85.43
indicator
Compared 0.519 11.27 0.202 61.56 58.99 84.51
process
indicator
Difference −0.001 −0.39 −0.034 6.77 6.95 0.92
machines to the concentrators. Through several trial stops during the test, it can
be seen that the KYF-200 flotation machine can be started normally under the full
load.
D. Determination of power consumption of the flotation machine

the performance of the flotation machine. During the test, the main motor power of
the KYF-200 flotation machine was measured under different aeration rates with the
pulp concentration of 30%. The data is shown in Table 8.13, and the results after
collation are shown in Fig. 8.25.
After fitting, the relationship between aeration rate and power of the KYF-200
flotation machine is
59.5
y = 129.6 + (x−0.91)
(8.2)
1+e 0.266
where
y motor power;
x aeration rate.
Table 8.13 Relationship between aeration rate and power

Aeration rate/m3 0.70 0.85 0.92 1.00 1.10 1.20 1.30 1.40 1.48
(m2 min) −1
Power/kW 170.00 162.3 154.2 144.00 140.21 135.25 130.53 124.57 120.09
Fig. 8.25 The relationship between aeration rate and power

Since the pulp concentration was controlled at 30% ± 2% and the aeration rate was
generally adjusted between 1.0 and 1.2 throughout the test, the power consumption
of a single unit was 140 ~ 150 kW, the aeration power consumption of two flotation
machines was about 110 kW in total and the total power consumption of two KYF-200
flotation machines was 390 ~ 410 kW.
E. Determination of pulp suspension capacity
To investigate the pulp suspension capacity, the distribution of mineral particles at

different depths in the flotation machine was measured, i.e. samples were taken at
eight pulp levels as deep as 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0 and 4.5 m from the lower
part of the overflow weir, and hydraulic analysis and grade analysis were carried out.
The results of detection and analysis show that the distribution of partial sizes in the
pulp in the tank of the KYF-200 flotation machine is uniform, without stratification
of coarse and fine particle sizes, which indicates that the flotation machine has good
suspension capacity of mineral particles that meets the design requirements.
Statistical data of the dynamic test of the 320 m3 flotation machine is shown in Table
8.14.
Through the above tests, the clean water test condition and related laws of the
320 m3 flotation machine are shown in Figs. 8.26, 8.27 and 8.28.
The following conclusions can be drawn for the equipment: at the speed of
107 r/min, the maximum degree of air dispersion is 2.01 and the minimum degree
of air dispersion is 1.31. It can be seen that at the speed of 107 r/min, all the degrees
of air dispersion are above 1.5, which are not very different from each other, and
all of them are ideal with uniform changes. The maximum current is 305A and the
minimum current is 280A when the aeration rate is 0.9 ~ 1.4 m3 /(m2 min) and the
speed is 107 r/min. At the speed of 107 r/min, the maximum air holdup is 12.88%
and the minimum air holdup is 11.36%. At the same liquid level, the changes in the
air holdup with the aeration rate are the most obvious at the speed of 107 r/min.
To sum up, at the five speed levels, when the speed is greater than 107 r/min,
the air in the tank can be dispersed in the tank uniformly, but with the increase of
speed, the spindle power consumption of the flotation machine increases, and when
the speed is 107 r/min, the changes in the air holdup with the aeration rate are the
most obvious. Therefore, the pulp test speed of the flotation machine is determined
as 107 r/min, which is consistent with the design requirements.
Table 8.14 Clean water test data

Speed/r min−1 Aeration rate/m3 (m2 min) −1 Air dispersion Current/A Air holdup/%
98 0.95 1.63 242 11.14
1.07 1.47 230 11.87
1.15 1.39 223 12.43
1.27 1.27 214 12.68
102 0.98 1.83 269 11.43
1.08 1.61 259 11.95
1.19 1.55 250 12.67
1.31 1.29 242 12.50
107 0.95 2.01 300 11.36
1.06 1.8 305 12.15
1.17 1.74 295 12.73
1.36 1.31 280 12.88
111 0.96 1.98 340 11.49
1.08 1.75 326 12.29
1.17 1.66 318 12.05
1.26 1.45 311 12.64
115 0.94 2.09 384 11.24
1.07 1.85 370 11.85
1.15 1.7 361 12.67
1.27 1.55 351 12.84
Fig. 8.26 Air dispersion rate versus aeration rate
B. Pulp tests
To investigate the separation performance of the 320 m3 flotation machine, the run-
of-mine, concentrate and tailings of the test system were sampled and tested during
Fig. 8.27 Power consumption versus aeration rate
Fig. 8.28 Air holdup versus aeration rate
the test. Samples were taken once an hour and sent for the laboratory test once per
shift.
The pulp test production stage lasted for 10 days. The cumulative indexes are
shown in Table 8.15.
It can be seen from Table 8.15 that at the feed copper grade of 0.060%, the copper
grade of concentrate is up to 1.256%, and the copper enrichment ratio is up to 20.62.
At the feed sulphur grade of 0.386%, the sulphur grade of concentrate is up to 24.83%,
and the sulphur enrichment ratio is up to 71.44.
C. On-load start test
To reduce the economic loss of the concentrator caused by the failure of full-load stop
of the supersized flotation machine, the supersized flotation machine must realize
on-load start. The full-load start tests of the flotation machine were conducted in the
last stage of the test in order not to affect the tests. The 320 m3 pneumatic mechanical
agitation flotation machine was successfully started after full-load stop for 0.5, 1, 2
294
Table 8.15 Comparison of copper indexes in the industrial test stage

