FLOTATION KINETICS

A flotation model is similar to chemical kinetics

dN/dt =-k
1
N
1
a
- k
2
N
2
b

N - species (1 and 2) concentration
t- time
k - rate constant(s)
a, b process order
-negative sign indicates that the concentration is diminishing due to the loss
of particles being floated.
-exponents a and b signify the order of the process

Since flotation seems to depend only on particles concentration

dN/dt =-k
1
N
1
a

Model Relation
Classic first order
c = c

[1 exp (k
1
t)]
Modified first order
c = c

{1 1/(k
2
t)[1 exp (k
2
t)]}
For reactor with ideal mixing
c = c

[1 1/(1 + t/k
3
)]*
Modified for gassolid adsorption
c = c

k
4
t/(1 + k
4
t)*
Kinetics of second order
c = (c

)
2

k
5
t/(1 + c

k
5
t)
Modified second order
c = c

{1 [ln (1 + k
6
t)]/(k
6
t)}
Two rate constants
c = c

[1 { exp (k
7
t) + (1 ) exp(k
8
t)}
Distributed rate constants
c = c

[1 exp(kt) f (k, 0) dk]
0

}
* Equivalent models because k
3
= 1/k
4
.
c flotation recovery after time t,
c

maximum recovery,
fraction of particles having lower flotation rate constant, k7,
k flotation rate constant.
Flotation kinetics models
Selected kinetic equations ( recovery of a component in separation product,
max
maximum recovery of the
same component in separation product, k rate constant of separation, t separation time
Model Formula
Zeroth-order model t k = (1)
First-order model ( )
t k
e

= 1
max
(2)
First-order with rectangular distribution of
floatabilities
( )
(

=
t k
e
t k
1
1
1
max

(3)
Fully mixed reactor model
|
|
|
|
.
|

\
|
+
=
k
t

1
1
1
max

(4)
Improved gas/solid adsorption model |
.
|

\
|
+

=
t k
t k

1
max

(5)
2
3
-order model
|
|
|
|
|
.
|

\
|
|
.
|

\
|
+
=
2
max
max
2
1
1
1
1
t k


(6)
Second-order model
t k
t k

+

=
max
2
max
1
(7)
Second-order model with rectangular of
floatabilites
( ) | |
)
`

= t k
t k
1 ln
1
1
max

(8)

A. Bakalarz, J. Drzymala, 2013, Interrelation of the Fuerstenau upgrading curve parameters with kinetics of separation, Physicochemical
Problem of Mineral Processing, 49(2), 443-451
more

0
20
40
60
80
100
0 10 20 30
r
e
c
o
v
e
r
y

o
f

a

c
o
m
p
o
n
e
n
t

i
n

c
o
n
c
e
n
t
r
a
t
e
,

,

%
separation time, min
remaining components
component 1
Flotation kinetics of the whole mass and components
components (recovery vs time)
0
10
20
30
40
0 10 20 30
y
i
e
l
d

o
f

c
o
n
c
e
n
t
r
a
t
e
,

,

%
separation time, min
sum of kinetics of
component 1 and
remaining components
Flotation results plotted as a relationship between recovery of each component in
concentrate and separation time (a), yield of components forming concentrate vs.
separation time (b)
product (yield vs time)
A. Bakalarz, J. Drzymala, 2013, Interrelation of the Fuerstenau upgrading curve parameters with kinetics of separation, Physicochemical
Problem of Mineral Processing, 49(2), 443-451

0
20
40
60
80
100
0 10 20 30
r
e
c
o
v
e
r
y

o
f

c
o
m
p
o
n
e
n
t

1

i
n

c
o
n
c
e
n
t
r
a
t
e
,

1
,
c
,

%
separation time, min
component 1

0
20
40
60
80
100
0 20 40 60 80 100
r
e
c
o
v
e
r
y

o
f

c
o
m
p
o
n
e
n
t

1

i
n

c
o
n
c
e
n
t
r
a
t
e
,

1
,
c
,

%
recovery of component 2 in concentrate,

2,c
, %
ideal upgrading
i
d
e
a
l
u
p
g
r
a
d
i
n
g
Fuerstenau curve



0
20
40
60
80
100
0 10 20 30
r
e
c
o
v
e
r
y

o
f

c
o
m
p
o
n
e
n
t

2

i
n

c
o
n
c
e
n
t
r
a
t
e
,

2
,
c
,

%
separation time, min
component 2

a b

relation between flotation kinetics and upgrading curves
The kinetics of separation of feed components (a) provide separation results in the form of
the Fuerstenau upgrading curve (b).
A. Bakalarz, J. Drzymala, 2013, Interrelation of the Fuerstenau upgrading curve parameters with kinetics of separation, Physicochemical
Problem of Mineral Processing, 49(2), 443-451

