University OF Engineering and Technology, Lahore

Department of Chemical Engineering

Lab Report on Froth Flotation

Course Name and Course Code:

Ch. E203L: Particle Technology Lab

Submitted by:
Muhammad Ahmad

Registration No:
2012-MA-99

Submitted to:
Sir Umer
Particle Technology Lab Froth Flotation 2022-CH-47

Table of Contents:
1. Abstract............................................................................................................................

2. Related theory..................................................................................................................

2.1: Related Terminologies..................................................................................

2.2: Introduction...................................................................................................

2.3: Flotation Product...........................................................................................

a) Concentrate...................................................................................................

b) Tailings.........................................................................................................

2.4: Flotation Reagents........................................................................................

a) Collectors.....................................................................................................

b) Frothers........................................................................................................

c) Regulators/Modifiers....................................................................................

2.5: Types.............................................................................................................

2.6: Construction..................................................................................................

a) Froth Flotation tank......................................................................................

b) Launders.......................................................................................................

c) Air Supply....................................................................................................

d) Impeller........................................................................................................

e) Paddle mechanism........................................................................................

2.7: Working........................................................................................................

2.8: Performance indicators:..............................................................................

a) Separation Efficiency.................................................................................

b)Concentration Ratio....................................................................................

c)Recovery......................................................................................................

d)Enrichment Ratio........................................................................................

e)Ash Rejection..............................................................................................

2.9: Parameters Affecting Performance.............................................................

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a) Design parameters:.....................................................................................

b)Operating Parameters..................................................................................

c)Feed Characteristics....................................................................................

2.10: Applications..............................................................................................

2.11: Features.....................................................................................................

2.12: Limitations................................................................................................

2.13: Specifications............................................................................................

3. Procedure.......................................................................................................................

3.1: Machine Study............................................................................................

3.2: Performance................................................................................................

3.3: Calculation Formula....................................................................................

4.Observation, Calculation and Results.............................................................................

5. Discussion......................................................................................................................

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List of Figures:
Figure 1: Froth Flotation Equipment..............................................................................4
Figure 2: Concentrate Froth...........................................................................................6
Figure 3: Collector Dissolved in Aqueous Phase...........................................................7
Figure 4:Adsorption of Collector onto a Mineral Surface.............................................7
Figure 5: Construction of Froth Flotation Cell..............................................................9
Figure 6: Working of Flotation Equipment..................................................................10

List of Tables:
Table # 01: Specifications of Laboratory Flotation Tank……………………………15
Table # 02: Ash analysis on feed……………………………………………...…......16
Table # 03: Ash analysis on concentrate………………………………………....….17
Table # 04: Ash analysis on Tailings…………………………………………...…...17

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Froth Flotation

1. Abstract:
One surface-based method of separation used for enrichment is froth flotation. It is a
general-purpose, adaptable method that works with any type of material. Its main
objective is to enrich one composition of particle from another. The process of
flotation involves making precious particles more hydrophobic and boosting their
attraction to a particular reagent known as the collector. Flotation causes the feed to
separate into two product fractions: one that has more of the desirable particles and
the other that is left over with the unwanted ones. On a coal sample, we conducted a
concentration test in the lab. Analyzing the flotation cell's functioning, studying its
various components and their functions, and applying equations to compute its
performance indicators are the goals of the enrichment test. Flotation caused a 10%
increase in the amount of ash-free bulk in coal.

Figure 1: Froth Flotation Equipment

2. Related theory:
2.1: Related Terminologies:
Some important terms regarding froth flotation are:
 Hydrophobicity:

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The quality of a material that makes it repel water is called hydrophobicity. To

be hydrophobic is to have no affinity for water.
 Hydrophilicity:
Any substance that is drawn to water is said to possess hydrophilicity. It denotes a
particular affection for the water.
 Adsorption:
Adsorption is the process of forming a film or layer on an absorbent surface by
adhering to the surface of a material. The term "absorbent" refers to the substance
that the second substance adheres to.
2.2: Introduction:
Particularly in all mineral processing sectors, flotation has become a crucial process.
It is used in these industries to process low-grade ores in order to extract valuable
minerals. We must add more of such particles, for instance, when we extract a
material from Earth and it does not contain the desired mineral particles up to a
particular proportion needed by the process plant. We use froth flotation to do this.
The process of flotation involves adding feed to a water-filled tank or cell. Its
foundation is the attachment of the surface of beneficial particles to a collector,
followed by their removal from the flotation tank's top.

2.3: Flotation Product:

After flotation, we get two fractions of product; one is concentrate and second is
called tailings.

a) Concentrate:
The product distribution known as concentrate is what we gather at the top of the
flotation cell and contains a higher percentage of valuable material.