Item Raw ore Concentrate grade/% Tailing grade/% Recovery rate/% Productivity/g Flotation Enrichment ratio
grade/% efficiency/%
Cu S Cu S Cu S Cu S Cu S Cu S Cu S
Value 0.060 0.386 1.256 24.830 0.053 0.218 12.80 39.73 0.64 0.72 12.19 39.50 20.62 71.44
Fig. 8.29 Solids percentage at different depths
and 4 h, respectively, which indicates that the 320 m3 pneumatic mechanical agitation
flotation machine can be started normally after on-load stop.
D. Determination of power consumption of the flotation machine

the performance of the flotation machine. During the test, the pulp concentration
was 30%. When the aeration rate was 1.0 ~ 1.4 m3 /(m2 min), the host current of the
flotation machine was always about 320A, and its actual power consumption was
about 160 kW.
E. Determination of pulp suspension capacity
To investigate the pulp suspension capacity, the distribution of mineral particles
at different depths in the flotation machine was measured, i.e. samples were taken
at eight pulp levels as deep as 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, 5.0 and 5.5 m
from the lower part of the overflow weir, and hydraulic analysis was carried out. The
results are shown in Fig. 8.29 and Fig. 8.30. It can be seen from the figure that the
pulp size is distributed evenly in the tank of the 320 m3 flotation machine, without
showing the stratification phenomenon between coarse and fine particles; it means
that the flotation machine has a good mineral suspension capability and meets the
design requirement.
The inner part of the flotation machine is usually divided into four areas: rotor agita-
tion area, transport area, separation area and froth area, each of which has its own
functional features. The areas should not be simply scaled up in the process of rapid
upsizing of the flotation machine volume. For the purposes of full agitation and
suspension of the mineral particles and effective contact with the bubbles, the rotor
agitation area is scaled up to a great extent, and enough space and time are provided
Fig. 8.30 PSD at different depths
to enable effective bubble–particle contact for mineralization. The KYF-680 super-

sized flotation machine is supported by the amplification theory of the BGRIMM
flotation machine, and a flotation dynamics control technique for the characteristics
of target minerals has been developed so that coarse minerals can be transported
to higher areas to facilitate the rapid recovery in a short distance and realize the
relatively shallow tank flotation process. The bubble mineralization in the flotation
machine tanks mainly occurs in the way of downstream flow, while rotor agitation
and stator current stabilization are the main ways for formation of mineralization
environments. For the design of the rotor stator of the KYF-680 flotation machine
based on the optimal control strategy for the turbulent dissipation rate, the rotor agita-
tion area is enabled to form a powerful circulation output and produce a uniform and
stable gas–liquid–solid three-phase velocity gradient field. In the rotor chamber area
with high turbulent dissipation rate and great velocity gradient, fine minerals can
realize mineralization with the bubbles in advance here. Outside the rotor area, the
turbulent dissipation rate is moderate subject to the regulation effect of stator current
stabilization. In this state, the space area in the tank is the largest, and the coarse
connate minerals mainly collide with and adhere to the bubbles here. As the mineral-
ized bubbles carrying the coarse and fine minerals float up, the turbulent dissipation
rate gradually decreases so that the mineralized bubbles can smoothly enter the froth
layer for recovery.
From Fig. 8.31 which shows the cumulative mean values of the aeration rate and
the degree of air dispersion under the ore carrying condition, we can see that the
degree of air dispersion can reach 7 at the aeration rate of about 1.0 m3 /(m2 min),
showing excellent air dispersibility. From Fig. 8.32, it can be seen that the gas holdup
in the whole flotation tank varies at different depths. The closer the gas holdup is to
the liquid level, the higher the gas holdup is, which is consistent with the distribution
characteristics of gas holdups in the tank. By calculating the comprehensive gas
Fig. 8.31 Air dispersion rate
Fig. 8.32 Air holdup at