c , 1
c


c , 2
c

0 1
2
3

2
0
,c
k
,c

2 1
=



|
|
.
|

\
|
=
100
2
ln
1
,c

k'
,c

(
(

+
=
2
)
2
5 1 (
1
1 100
1
,c
k
,c

)
2
100 ( 100
2
1
,c

,c
k'
,c

=



1
|
|
.
|

\
|
=
100
2
ln
1
,c

k
,c

(
(

|
|
.
|

\
|
=
k
,c

,c

100
2
100
1 100
1



(
(
(
(
(
(

|
|
.
|

\
|
|
|
.
|

\
|

=
2
100
2
100
ln 5 1
1
1 100
1
,c

k
,c

1
100
2
100
ln 100
100
2
100
ln
2
100
1

=
|
|
.
|

\
|
|
|
.
|

\
|
,c

k
,c

k
,c

2
3


(
(

+
=
2
)
2
5 1 (
1
1 100
1
,c
k'
,c

(
(
(
(
(
(

|
|
.
|

\
|
|
|
.
|

\
|

=
2
100
2
100
ln 5 1
1
1 100
1
,c

k'
,c

(
(
(
(
(
(
(

|
|
.
|

\
|

+
=
2
2
100
)
2
100 10 (
1
1
1 100
1
,c

,c
k
,c

(
(
(
(
(
(

|
|
.
|

\
|


+
=
2
)
2
100 ( 20
2
1
1
1 100
1
,c

,c
k'
,c

2
)
2
100 ( 100
2
1
,c

,c
k
,c

=



1
100
2
100
ln 100
100
2
100
ln
2
100
1

=
|
|
.
|

\
|
|
|
.
|

\
|
,c

k'
,c

k'
,c

(
(
(
(
(
(

|
|
.
|

\
|


+
=
2
)
2
100 ( 20
2
1
1
1 100
1
,c

,c
k
,c

100 ) 1 (
2
2
100
1
+

=
k
,c

,c
k
,c

ugrading curves (here Fuerstenaus) equations based on kinetics of flotation
c
c,1
recovery of component 1 in concentrate c
c,2
recovery of component 2 in concentrate
4
9
7
13
0
20
40
60
80
100
0 20 40 60 80 100
r
e
c
o
v
e
r
y

o
f

c
o
m
p
o
n
e
n
t

1

i
n

c
o
n
c
e
n
t
r
a
t
e
,

1
,
c
,

%
recovery of component 2 in concentrate,
2,c
, %
k=1.5
k=3
k=0.5
k=1
0
20
40
60
80
100
0 20 40 60 80 100
r
e
c
o
v
e
r
y

o
f

c
o
m
p
o
n
e
n
t

1

i
n

c
o
n
c
e
n
t
r
a
t
e
,

1
,
c
,

%
recovery of component 2 in concentrate,
2,c
, %
k=5
k=2
k=0.4
k=1
Theoretical shape of the separation data in the Fuerstenau plot
0
20
40
60
80
100
0 20 40 60 80 100
r
e
c
o
v
e
r
y

o
f

c
o
m
p
o
n
e
n
t

1

i
n

c
o
n
c
e
n
t
r
a
t
e
,

1
,
c
,

%
recovery of component 2 in concentrate,
2,c
, %
k=0.005
k=0.5
k=0.02
k=1
4
9 7
0
20
40
60
80
100
0 20 40 60 80 100
r
e
c
o
v
e
r
y

o
f

c
o
m
p
o
n
e
n
t

1

i
n

c
o
n
c
e
n
t
r
a
t
e
,

1
,
c
,

%
recovery of component 2 in concentrate,
2,c
, %
k=3
k=0.5
k=0.2
k=1
13
*for a suitable equation see previous slide
(more plots in A. Bakalarz, J. Drzymala, 2013, Interrelation of the Fuerstenau upgrading curve parameters with kinetics of separation,
Physicochemical Problem of Mineral Processing, 49(2), 443-451
*
Remeber: for characterizing separation results we need
either two parameter or a law governing separation and
then you can use one parameter which can be called
selectivity as in these plots selectivity k
An example of separation results approximation using the Fuerstenau plot
plant 3, trial 1
a=102.28

c,
0 20 40 60 80 100
c
r
,

0
20
40
60
80
100
c=a(100-c
r
)/(a-c
r
)
Polish copper ore lab tests with xanthate
0 20 40 60 80 100
Ec
component 2 in product 2,
%
0
20
40
60
80
100
E
c
(
c
o
m
p
o
n
e
n
t