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Figure 2: Concentrate Froth

b) Tailings:
Flotation Tailings are the byproducts that remain after the targeted particles have
been enriched, and they contain a higher percentage of contaminants and a very little
amount of valuable material. To retrieve more beneficial particles, tailing might be
treated once more.
Concentrate

Feed

Flotation Tank

Tailings

Example: We have removed an ore with a mass of five tons from the Earth that
contains one ton, or twenty percent, of valuable stuff. The five tons of total mass that
were floated are separated into concentrate and tailings. Additionally, these two parts
contain the precious substance as well. A higher proportion of precious grains will be
present in the concentrate. Say there are currently 0.8 tons of useable particles in the
concentrate out of a total of 1 tons, and only 0.2 tons of pure particles are obtained in
the tailings.

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2.4: Flotation Reagents:

The reagents used in flotation are:
a) Collectors
b) Frothers
c) Regulators
a) Collectors:
The reagents known as collectors are added to the flotation tank in order to
hydrophobically coat the surface of precious grains. This allows the grains to cling to
the collector and be repelled by water, allowing for their separation during the
process. The choice of collector varies depending on the kind of substance. It is
dependent on the type of grain that needs to be gathered. For instance, diesel and
kerosene oil are utilized as collectors in the coal and other industries. The collectors
could be non-ionic or ionized. In addition, ionic collectors might be cationic or
anionic.

Figure 3: Collector Dissolved in Aqueous Phase

Figure 4:Adsorption of Collector onto a Mineral Surface

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b) Frothers:
A stable froth that forms at the top of the tank holding the concentrate slurry is what
the frother's function is in flotation. In order to handle the two operations
independently, the perfect frother should not have a collecting nature.
Common frothers are:
 Pine oil
 Cresylic acid
 Polyglycol ethers etc.
c) Regulators:
These kinds of reagents aren't good for foaming or collecting. They have only been
included to serve a few more purposes. These are further divided into:

 Activators: Occasionally, the collector is not firmly affixed to the particle surface.
To improve the collector's adsorption in this instance, a reagent is required. An
activator is a type of reagent. Serving as a link between the collector and the
grains to be separated, it acts as a bridge.
.
 Depressants: This chemical is necessary to stop unwanted particles from adhering
to the collector. For Example:
 Starch
 sodium cyanide
 PH regulators: pH regulators are added to maintain the pH of froth. Common pH
regulators are:
 soda ash
 lime
 sulphuric acid
2.5: Types:
For froth to form at the top of the flotation process, air must be introduced. Depending
on how air is injected into the cell, there are various types of flotation tanks. These
are:
a) Mechanical flotation tank
b) Pneumatic flotation tank
c) Vacuum flotation tank
d) Electro flotation tank

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e) Dissolved air flotation tank

2.6: Construction:
The construction of froth flotation equipment is very simple. Froth Flotation
equipment consists of following components:
a) Flotation tank
b) Launders
c) Impeller
d) Air supply
e) Peddle mechanism
Mechanical flotation tank is most commonly used.
a) Froth Flotation tank:
The flotation procedure is executed within this tank or cell. This tank is either long
and rectangular. The top of it has a feed port where feed is inserted into the tank..
b) Launders:
Two launders are present in commercial flotation cells to collect the residual pulp and
concentrate foam independently. The recovered pulp is then added to the subsequent
flotation cell to aid in the recovery of more desirable particles.
c) Air Supply:
In order for the hydrophobic particles to become trapped in air bubbles and be hoisted
up during the foam flotation process, air supply is necessary.
d) Impeller:
There is an impeller in the middle of the tank, and it is spinning quickly. The purpose
of the feed material that is added to the tank is to maintain the suspended particles.
Additionally, adding air causes the slurry to become more air-particle interaction and
disperses the air bubbles among the particles.
e) Paddle mechanism:
Occasionally, a paddle mechanism is also present at the top of the tank to collect the
concentrate's foam.

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Figure 5: Construction of Froth Flotation Cell

2.7: Working:
A foam flotation cell operates in a very straightforward manner. It is predicated on
how much the desired mineral and impurities wettability differs. Initially, the feed
material is added to the water-filled tank. Every particle will remain suspended if an
impeller rotates continuously. Following that, a collector is injected, attaching the
beneficial grain and turning it hydrophobic, while the hydrophilic impurities are not
drawn to the collector. We add a foaming agent to the mixture once it has had enough
time to condition, resulting in a stable froth of the target particles on top.
Subsequently, air bubbles are created in the slurry, trapping the precious particles
stuck to the collector and raising them to the top. The useable grain froth, or
concentrate, is then collected and separated from the impure particle-containing
slurry.