different depths
holdup of the whole flotation tank, it can be seen that the comprehensive gas holdup
of a 680 m3 flotation machine was 7.06% under the test conditions at that time.
The circulating capacity of the 680 m3 supersized flotation machine at the design
speed can reach 500 m3 /min, and the powerful circulating capacity ensures the full
suspension of coarse minerals. The relationship between different aeration rates and
circulation volumes is shown in Fig. 8.33. The circulation volume decreases as the
aeration rate increases. Figure 8.34 shows the change law curves of the speed and
power consumption of the supersized flotation machine under different aeration rate
conditions. It is obvious that the power consumption of the flotation machine shows
a fast-increasing trend as the speed increases, and the input power consumption of
the flotation machine can be reduced with the increase of the aeration rate.
Test on the suspension capacity of the 680 m3 flotation machine. The test contents
include concentration distribution and size fraction distribution at different depths.
From Fig. 8.35, it can be seen that all the concentration distributions of the pulp at
different depths are within the range of 30 ~ 35%. From Fig. 8.36, it can be seen
that the consistency of size fraction compositions is good in the same depth position,
Fig. 8.33 Pumping capacity versus rotor speed
Fig. 8.34 Power consumption versus rotor speed
which shows that the distribution effect of suspension of all size fractions at different
depths is quite good.
The flotation dynamics parameters which affect and reflect the performance of
the flotation machine itself were measured in the process of dynamic tests. Under
the optimal aeration rate condition, the degree of air dispersion can reach above 7,
with a good dispersion effect. The mean gas holdup under ore carrying conditions is
about 7%. The pulp concentrations are distributed uniformly at different depths, and
the size fractions also have consistent distributions in their depths. The circulation
Fig. 8.35 Concentration distribution in open-circuit test
Fig. 8.36 Suspended particle distribution in open-circuit test
volume can reach 500 m3 /min, and the operational power consumption is 360 ~
400 kW.
The behaviour of short circuit in the pulp flow is more common in supersized
flotation machines. The residence time distribution of the KYF-680 flotation machine
was studied in tests. Figure 8.37 shows that the mean residence time of the KYF-680
flotation machine is 17.81 min, which is 89% of the ideal residence time (20 min).
Therefore, there is no obvious short-circuit or dead zone phenomenon in the KYF-680
flotation machine.
Fig. 8.37 Residence time distribution of the KYF-680 flotation machine
8.2 XCF Automatic Suction Pneumatic Mechanical

Agitation Flotation Machine
The pneumatic mechanical agitation flotation machine has the characteristics of

good flotation process index, reduction of energy consumption and power consump-
tion, simple structure, convenient operation, maintenance and management, etc. The
traditional pneumatic mechanical agitation flotation machine does not have the pulp
suction capability, the step configuration is adopted between floatation operations
and the middlings must be returned by the froth pump. Since the froth pump is
easy to wear, it is difficult to lift the sticky and non-breakable froth, which makes it
difficult for the process to become unblocked, and the configuration is difficult for
complex processes and cleaner bank. For the newly built concentrator, the invest-
ment of capital construction is increased due to the step configuration, as shown
in Fig. 8.38. The transformation of old concentrators is difficult because both plant
height and process height difference are fixed, which limits the application scope of
the pneumatic mechanical agitation flotation machine. Therefore, the development
of an automatic suction pneumatic mechanical agitation flotation machine having
both the advantages of the pneumatic mechanical agitation flotation machine and
the pulp suction capacity is good for saving the return of middlings to the pump,
reducing the plant height, reducing the capital costs, etc. and is of great significance
to the construction and transformation of new and old mines. The XCF automatic
suction pneumatic mechanical agitation flotation machine is used either separately or
formed into an aggregate unit with the conventional pneumatic mechanical agitation
flotation machine so that different flotation operations are configured horizontally
without the froth pump, as shown in Fig. 8.39.
8.2 XCF Automatic Suction Pneumatic Mechanical Agitation … 301
Fig. 8.38 Step configuration of flotation bank
Fig. 8.39 Horizontal configuration of flotation bank
8.2.1 Working Principle and Key Structures of XCF

Flotation Machine
The structure of the XCF automatic suction pneumatic mechanical agitation flotation
machine is shown in Fig. 8.40. This flotation machine consists of tank bodies for
accommodating the pulp, big isolation disc rotors with upper and lower blades, seat-
type stators with radial blades, split disc-shaped cover plates, split central cylinders,
connecting pipes with exhaust holes, bearing blocks, hollow spindles, air regulating
valves, etc. There are two kinds of structures, i.e. open and closed. There are seat-type
and side-attached bearing blocks installed to the cross member which also serves as
an air supply pipe. Figure 8.41 is an aggregate unit formed by the XCF automatic
suction pneumatic mechanical agitation flotation machine and the KYF pneumatic
mechanical agitation flotation machine.
A. Working principle
The motor drives the rotor to rotate through the transmission device and the hollow
spindle. The pulp is sucked into the space between the lower rotor blades via the
inner edge of the lower rotor blades. Meanwhile, the low-pressure air supplied from
the outside enters the air distributor in the lower rotor chamber through the cross
Fig. 8.40 Structure diagram of XCF flotation machine (1—lower rotor blade; 2—stator; 3—isola-
tion disc; 4—lower rotor blade; 5—rotor cover plate; 6—central cylinder; 7—hollow spindle;
8—tank body; 9—middlings pipe; 10—feed pipe)
Fig. 8.41 Combined unit of XCF/KYF flotation machines

