Froth Flotation- Plant Design

(Sampling & Lab Testing )

Flotation Control Objective
 F.F. Plant Design- Data Requirements & Testing

Laboratory Testing
• Batch Tests
• Continuous Process testing
Pilot Scale Testing
• Batch Tests
• Continuous Process
Industrial Scale Plant Erection and Commissioning
Laboratory Flotation Cell
Ore Microscopy Pictograph
Hallimond Tube
 Hallimond Tube
• For conducting micro-flotation tests
• Initial floatability tests are made on liberated mineral particles –
• to asses the ‘Range of suitable collectors and regulators’
• To determine the effective Ph for flotation.
• ‘Dynamic Conditions’ are present in Hallimond tube technique
• Mineral particles are held on a support of sintered glass inside the
tube containing the distilled water and the collector being tested
• Air bubbles are introduced through the sinter and all hydrophobic
mineral particles are lifted by the bubbles which burst at the water
surface allowing the particles to fall in the collecting tube.
 Batch Flotation Tests ( Important Features of Tests )
• ‘Vigorous agitation’ of the pulp to keep all solids in suspension ( Without
breaking the mineralised froth column )
• Appropriate conditioning of the pulp with Flotation Reagents ( Few
minutes to 45 minutes, before turning on Aeration )
• Stage Additions of Frother ( to control the Volume of Froth- Normal
Froth Depth is 2-6 Cm )
• Conduct Flotation in “as Dense a Pulp” as possible, consistent with
‘Good Selectivity’ and operating conditions
• Denser Pulp- Lesser Cell Volume-less reagent requirement.
• Most Commercial floats are 25%-40% solids ( General Range 8% to 60%
Solids ).
• In Batch flotation, Pulp Density varies continuously from beginning to
end as solids are removed from the froth.
 Batch Flotation Tests ( cont…)
• This continuous variation changes the concentration of reagents
( Hence the need for automatic monitoring and process control ).
• Same “quality of water” as used in the commercial plant must be
used for lab testing purposes.
• Very small quantities of reagents are required for batch tests
( Therefore reagent concentration monitoring, reagent addition are
required for a continuous operating froth flotation plant)
• Recovery of froth is sensitive to the operator technique.
• Most commercial flotation plants include at least “one cleaning stage"
in which froth is re-floated to increase its GRADE.
 Pilot Scale Tests
• Laboratory flotation tests form the “Foundation” for design of the
commercial plant.
• Pilot Scale Tests helps to:
• (a ) To provide ‘continuous operating data’ for design. Lab Tests are batch
processes.
• ( b ) Prepare large samples of “concentrate” for survey by smelters ( Penalties
or Bonuses for presence of Trace impurities )
• ( c ) Compare costs and alternative process methods.
• ( d ) Compare equipment performance.
• ( e ) Demonstrate the feasibility of the process to non-technical investors.
Laboratory and Pilot Scale data should provide the “Optimum conditions” for
concentrating the ore and the effect of CHANGE in process variables.
 Data Obtained by Testing
• “Optimum Grind size” of the Ore. ( Particle size at which the most
Economic Recovery is obtained ). A function of “Grindability and
Flotability of ore / values”.
• Readily floatable minerals can be floated well above the liberation size
of the mineral particles ( Upper size limit is 300µm & Lower size limit
is 5µm )
• ‘Quantities’ of reagents required and ‘location’ of the addition points
in the flotation circuit / Grinding circuit.
• ‘Pulp Density’ – to finalize the number of flotation cells required.
• ‘Flotation time’ – time required for separation into Concentrate and
tailings ( Particle size, reagents used, plant size etc.)
• ‘Pulp Temperature’ – affects reaction rates
 Data Obtained by Testing
• Degree of ‘Uniformity of the ore’ – Variations in Hardness,
grindability, mineral content and floatability ( To accommodate Design
variations / plant flexibility ).
• Corrosion and Erosion qualities of the ore – ( Selection of plant
construction materials – Rubber, Plastic, Steel quality etc. )
• Circuit configurations – Series and Parallel types ( Circuit flow
schemes generally evolve over a long time – not possible right in the
first attempt ).
• A Key issue in pilot plant testing – ‘Flexibility’ and ‘Consistency’ of
operations .
 Instrumentation and Control of Froth Flotation
• Requires Extensive Instrumentation for all Control Parameters ( Feed,
Reagent addition/control , Aeration , PH Moderation , Assay
Determination Etc.)
• Capital Outlay required
• Economic Benefits
• Metallurgical Benefits
• Cost- Benefit Analysis
• Management Philosophy / Long Term Objectives
• Capacities of Processing & Life of the mine / Processing Plant
Sullivan Concentrator Flowsheet
Flotation Circuit –Example Brunswick
Copper-Zinc-Tin Separation Circuit