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Powder Technology
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a r t i c l e
i n f o
Article history:
Received 14 December 2015
Received in revised form 8 February 2016
Accepted 10 February 2016
Available online 13 February 2016
Keywords:
Froth rheology
Bubble size
Fraction of lamellae covered by solids
Flotation
a b s t r a c t
Froth otation is a widely used process of particle separation exploiting differences in surface properties. The
froth performance in a otation cell is expected to be affected by the froth rheology, as it affects the froth residence time that determines the probability of recovery of valuable minerals in the froth phase. Flotation froths
have a similar structure to the gasliquid foams whose rheology has been widely studied. However, to date,
very little work has been done in the rheology of otation froths owing to their instability and the presence of
solid particles (on bubble surfaces and in the plateau borders) that are believed to inuence froth rheology
and complicate any investigation. In this paper, the effects of froth properties on froth rheology were studied
by examining the results of 33 otation tests performed under various conditions that resulted in changes in
the froth properties and, consequently, the froth rheology. The experiments were performed in a 20 L continuous
otation cell. It was found that the bubble size and the fraction of lamellae covered by solids dened the froth
rheology, while the presence of particles in the plateau borders contributed very little to the froth rheology. A
model structure was developed by taking into account froth properties to predict froth viscosity.
2016 Elsevier B.V. All rights reserved.
1. Introduction
In otation, the froth phase plays the role of transporting the hydrophobic minerals from the collection zone to the concentrate launder.
Froth transportation consists of both vertical and horizontal motion:
the vertical motion is dened by the ow of bubbles that carry particles
moving from the pulpfroth interface to the launder lip level, while the
horizontal motion describes the motion towards the overow weir [1].
Drainage of valuable minerals occurs during froth transportation owing
to bubble bursting and bubble coalescence. Froth residence time, which
determines the probability of recovery of valuable minerals, is a function of the time bubbles take to move both vertically and horizontally.
The vertical motion is driven by the supercial gas velocity. The horizontal ow is a consequence of three factors that include the force of
gravity, the froth stability and the resistance to froth ow. The inuence
of the froth stability on the efciency of froths in recovering valuable
minerals has been extensively studied [25]. The resistance to froth
ow is supposed to be directly associated with froth rheology, and,
therefore, the importance of froth rheology on otation performance
has also been recognised. Shi and Zheng [6] and Farrokhpay [7] have
clearly shown that froth rheology can affect the froth mobility as
well as the froth stability, and ultimately inuence the otation performance. However, to date, it is not clear what froth properties affect froth rheology.
Rheology is a measure of the ow characteristics of a substance. It is
usually represented by a rheogram which plots the shear stress of a uid
Corresponding author.
E-mail address: c.li7@uq.edu.au (C. Li).
http://dx.doi.org/10.1016/j.powtec.2016.02.018
0032-5910/ 2016 Elsevier B.V. All rights reserved.
56
Fig. 1. Schematic diagram of shear rate as a function of shear stress for different types of uid.
After Mewis and Wagner [8].
in the plateau borders and vertices form the local solidliquid suspension. According to the study of suspension rheology, the solids volume
fraction in the suspension inuences the rheology [19]. Hence, whether
the solids volume fraction in the plateau borders and vertices is also a
crucial factor affecting froth rheology needs to be investigated.
Previously, the authors have investigated the effects of various otation conditions (viz. froth height, gas rate, impeller speed, feed particle
size and feed grade) on froth rheology. A Central Composite Rotatable
Design (CCRD) study was carried out, in which 33 otation tests were
performed in a 20 L continuously-operated otation cell [20]. The froth
rheology was measured using a method developed recently by the authors [21]. Ultimately, the otation conditions inuence the froth rheology through their effect on the froth properties. In this current work, the
results of the previous experiments (from the CCRD study) are examined
to fundamentally investigate the direct effect of the froth properties on
froth rheology. The froth properties of interest were identied above as
bubble size, fraction of lamellae covered by solids and the solids volume
fraction in the plateau borders and vertices. The method of evaluating
these froth properties is developed below.
2. Experimental
differs from a two phase foam in that there are also solid particles
present both as attached particles on the lamella of the bubble surface
and in the plateau borders which form between the bubbles. It is not yet
clear how the presence of solid particles affects the rheology of otation
froths. The hydrophobic particles attached on the lamellae in otation
froth function as the surfactant adsorbed on the interface lm in aqueous foam. The surfactant adsorbed on the interface lm lowers the interface tension and resists bubble coalescence, stabilizing the foam. The
presence of surfactant on the lm is characterized as its adsorbing thickness [18]. In this study, the presence of solid particles attached to the lamellae can be represented by the fraction of lamellae covered by solid
particles which takes into account the mass of solid particles attached
to the lamella per unit area and the size distribution of the solid particles. It is expected that the particles on the lamellae change the bubble
rigidity and smoothness. In addition, the particles trapped unselectively
hydrophobic particle).