member, the air regulating valve and the hollow spindle, and then enters the space
between the lower rotor blades through the small holes around the air distributor. The
pulp and air are discharged from the outer edges of the lower rotor blades after being
fully mixed in the space between the lower rotor blades. A certain negative pressure
is generated in the upper rotor blades due to the rotor rotation and the combined
action of the cover plate and central cylinder so that the middlings froth and the
feed flow into the central cylinder through the middlings pipe and the feed pipe and
enter the space between the upper rotor blades, and finally they are discharged from
the outer edges of the upper blades. The pulp discharged from the upper and lower
blades of the rotor enters the tank after current stabilization and orientation by the
stator. The mineralized bubbles ascend to the tank surface and form the froth which
flows into the froth tank. Then the pulp is returned to the rotor area for recirculation,
and the other part enters the next tank for re-separation through the circulation holes
in the wall between the tanks. The function of the rotor isolation disc is to make the
mixture of pulp and air discharged from the lower blades not affect the pulp suction
of the upper rotor blades.
B. Key structures
The design of the XCF automatic suction pneumatic mechanical agitation flotation
machine focuses on the structures and parameters of the tank body, rotor, stator,
cover plate, connecting pipe, etc., as well as the coordination relationship among
them. The main parts and components are designed as follows:
a. Tank body
The tank body of the XCF flotation machine is designed into a U shape, which is
favourable for the coarse mineral particles to return to the rotor area for recircu-
lation to avoid the accumulation of ore sand and reduce the phenomenon of pulp
short circuit. To facilitate manufacturing and installation, trapezoid-shaped tanks are
generally used when the tank volume is less than 3 m. When the XCF flotation
machine is combined with other pneumatic mechanical agitation flotation units to
form an aggregate unit, the shape of the tank body may be consistent with that of the
direct current tank body for convenient connection between tank bodies. To provide
the XCF flotation machine with the advantages of a general pneumatic mechanical
agitation flotation machine and make it easily combined with the general pneumatic
mechanical agitation flotation machine to form the aggregate unit, a deep tank struc-
ture is adopted, which creates an obstacle to automatic pulp suction and increases
the difficulty in the development of the rotor–stator mechanism.
b. Spindle
Since low-pressure air is compressed into the general pneumatic mechanical agitation
flotation machine, the negative pressure in the central area of the rotor is reduced,
making it difficult to suck the pulp. For this reason, we have designed the spindle
assembly with a pneumatic agitation area and a pulp sucking area, which are separated
by the isolation disc. The pulp sucking area consists of the upper rotor blades, disc-
shaped cover plate, central cylinder, connecting pipe, etc. and the pneumatic agitation
area consists of the lower rotor blades, air distributor, etc.
c. Rotor
The rotor is the main component of the flotation machine and one of the key points
in the design of the flotation machine. The rotor is designed to have upper and lower
blades separated by the isolation disc in order to separate the pneumatic agitation
area from the pulp sucking area. The upper rotor blades are designed into radial
straight blades which can produce suitable suction force and static pressure head,
and reduce the counterflow between the blades and avoid the return of the air in the
main tank into the central cylinder and connecting pipe. The lower rotor blades are
backward-inclined centrifugal blades with high specific speed, low dynamic head
and high flow rate. They are used only for pulp circulation and air dispersion to
meet the requirements of the flotation process for the flotation machine. The range
of aeration rate and the degree of air dispersion have great influences on the scope
of application and process indexes of the flotation machine. The air distributor is
designed in the lower blade chamber of the rotor in order to further improve the
aeration rate and degree of air dispersion. The air distributor is a cylinder with small
holes in the wall. It can distribute the air much more evenly in most areas of the rotor
blades in advance and provide a large number of pulp–air interfaces, thus improving
the air dispersion capability of the rotor.
d. Stator
In addition to making the rotating pulp flow radially and shear the air, the stator of the
XCF automatic suction pneumatic mechanical agitation flotation machine must also
protect the air aerated into the pulp via the lower rotor blades against the obstruction
of the stator so that the air can enter the main tank smoothly without entering the
pulp sucking area through the upper rotor blades.
The XCF flotation machine is provided with an open stator with suspended radial
short blades. The stator is installed above the periphery of the rotor and fixed to the
tank bottom by support members. There is a large radial clearance between the stator
and the rotor and a large area for pulp circulation around the lower area of the stator
so that the unnecessary interference of the lower parts on the pulp is eliminated,
which is favourable for the flow of pulp to the lower area of the rotor, reducing the
power consumption and enhancing the circulation in the lower circulation area and
the suspension of solid particles.
Currently, the XCF flotation machine has many specifications with the volumes
of 1 ~ 70 m3 , and the technical parameters are shown in Table 8.16.
Table 8.16 Technical parameters of XCF flotation machine