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Figure 6: Working of Flotation Equipment

2.8: Performance indicators:

The performance of the froth flotation process is indicated by the factors:
a) Separation Efficiency
b) Concentration Ratio
c) Recovery
d) Enrichment ratio
e) Ash Rejection
Capacity, energy consumption, recovery, and one additional element make up the
entire flotation process performance profile. Since we have floated coal samples in the
lab, the calculations for these indicators are based on ash analysis.
2.8(a) Separation Efficiency:
The ratio of the amount of material separated to the amount of material that has to be
separated is called separation efficiency.
In case of flotation, it is given by following formula:
Y (F A−C A )
Separation Efficiency= … … Eq .(i)
F A (100−F A )
where,

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FA = Ash % in Feed
CA = Ash % in Concentrate
Y = Yield which is found by:
Mass of Concentrate
Y= … … Eq .(ii)
Mass of Feed

2.8(b): Concentration Ratio:

The whole mass of the feed divided by the whole mass of the concentrate yields the
concentration ratio. The reciprocal of yield is this. At the industrial level, we need a
high concentration ratio, which implies that the concentrate's total mass should be
minimal but its concentration of important particles should be significant.
Mass of feed
Concentration ratio= … … Eq .(iii )
Mass of Concentrate

2.8(c): Recovery:
Recovery refers to the quantity of valuable material reported in the concentrate.
Mass of Valuable material∈concentrate
Recovery =
Total mass of valuable material ∈feed
Which is equal to:
Y (100−C A )
Recovery = ∗100 … … Eq .(iv)
100−F A
Industrially, we'd like to have near-100% recovery rates. Our recovery rate is often
close to 90%. Furthermore, the concentration ratio and recovery are inversely related.

2.8(d): Enrichment Ratio:

The grade of concentrate divided by the grade of feed material is known as the
enrichment ratio. Therefore, Enrichment Ratio is written as:
Grade of Concentrate
Enrichment Ratio = … … Eq .(v )
Grade of Feed
Grade of Concentrate = Valuable material percentage in concentrate
Grade of Feed = Valuable material percentage in feed
The relationship between the enrichment ratio and the recovery and concentration
ratios is inverse. The enrichment ratio will decrease as the concentration ratio
increases. Additionally, the enrichment ratio decreases as recovery increases.

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2.8(e): Ash Rejection:

Only when working with coal is Ash Rejection computed. When it comes to coal, the
gangue material is ash, and the valuable material is the ash rejection, which is
recorded as a higher proportion in the concentrate. Since coal is burned, a higher ash
percentage indicates a lower level of combustibility in the coal. Foam flotation is
therefore used to enhance coal with combustion materials. Ash rejection is computed
using:
( F ¿ ¿ A−C A )∗100
Ash Rejection = … … Eq .(vi)¿
FA

2.9: Parameters Affecting Performance:

There are 3 types of parameters that may affect the efficiency or performance of
flotation tank.
a) Design parameters
b) Operation parameters
c) Feed characteristics
These factors influence concentrate recovery and grade, which in turn impact process
performance.
2.9(a): Design parameters:
These are the fixed parameters that are chosen in accordance with specifications
during the equipment's design process. Each of the five varieties of flotation machines
has a unique design that is determined by the size of the impeller and the air jet.
2.9(b): Operating Parameters:
Operating parameters are variable and can be changed during the operation of the
machine. These are:
a) Impeller Speed
b) Collector type and dosage
c) Frother type and dosage
d) Other reagents types and dosages
e) Conditioning time
f) Process time
a) Impeller Speed:

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Impeller speed has a significant effect on flotation efficiency. Lower impeller

speed causes greater agitation in the cell, while higher impeller speed prevents
particles from remaining in suspension and causes them to settle at the tank's base,
decreasing recovery. Because of this, bubbles become disoriented and only pure,
stable bubbles are recorded in the concentration, which lowers recovery and raises
grade. (1)
b) Collector type and dosage:
Which substance to collect in concentrate is what determines a collector's decision. As
a result, there are various kinds of collectors, each with a unique impact and
recommended usage quantity. Regarding the quantity of feed material, there is an
ideal dosage for each kind of collector:
Quantity of Collector
Optimum Dosage =
Quantity of Feed
c) Frother type and dosage:
The type and dosage of the frother have an impact on the froth quality and influence
how well the flotation process works. Additionally, the kind of frother used depends
heavily on the feed material. Additionally, attention should be taken when choosing
the second amount.
d) Other reagents types and dosages:
We must inject additional chemicals, such as depressants, activators, and modifiers of
a particular type and quantity, when the collector and frother are insufficient for the
flotation process.
e) Conditioning time:
It's the window of time the collector has to hold onto the priceless grains. Longer
conditioning periods are associated with better recovery but worse grades.
f) Process time:
We refer to Process Time as the amount of time allotted for the flotation process. That
has to do with capacity. While recovery and grade will both increase, capacity will
decrease with longer process times.
2.9(c): Feed Characteristics:
The Characteristics of feed which determine the performance of flotation process are
as follows:
a) Feed particle size
b) Feed percent solids