1

i
n

p
r
o
d
u
c
t

1
)
%





ideal upgrading
F = (89/89)
no upgrading
a
=
1
0
0

Homework
Calculate the rate constant and order of a set of yield flotation data
Microlaboratory cells
Laboratory cells
Laboratory machines
Industrial machines
Mechanical
Pneumo-mechanical
Pneumatic
Pressurized (DAF)
Other (sparged hydrocyclone, ASH)


gas
magnetic stirrer
porous glass
water level
froth
product
x
gas
deflector
stirrer
flotaton product
water level
porous glass
Other laboratory flotation devices
a) cylindrical cell equipped with magnetic stirrer (Fuerstenau, 1964)
b) laboratory flotation device of Partridge and Smith, 1971
Laboratory cells
air
drive
Laboratory Mechanobr flotation machine
Laboratory Denver flotation machine
EIMCO Product Leaflets, 2000
Industrial flotation
Flotation machines are used individually and as a group (bank)
Svedala Product Handbook, 1996
Flotation machines are rectangular and circular
Constructions and impellers of flotation machines are different

Denver
Mechanobr
Fagergreen (WEMCO-EIMCO)
DENVER
Wemco-Fagergreen (V=0.085 85m
3
)
Kelly E.G., Spottiswood D.J., Introduction to mineral processing. J.Wiley& Sons, N.Jork 1985
Wemco-Fagergreen (WEMCO-EIMCO)
mechanical flotation machines
EIMCO Product Leaflets, 2000
Denver
Agitair
Metso RCS (Metso Minerals)
Outotec (Outokumpu)
X-Cell (FLSmidth Minerals)
Humbolt-Wedag
IMN Gliwice

Wills B.A., Mineral processing
technology. Pergamon Press 1983
Fragment of mechano-pneumatic flotation machine
(continueous, multi-impeller tankless Denver D-R
Pneumo-mechanic multi-tank (15m
3
each)

(Aker FM Humbold Wedag)
Humbold-Wedag Product Leaflets, 1998
t
a
i
l
i
n
g

Maszyna
jednowirnikowa
Maszyna przepywowa
wielowirnikowa
Pneumo-mechanical flotation machines IMN
New machines: large volume and output, saving energy
Flotation technologies. Outotec Leaflets 2007
Historyczny rozwj pojemnoci maszyn flotacyjnych
Outokumpu Oy Leaflets 2000
(Outokumpu OK-100, V= 100m
3

TankCell

300
300m
3
Flotation technologies, Outotec Oyj. Leaflets 2007
2012 Outotec Oyj. www.outotec.com
Outotec TankCell

500 (500m
3
)

RCS (Reactor Cell System) from 5 to 200 m
3
(Metso
Minerals/Svedala)
1-radial flow of
slurry to tank
wall
2-primary slurry
stream to
benith impeller
3-secondary
recirculation
towards upper
part of tank
Basics in mineral processing. Metso
Minerals 2003
RCS (Reactor Cell System) from 5 to 200 m
3
(Metso Minerals)
Basics in mineral processing. Metso Minerals 2003
RCS (Reactor Cell System) from 260 m
3
(Metso Minerals)
pneumo-machanic
XCELL (FLSmidth Minerals)
XCELL Flotation Machines. FLSmidth Mineralss brochure 2008.
FLOTATION COLUMNS
Metso
Outotec (Outokumpu)


Jameson Cell
Imhoflot
Pneuflot (Humbolt-Wedag)

Injection Jameson Cell
Pneumatic PNEUFLOT
Pneumatic flotation with PNEUFLOT cells HUMBOLDT WEDAG leaflet 2009
Pneumatic cell Imhoflot. Maelgwyn Mineral Service leaflet 4/06 Chile 2006
Multi-injection Imhoflot 3 (centrifugal flotation)
concentrate
tailing
feed pump
tailing pump
feed reagents
compressed
air
feed
air plus
suspension
Siemens
SIMINE Hybrid Flot
Metals and Mining, Siemens VAI, No. 1, 2011
Injection column

Dissolved air flotation (DAF)
Dissolved air flotation (DAF)
Flotation, ZWR Polkowice