Specification Effective Installed Minimum inlet wind Aeration rate/m3
volume/m3 power/kW pressure/kPa (m2 min) −1
XCF-1 1 4 >11 0.05~1.4
XCF-2 2 7.5 >12 0.05~1.4
XCF-3 3 11 >14 0.05~1.4
XCF-4 4 15 >15 0.05~1.4
XCF-6 6 18.5 >17 0.05~1.4
XCF-8 8 22 >19 0.05~1.4
XCF-10 10 30 >20 0.05~1.4
XCF-16 16 45 >23 0.05~1.4
XCF-20 20 45 >25 0.05~1.4
XCF-24 24 55 >27 0.05~1.4
XCF-30 30 55 >31 0.05~1.4
XCF-40 40 75 >32 0.05~1.4
XCF-50 50 90 >33 0.05~1.4
XCF-70 70 110 >33 0.05~1.4
8.2.2 Fluid Dynamics Research in XCF Flotation Machines
The automatic suction pneumatic mechanical agitation flotation machine has the
performance in two aspects, one is the flotation separation performance and the
other is suction of middlings or feed. The suction of middlings or feed may be
turned on or off according to the requirements of the flotation flow. By taking the
XCF-0.2 m3 flotation machine as an example, the fluid dynamics characteristics in
the automatic suction flotation machine are introduced. Figure 8.42 reveals the flow
pattern of the automatic suction pneumatic mechanical agitation flotation machine
without middling suction under the condition of single-phase pure water. An upper
flow circulation and a lower flow circulation appear inside the flotation machine,
which is the basis of ensuring the excellent separation performance. Similar to the
conventional flotation machines, the pulp enters the rotor area from the area below the
rotor. The fluid is separated into upward and downward flows after being discharged
under the action of the rotor blades. Figure 8.43 reveals the flow pattern of the
automatic suction pneumatic mechanical agitation flotation machine with middling
suction under the condition of single-phase pure water. The structure of the circulating
flow field is comparative to the overall flow pattern of the flotation machine, that is to
say, middling suction does not destroy the fluid dynamics state in the tank, which is
essential for ensuring the separation performance of the automatic suction pneumatic
mechanical agitation flotation machine. The fluid is sucked from the outside into the
middling pipe or feed pipe, supplied into the rotor area through the central cylinder,
and then discharged by the rotor. Intense collision and mixing occur to the middling
and the pulp sucked in below the rotor in the rotor discharge area. It is foreseeable that
Fig. 8.42 Flow patten of single phase—without middling suction
this is beneficial to increasing the turbulence intensity in the agitation and mixing area
of the flotation machine and improving the collision between particles and bubbles.
Relative to general pneumatic flotation machines, the rotor is the key to the double
function of the automatic suction pneumatic mechanical agitation flotation machine.
Figure 8.44 shows the rotor structure and negative pressure distribution of the auto-
matic suction pneumatic mechanical agitation flotation machine. The rotor consists
of upper and lower blades which are separated by a baffle plate. A wide range of nega-
tive pressure is produced at the leeward side of the pulp of the blades whether they
are upper blades or lower blades. Therefore, under the action of negative pressure
driving force, the pulp in the tank is circulated by the lower blades, and the middlings
are sucked by the upper blades, as shown in Fig. 8.45. In theory, it is contradictory
that negative pressure suction is formed in a low-pressure aerated environment. The
automatic suction flotation machine realizes the relative isolation of the low-pressure
aeration path from the suction path through a series of engineering design, thus
solving the problem of middling suction in the pneumatic flotation machine.
Fig. 8.43 Flow patten of single phase—with middling suction
Figure 8.46 reveals the axial flow distribution in the middle section of the stator
ring with or without middling suction. The flow patterns in both cases are similar, with
certain differences in the local velocities only. Table 8.17 Influence of pulp suction
on fluid dynamic performance Table 8.17 gives a comparative analysis of the main
dynamic performance parameters with or without middling suction. It can be seen that
the rotor circulation volume does not change much. This is very important to maintain
the stable performance of the automatic suction pneumatic mechanical agitation
flotation machine under different working conditions. From the data, it is seen that
the middling pumping effect of the automatic suction pneumatic mechanical agitation
flotation machine has no significant effect on the fluid dynamic flow pattern in the
flotation machine, but the operational power consumption is relatively increased to
a large extent by about 15%.
Fig. 8.44 Negative pressure

distribution on impeller of
the automatic suction
air-forced mechanical
agitation flotation machine
(a) Upper blades
(b) Lower blades
8.2.3 Performance and Application of the XCF Flotation