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c) Dry feed rate

a) Feed particle size:
Only highly hydrophobic particles are observed in concentrates as feed particle size
increases, improving grade; however, because there are relatively few of these
exceptionally pure particles, recovery will be reduced.
b) Feed percent solids:
Greater the feed's percentage of solid particles, the larger the froth concentration,
which raises recovery but lowers quality.
c) Dry feed rate:
The effects of dry feed rate and feed % solids on concentrate grade and recovery are
identical. Higher concentration of solid particles in the feed indicates higher recovery
and lower grade.
2.10: Applications:
Almost any type of material can be enhanced using the selective, all-purpose method
known as foam flotation. The mineral and ore industries have made extensive use of
it. This method is applied to enrich lead, zinc, copper, nickel, sulfur, oxide, and iron
ores all over the world. Froth flotation is another method occasionally used to
concentrate gold.
2.11: Features:
Advantages of froth flotation are:
 Simple structure
 Easy handling and usage
 Reliable work
 Simple operation
 Very less maintenance requirement
 Universal applications
2.12: Limitations:
Froth flotation has some limitations as well:
 Large capacity cannot be attained with a single flotation tank due to its relatively
modest size. We must install several flotation tanks in order to achieve this.
 • It cannot be used to separate very large sized particles. Particles smaller than
150µm are required.

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2.13: Specifications:
Table # 01: Specifications of Laboratory Flotation tank

Name of Machine
Denver Flotation tank
Motor Power 0.5hp

Impeller RPM 2000

Motor RPM 1800

Feed Size Range 15+325mesh

3. Procedure:
3.1: Machine Study:
 Extensive research was conducted on the mechanism and uses of froth flotation,
including its working principle, features, advantages, and limitations..
 We also looked at the flotation tank's essential parts and how each one works.
 We became familiar with all of the technical terms used in froth flotation,
including hydrophobicity, hydrophilicity, adsorption, concentrate, and tailings.
 Extensive research was conducted on many indicators that are used to assess the
flotation performance, including recovery, enrichment ratio, concentration ratio,
ash rejection, and separation efficiency.
 Talked about the numerous operating, design, and feed variables that impact
flotation performance.

3.2: Performance:
 Measured the ash content of 50 grams of feed.
 Changed to a machine and thoroughly examined each of its components.
 Turned on the machine, fed it feed, and collected the froth that resulted from the
flotation process. After then, the foam is given time to calm.
 The froth and tailings are collected separately, then dried.
 Following this, ash analyses of the concentrate and tailings were completed, and
the findings were recorded.
3.3: Calculation Formula:
 Separation is calculated by Eq.(i):

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Y (F A−C A )
Separation Efficiency=
F A (100−F A )
 Concentration ratio is found by following Formula written in Eq(ii):
Mass of feed
Concentration ratio=
Mass of Concentrate
 Recovery is found by using:
Y (100−C A )
Recovery = ∗100
100−F A
 Formula to find enrichment ratio is:
Grade of Concentrate
Enrichment Ratio =
Grade of Feed
 Ash Rejection is calculated from Eq(vi):
( F ¿ ¿ A−C A )100
Ash Rejection = ¿
FA

4.Observation, Calculation and Results:

4.1: Observation and Calculation:
Feed Analysis:
Feed Sample = Dirty Coal
Feed Size = less than 0.2mm
Feed weight = 50g
Collector= Kerosene Oil
Frother = MIVC
Conditioning time = 2 to 3 min

Table # 02:Ash analysis on feed:

Weight of
Weight of
crucible and
Weight of crucible and Ash
sample Average
Sr. # crucible ‘A’ sample after content
before Ash %
(g) combustion ‘C’ %
combustion
(g)
‘B’(g)

1 25.05 26.04 25.82 45

39.5
2. 20.66 21.65 21.44 34

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Product Analysis:
a) Concentrate:
Weight of Concentrate = 22g

Table # 03:Ash analysis on concentrate:

Weight
Weight of crucible Weight of crucible Ash
Sr. of Average
and sample before and sample after content
# crucible Ash %
combustion 'B'(g) combustion ‘C’(g) %
‘A’(g)

1 22.58 23.58 22.88 30

29.5
2 26.96 27.96 27.25 29

b) Tailings:
Weight of tailings = 27g

Table # 04:Ash analysis on Tailings:

Weight
Weight of crucible Weight of crucible Ash
Sr. of Average
and sample before and sample after content
# crucible Ash %
combustion ‘B’(g) combustion ‘C’(g) %
‘A’(g)

1 24.97 25.97 25.56 59

58.5
2. 21.10 22.10 21.68 58

4.2: Calculations of Performance Indicators:

Mass of Concentrate
 Yield = Y= Mass of Feed
Y = 22/50
Yield = 0.44

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Y (F A−C A )
 Separation Efficiency=
F A (100−F A )
0.44(39.5−29.5)
= ∗100
39.5(100−39.5)
Separation Efficiency = 18.4 %

Mass of feed
 Concentration ratio= Mass of Concentrate

Concentration Ratio = 50/22

Concentration Ratio = 2.27

Y (100−C A )
 Recovery = ∗100
100−F A
44 ( 100−29.5 )
Recovery = ∗100
100−39.5
Recovery = 51.27%

Grade of Concentrate
 Enrichment Ratio =
Grade of Feed
Grade of Concentrate = 100-29.5=70.5
Grade of Feed = 100-39.5=60.5
Enrichment ratio=70.5/60.5
Enrichment Ratio=1.16

( F ¿ ¿ A−C A )100
 Ash Rejection = FA
¿

( 39.5−29.5 )∗100
Ash Rejection =
39.5
Ash Rejection =25.32%

5. Discussion:
5.1: Discussion on performance indicators:
a) Separation Efficiency:

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With an improvement in separation efficiency, flotation equipment becomes more

effective. The laboratory flotation tank's separation efficiency was determined to be
approximately 18.4%, although this number is significantly higher at the industrial
level. This separation efficiency number is obtained because flotation is carried out in
a smaller tank in the laboratory. Additionally, the time needed for conditioning might
not be enough for the collector to stick the useful grains.
b) Concentration Ratio:
A higher concentration ratio indicates improved flotation apparatus performance.
Compared to industrial flotation models, the concentration ratio of the laboratory
flotation cell is less than or about equivalent to 2.27. This could be as a result of
inefficiencies in the collector or variations in the design of the laboratory model.
c) Recovery:
The flotation process should have the highest possible recovery. In the business
world, it typically exceeds 90%. Less than 90% recovery suggests that the cell's
performance is not up to par. Upon doing a concentration test on a laboratory flotation
machine, we discovered that the machine's recovery was only approximately 51%,
suggesting that the desired material's mass or quantity was less concentrated than
anticipated. The tank's size, the collector's inefficiency, the shorter process time
offered, etc., could all be contributing factors.
d) Enrichment Ratio:
The ratio of valuable grains reported in concentrate to valuable grains present in feed
is called the enrichment ratio. Better flotation results from a higher enrichment ratio.
The laboratory tank's enrichment ratio was determined to be 1.16. This figure is lower
than that of industrial models, indicating a lower operational efficiency.
e) Ash rejection:
As was previously said, improved coal quality results from a reduced ash
concentration and a larger ash rejection. We therefore hope to attain more ash
rejection. The ash rejection percentage in the lab flotation tank is 25.32%. The next
step in an industry's coal use process after enrichment determines the required
percentage of ash rejection. We must float in a sequence of numerous tanks in order to
attain a better ash rejection rating.
5.2: Discussion on Experiment:
We utilized 50g of unclean coal with an ash content of 39.5% as feed for this
experiment. The collector utilized 0.2 milliliters of kerosene oil. Three minutes were

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given to the collector to condition the ash-free material to adhere to itself. Following
this conditioning period, a frother, MIVC, was injected. To make the froth rise, air
was added. Following completion of the procedure, we collected the froth from the
top and let it settle fully. We then conducted an ash analysis on both the concentrate
and the tailings, noting the results and computing the operation's performance using
several formulas.
5.3: Conclusion:
This flotation experiment led us to the conclusion that, because laboratory flotation
tanks are smaller than industrial versions, they work less efficiently overall.
Inadequate conditioning and processing time, an ineffective collector, or a little
dosage of the collector could be additional issues contributing to decreased
performance efficiency.
5.4: References:
 Smith, J. (2010). Mining Techniques: Past, Present, and Future. [Mining
Publications].
 Smith, C.D. (2018). Froth Flotation Techniques in Mining. [Springer International
Publishing].

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