Froth
height
(cm)
Supercial
gas velocity
(cm/s)
Impeller
speed
(rpm)
Chalcopyrite
particle size
P80 (m)
Copper
grade (%)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
7
6
6
8
6
6
6
6
7
7
8
7
8
8
8
6
8
7
7
8
8
6
7
5
7
7
7
7
7
7
9
7
7
1.4
1.0
1.8
1.8
1.0
1.8
1.0
1.8
1.4
1.4
1.8
1.4
1.0
1.8
1.0
1.8
1.8
1.4
1.4
1.0
1.0
1.0
1.4
1.4
0.6
1.4
1.4
1.4
1.4
2.2
1.4
1.4
1.4
900
750
1050
750
750
750
1050
1050
900
900
750
900
1050
1050
750
750
1050
900
900
750
1050
1050
900
900
900
900
1200
900
600
900
900
900
900
80
50
50
50
110
50
50
110
80
80
110
80
110
110
110
110
50
80
80
50
50
110
140
80
80
80
80
80
80
80
80
80
20
1.0
1.4
1.4
1.4
0.6
0.6
0.6
0.6
1.0
1.0
0.6
1.0
0.6
1.4
1.4
1.4
0.6
1.0
1.0
0.6
1.4
1.4
1.0
1.0
1.0
1.0
1.0
1.8
1.0
1.0
1.0
0.2
1.0
57
size and the froth velocity prole towards the cell launder lip. A single
light source was mounted above the froth surface as this results in a
single bright light on each bubble a requirement of the froth analysis
algorithm. An Anglo-Platinum bubble sizer was used to measure the
bubble size in the pulp at the end of each test.
VA
V A V cs
58
the concentrate is roughly equal to the mass ow rate of chalcopyrite from the pulp to the froth.
Rc R f
100
Rc R f 1Rc
The bubble surface area ow rate entering the froth phase can be determined by using the bubble surface area ux (Sb) which is a measure
of the fresh bubble surface area per cross-sectional area being supplied
to the cell. It is determined by the supercial gas velocity (Jg) and Sauter
mean bubble diameter (D32) as shown in Eq. (3) [27]. The cell crosssectional area (A) is known. Hence the bubble surface area ow rate in
the pulp (p) can be calculated by Eq. (4).
Sb
6J g
D32
p Sb A
Table 2
Data required for calculation.
Test
R (%)
Jg
(cm/s)
D32
(cm)
vf
(cm/s)
h
(cm)
c
(g/s)
G (%)
Vw
(cm3/s)
P50
(m)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
93.73
89.90
98.30
95.51
93.83
93.56
93.53
94.38
94.40
94.42
95.44
94.57
78.51
92.35
95.05
95.48
91.87
94.52
85.35
81.38
90.72
85.26
91.63
92.11
76.62
93.04
89.05
94.37
95.89
97.26
93.99
89.71
92.87
1.4
1.0
1.8
1.8
1.0
1.8
1.0
1.8
1.4
1.4
1.8
1.4
1.0
1.8
1.0
1.8
1.8
1.4
1.4
1.0
1.0
1.0
1.4
1.4
0.6
1.4
1.4
1.4
1.4
2.2
1.4
1.4
1.4
0.043
0.048
0.053
0.051
0.048
0.051
0.048
0.053
0.043
0.043
0.051
0.043
0.048
0.053
0.048
0.051
0.053
0.043
0.043
0.048
0.048
0.048
0.043
0.043
0.058
0.043
0.042
0.043
0.057
0.048
0.043
0.043
0.043
5.54
3.10
4.87
4.95
3.93
5.31
4.05
5.67
5.48
5.35
5.12
5.65
3.93
5.39
3.80
5.30
4.40
5.98
6.15
1.99
3.01
2.16
2.96
6.22
1.57
5.96
6.02
5.69
5.72
6.64
6.00
4.74
5.24
2.30
2.40
2.80
2.50
1.40
2.20
1.90
2.10
2.00
2.00
1.90
1.90
2.10
2.30
1.80
2.10
2.60
2.00
2.10
1.80
2.90
1.30
0.80
2.10
1.20
2.30
1.90
3.10
2.10
2.50
2.20
1.50
2.90
14.82
7.63
19.82
11.45
10.47
14.05
11.58
13.68
13.50
16.99
13.75
15.49
10.57
12.65
11.82
9.02
4.17
16.01
16.84
1.97
4.79
4.79
5.46
17.35
5.19
16.66
15.78
16.44
12.78
17.37
12.19
7.27
11.45
8.15
11.67
4.56
9.25
3.42
2.08
2.82
2.65
7.61
8.30
3.04
6.17
3.83
10.98
12.74
10.95
6.91
6.50
5.30
9.57
15.97
21.31
12.71
4.37
13.34
6.78
7.71
12.38
13.17
6.58
11.34
1.74
6.53
56.03
28.75
59.06
36.33
32.21
47.80
42.19
52.50
50.34
53.58
44.99
50.22
36.03
44.19
33.81
31.49
23.51
56.09
56.43
11.34
18.85
12.21
21.15
58.68
14.93
56.20
59.06
58.06
43.06
63.15
48.17
37.35
49.11
10.21
8.44
10.64
8.91
5.54
11.79
10.17
9.73
10.97
14.08
9.18
9.64
8.90
13.19
18.86
14.14
2.52
12.08
9.83
3.69
9.16
26.01
10.06
13.20
18.11
12.38
11.67
13.58
15.57
12.66
10.93
3.52
4.62
2:89c G
100 p
To simplify the analysis, the shape of the solid particles on the lamellae is assumed to be spherical. The mean particle size of the solids on the
lamellae (P50) is assumed to be the same as that of the sized concentrate. It is assumed that the particles exhibit a monolayer distribution
on the lamellae. Hence, the area of a particle occupying the lamella is
equal to its projected area. The fraction of the lamella covered by solids
() can be calculated by Eq. (6). Density in this equation is required to
convert the mass of chalcopyrite loaded on bubbles into a project area
(c = 4.18 g/cm3).