Machines
8.2.3.1 Performance of XCF-8 Flotation Machine
A. Pulp test
With the XCF-8 flotation machine as the testing object, its flotation dynamics in
clean water was tested, and the degree of air dispersion, pulp sucking capacity,
power consumption gas and other related parameters were mainly tested.
At the linear velocity of 7.54 m/s, the mean degree of air dispersion is 2.56 and
the pulp sucking capacity is 4.5 ~ 7 m3 /min. At the linear velocity of 6.97 m/s, the
degree of air dispersion is 3.68 and the pulp sucking capacity is 3.6 ~ 5.5 m3 /min.
Fig. 8.45 Flow path of air

and pulp in the automatic
suction air-forced
mechanical agitation
flotation machine
According to the clean water test, it can be determined that the linear velocity of the
flotation machine within 7 ~ 7.5 m/s fully meets the requirements of the pulp test.
Industrial tests were conducted in order to investigate the separation performance
of the flotation machine, and Table 8.18 shows the index comparison in the debugging
stage.
As can be seen from Table 8.19, the recovery rate of lead is increased by 0.87%
according to the test results of the XCF/XCF-8 flotation machine.
Subsequently, the industrial tests were conducted for 1 month, with the test indexes
as given in table.
As can be seen from Table 8.19, the indexes of the XCF/XCF-8 flotation machine
are better than those of the 6A flotation machine.
B. Comparison of power consumptions
The power consumptions were measured in order to compare the power consumptions
of individual flotation machines, as shown in Table 8.20.
As seen from Table 8.20, the specific power of the XCF-8 flotation machine is
10.80 lower than that of the 6A flotation machine, which shows that the XCF-8
flotation machine has a low power consumption that meets the design requirements.
C. Comparison of losses of wearing parts
The rotor stator of the 6A flotation machine has a service life of about 3 months. The
wear condition of the rotor stator was checked after the XCF-8 runs for 2000 h. It
Fig. 8.46 Axial flow

distribution in the middle
section of the stator ring
(a) Without pulp suction
(b) With pulp suction
Table 8.17 Influence of pulp suction on fluid dynamic performance

Serial No. Item Without pulp suction With pulp suction Unit
1 Torque 26 29.7 N.m
2 1.84 1.73 m3 /min
3 Middling pulp suction 0 0.82 m3 /min
volume
Table 8.18 Index comparison in the debugging stage

Raw ore grade Raw ore grade % Recovery rate (%) Remarks
%
Pb Zn PbK➀ Zn/PbK➁ PbK➀ Zn/PbK➁ ZnK
1 1.305 0.995 67.63 3.53 83.38 5.71 75.76 XCF/XCF-8
2 1.208 0.936 70.00 3.54 82.51 5.39 74.51 6A
3 1.244 1.092 69.38 3.69 82.71 5.29 79.77 6A
Note ➀ Lead concentrate; ➁ Lead concentrate with zinc
Table 8.19 Index comparison in the test stage

Raw ore grade/% Tailings grade/% Zinc Zinc Remarks
Pb Zn Pb Zn concentrate concentrate
grade/% recovery
rate/%
1 1.313 1.013 0.144 0.119 49.96 81.4 XCF/XCF-8
2 1.393 1.036 0.160 0.132 49.62 79.46 6A
3 1.208 0.936 0.167 0.167 49.50 74.57 6A
Table 8.20 Comparison of power consumptions of flotation machines

Item XCF XCF 6A
1 Tank volume/m3 8 8 2.8
2 Installed power/kW 22 15 10
3 Actual power consumption of spindle/kW 16.00 9.62 8.04
4 Aeration power/kW 4.47 4.47 0.00
5 Actual power consumption/kW 21.47 14.09 8.04
6 Specific power/kW m−3 2.56 1.76 2.87
7 Saving as compared with 6A/% 10.80 38.68
was found that the rotor stator was not worn seriously, with a minor impact on the
equipment performance. It was expected to be used normally for 7000 ~ 9000 h, and
the consumption of the wearing parts was reduced by about 70% compared with that
of the 6A flotation machine.
A. Dynamic test
The XCF-24 flotation machine is taken as the testing object and tested in terms of
its flotation dynamics in clean water, mainly including the determination of related
Table 8.21 Results of dynamic test

Rotor Aeration rate/m3 Air dispersion Current/A Air holdup Mean bubble
speed/r (m2 min) −1 % diameter/mm
min−1
145 0.95 2.49 73 12.6 1.32
151 1.13 2.80 75 12.3 1.41
157 1.08 3.89 84 13.4 1.22
163 0.97 3.33 88 11.2 1.20
parameters such as aeration rate, degree of air dispersion, speed, power, air holdup
and bubble diameter. The results of the dynamic test on the XCF-24 pneumatic
mechanical agitation flotation machine are shown in Table 8.21.
Through the testing and analysis of the dynamic parameters in the flotation
machine, the optimal dynamic performance of the pneumatic mechanical agitation
flotation machine can be determined to adapt to the separation requirements of the
process and achieve the optimal application effect of the equipment.
A total of four groups of tests were conducted in order to investigate the pulp
sucking capacity of the XCF-24 flotation machine and the influence on the pulp
sucking capacity after the rotor and cover plate are worn. The aeration rate is set
to about 1.23 m3 / (m2 min). Since the transient current of the flotation machine is
difficult to measure and record, only the maximum current value is determined when
the power consumptions are compared. The test results are shown in Table 8.22.
Table 8.22 Test on pulp sucking capacity of XCF-24 flotation machine (m3 /min)
Test No. 1 2 3 4
Test Rotor speed n = Rotor speed n = Rotor speed n = Rotor speed n =
condition 157 r/min 157 r/min 151 r/min 151 r/min
8 mm for the 15 mm for the 8 mm for the 15 mm for the
clearance clearance clearance clearance
between rotor between rotor between rotor between rotor
and cover plate and cover plate and cover plate and cover plate
Pulp 750 19.17 19.92 20.70 19.45
suction
height
850 18.16 15.02 19.81 15.82
950 19.19 17.42 17.71 16.22
1050 17.26 14.77 16.59 15.80
1150 16.62 13.42 15.17 13.18
1250 15.54 12.09 13.70 12.96
1350 13.36 10.59 11.50 11.51
Maximum 86 74 80 70
current/A
The clean water test shows that when the peripheral speed of the rotor of the
XCF-24 flotation machine is 7.5 m/s. When the aeration rate of the flotation machine
reaches 1.2 ~ 1.5 m3 /(m2 min), the aeration dispersion is good, the pulp level is
stable, and the power consumption is within the design scope.
B. Pulp tests
To investigate the separation performance of the flotation machine, a 4-month indus-

trial test investigation was carried out. The first 2 months were for the debugging
stage, the second 2 months were for the production stage and table gives a comparison
of investigation indexes (Tables 8.23 and 8.24).
The debugging index of the XCF/KYF-24 flotation machine presents an upward
trend month by month. As for the indexes in the production stage, the grade of
coarse ores and concentrates was improved by 3.91%, the rougher recovery rate was
improved by 0.9% and the total theoretical recovery rate was improved by 1.07%.
All the indexes met the design requirements.
Table 8.23 Statistics of indexes of XCF/KYF-24 flotation machine

Time Raw ore grade Grade of coarse Raw ore grade Rougher Concentration
% ores and % recovery rate recovery rate
concentrates (%) (%) (%)
April 0.131 7.55 0.0135 89.63 96.38
May 0.133 9.88 0.0137 89.72 97.76
June 0.118 9.48 0.0107 90.95 98.32
July 0.119 9.49 0.0106 91.06 98.36
Total 0.125 9.06 0.0121 90.58 97.71
Table 8.24 Statistics of indexes of A-type flotation machine

Time Raw ore grade Grade of coarse Raw ore grade Rougher Concentration
% ores and % recovery rate recovery rate
concentrates (%) (%) (%)
April 0.133 6.37 0.0141 89.34 98.06
May 0.131 6.74 0.0137 89.59 98.25
June 0.121 6.25 0.0126 89.64 98.27
July 0.119 5.71 0.0112 90.59 98.01
Total 0.125 6.34 0.0128 89.79 98.15
8.2.3.3 Performance of the XCF-50 Flotation Machine
A. Dynamic test
The XCF-50 flotation machine is taken as the testing object and tested in terms of
its flotation dynamics in clean water, mainly including the determination of related
parameters such as aeration rate, degree of air dispersion and power. The results of
the dynamic test on the XCF-50 pneumatic mechanical agitation flotation machine
are shown in Table 8.25.
The degree of air dispersion of the XCF-50 flotation machine is greater than 2.0 at
131 r/min, which meets the requirement of air dispersion. The aeration rate reaches
1.17 m3 /(m2 min)−1 , which meets the aeration rate required for conventional mineral
separation, and the power consumption is relatively low.
B. Investigation of pulp sucking capacity
To investigate the pulp sucking capacity of the XCF-50 flotation machine, it is essen-
tial to examine and evaluate the volume of pulp sucked into the flotation machine
per unit time.
When continuous and stable feeding and discharging volumes are maintained,
the liquid level Hf of the feed box will be lower than the liquid level Hc in the
tank of the flotation machine since the XCF-50 flotation machine has certain pulp
sucking capacity, so there is a height difference Hc-Hf inside the flotation machine
and the feed box. If the flotation machine is connected with the feed box, the pulp
in the flotation machine will flow into the feed box at a certain flow rate under the
action of the pressure difference Hc-Hf. This flow rate may be manually adjusted to
maintain the pulp level in the feed box to be always in a constant state, and then the
pulp sucking capacity of the flotation machine is equal to the feed plus the volume
returned by the flotation machine to the feed box.
The pulp sucking capacity of the XCF-50 flotation machine was actually examined
and evaluated according to this scheme which indicated that the pulp sucking capacity
of the XCF-50 flotation machine was greater than 12.8 m3 /min. The flotation machine
has a stable liquid level and the good phenomenon of bubble scraping under this
condition.
Table 8.25 Dynamics test results of XCF-50 flotation machine

Speed of flotation Mean aeration rate/m3 Air dispersion Current of flotation
machine/r min−1 (m2 min) −1 machine/A
1 136 1.22 1.63 143
2 131 1.17 2.07 152
3 126 1.15 1.71 150
Fig. 8.47 XCF-70

automatic suction air-forced
flotation machine
The XCF-70 flotation machine is an automatic suction pneumatic mechanical agita-

tion flotation machine with the largest volume in the world, which has been indus-
trially applied in the Wunugetushan Concentrator, Phase II Project, China National
Gold Group Co., Ltd., as shown in Fig. 8.47. The flotation machine runs smoothly,
with stable liquid level and good air dispersion effect, and there is no fluctuation of
the pulp level on the liquid surface. In addition, the flotation machine has sufficient
pulp sucking capacity, which meets the requirements of concentrator transformation
and realizes the smooth flotation flow and qualified process indexes on the premise
of no large-scale transformation of capital construction.
References
1. Zhengchang S (1996) Development of flotation machines in China in the past 15 years. Met Ore
Dressing Abroad 4:18–19
2. Zhengchang S, Shuaixing S, Shijie L, Huilin L (2004) Development survey of flotation
equipments, nonferrous metallurgical equipment. Supplements 21–26
3. Liang Dianyin Wu, Jianming SZ, Shijie Lu (2002) New development of mineral processing
equipment. Min Metall 7:12–15
4. Jonettis AJ (2001) Design, development, application and operation superiority of Outokumpu
100 m3 tankcell flotation machine. Met Ore Dressing Abroad 5:30–34
5. Oravaiyinia X (2002) Research and development of Outokumpu flotation machine. Met Ore
Dressing Abroad 4:32–34
6. Outokumpumintee (1994) Theory research and practice of Outokumpu flotation. Nonferrous
Mines (5):31–35
7. Burgess FL (1997) OK100 tank cell operation at Pasminco—broken hill. Miner Eng 7:723–741

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Chapter 8

BGRIMM Pneumatic Mechanical

© Metallurgical Industry Press 2021 263

8.1 KYF Pneumatic Mechanical Agitation Flotation

8.1.1 Working Principle and Key Structures of KYF Flotation

Fig. 8.1 KYF flotation machine

8.1.1.1 Working Principle

8.1.1.2 Key Structures

Fig. 8.2 Rotor of KYF flotation machine

Fig. 8.4 Stator of KYF

Fig. 8.5 Dual crowder and

1-outer launder 2-inner launder and crowder

Table 8.1 Technical parameters of KYF flotation machine

8.1.2 Fluid Dynamics Research in KYF Flotation Machines

8.1.2.1 Flow Field Characteristics of KYF Flotation Machines

Fig. 8.6 Velocity vectors of

(a) Velocity vector diagram (b) Velocity cloud picture

Fig. 8.7 Flow pattern of the lab-scale KYF-0.2 flotation machine

Fig. 8.8 Velocity contour on a plan below rotor lid

Fig. 8.9 Velocity vectors between rotor blades

8.1.2.2 Research on the Rotor of KYF Flotation Machine

Backward inclined rotor Radial rotor Forward inclined rotor

Fig. 8.10 Feature of KYF flotation machine rotor (top view)

(a) Test (b) CFD

Fig. 8.11 Power consumption comparison of the three rotors

8.1.2.3 Research on the Stator of KYF Flotation Machine

Fig. 8.12 Rotor blades with different inclined angles

(a) Standard stator (b) Stator with an annular reinforcing ring

Fig. 8.14 Different stator designs

(a) Standard stator (b) Stator with an annular reinforcing ring

Fig. 8.15 Flow patterns of different stator designs

8.1.3 Performance and Application of the KYF Flotation

8.1.3.1 Performance of the KYF-50 Flotation Machine

Table 8.2 Dynamics test results of KYF-50 flotation machine

grade of magnesium oxide is improved by 1.16% with a higher grade of selected

8.1.3.2 Performance of the KYF-160 Flotation Machine

To investigate the performance of the KYF-160 flotation machine, the dynamic

To investigate the pulp suspension capacity, the distribution of mineral particles at

Table 8.6 Test data of flotation dynamics tests

Fig. 8.16 Aeration rate

Fig. 8.17 Aeration rate

Fig. 8.18 Aeration rate

Fig. 8.19 Aeration rate

rougher in the original process

Table 8.8 Comparison of total system indexes (%)

The power consumption of the flotation machine is an important index to investigate

Table 8.9 Aeration rates and current change values

8.1.3.3 Performance of the KYF-200 Flotation Machine

To investigate the performance of the KYF-200 flotation machine, the dynamic

To investigate the separation performance of the two KYF-200 flotation machines,

Table 8.10 Data of dynamic test with clean water

Fig. 8.21 Air dispersion versus aeration rate

Fig. 8.22 Power consumption versus aeration rate

Fig. 8.23 Air holdup versus aeration rate

Fig. 8.24 Bubble size versus aeration rate

Table 8.11 Comparison of copper indexes in the commissioning stage (%)

The power consumption of the flotation machine is an important index to investigate

Table 8.13 Relationship between aeration rate and power

Fig. 8.25 The relationship between aeration rate and power

To investigate the pulp suspension capacity, the distribution of mineral particles at

8.1.3.4 Performance of the KYF-320 Flotation Machine

Table 8.14 Clean water test data

Fig. 8.26 Air dispersion rate versus aeration rate

Fig. 8.27 Power consumption versus aeration rate