30; 000LB
2c P50
the plateau borders (as silica is not hydrophobic). This can be calculated
based on the concentrate mass ow rate and the copper grade. The volumetric ow rate of silica in the concentrate (Vs) is determined by
Eq. (10) by considering the silica density (s = 2.65 g/cm3). The water
volumetric ow rate in the concentrate (Vw) is measured. Finally, the
solids concentration in the plateau borders (s) can be calculated using
Eq. (11).
Vs
c 1002:89G
100 s
10
Vs Vc
Vs Vc Vw
11
4. Results
4.1. Froth rheology
The measured froth rheology data were vane speed and torque as
shown in Fig. 5. This data was converted to shear stress and shear strain
to create the standard shear stress shear rate rheograms for each experiment using a method recently proposed for doing these calculations
when using a vane style rheometer surrounded by a tube [21].
The changing slope of the torque versus vane speed relationships
is an indication that the otation froths created in the test program
are exhibiting non-Newtonian shear-thinning behaviour. Thus the apparent viscosity of the froth increases as the shear rate applied decreases. As
the shear rate is expected to be related to froth velocity which is not constant throughout the froth phase, this poses a challenge when one wants
to compare the viscosity of different froths and how it changes with froth
properties. What viscosity should be compared?
The HerschelBulkley model (Eq. (12)) has been widely used to t
foam rheograms [2931]:
n
y _
1 6V a
2 D32
Vc
2:89c G100 LB f
100 c
12
The Sauter mean bubble diameter in the froth (D32 ) is obtained from
the surface froth image analysis. The bubble surface area ow rate
overowing the lip can be calculated using Eq. (8). The factor of 1/2 in
Eq. (8) corresponds to the sharing of each lamella by two neighbouring
bubbles. Hence the mass ow rate of chalcopyrite recovered in concentrate attached to lamellae (LB f) can be calculated. The volumetric ow
rate of chalcopyrite recovered by entrainment in the plateau borders
and vertices (Vc) can be calculated using Eq. (9).
f
59
60
Eq. (12) was used to t the data of shear rates and shear stresses collected from each test. These tted results show that the yield stress of
the froth in these experiments is very low, which may be a consequence
of the measurements being performed in a owing froth. Thus yield
stress in Eq. (12) can be made to equal zero without any signicant effect on the degree of t of the results. It was therefore removed from the
equation. In addition, it is apparent viscosity (), the ratio between the
shear stress and shear rate of a uid which is the most commonly
used rheological term to evaluate the rheology of non-Newtonian
ow. By dividing both sides of Eq. (9) by shear rate, an equation can
be developed relating the froth's apparent viscosity and the shear rate
being applied (Eq. (13)).
_
n1
13
14
Fig. 7. Flow indices calculated for each test showing their 95% condence interval.
where ni is the ow index and SEni is the standard error of ni. For the
whole set of n, using the calculated average standard error (SEn =
0.08) for the n value, Eq. (14) is changed to Eq. (15) as shown below:
n1 n2
t q :
2SEn 2
15
61
Table 3
Summary of froth properties.
Test
D32 (cm)
(Pasn)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
0.9524
0.9646
0.9586
0.9736
0.9595
0.9662
0.9484
0.9646
0.9564
0.9531
0.9689
0.9564
0.9564
0.9698
0.9598
0.9789
0.9846
0.9527
0.9524
0.9863
0.9776
0.9844
0.9821
0.9499
0.9698
0.9517
0.9493
0.9495
0.9618
0.9643
0.9585
0.9682
0.956
0.91
0.89
0.81
0.86
1.00
1.23
0.94
1.09
0.92
0.97
1.15
0.97
0.80
0.86
0.82
0.93
0.76
0.84
0.84
0.78
0.71
1.01
1.07
0.94
0.90
0.87
0.88
0.82
0.93
1.00
0.86
1.15
0.87
0.014
0.0194
0.0095
0.0128
0.0119
0.0027
0.0059
0.0042
0.0111
0.0118
0.0049
0.0117
0.0084
0.0118
0.0147
0.0075
0.0128
0.0102
0.0107
0.0094
0.0154
0.0072
0.0081
0.0068
0.014
0.0108
0.0121
0.0177
0.0167
0.0074
0.0149
0.0043
0.0191
0.0835
0.0807
0.1075
0.0968
0.1058
0.0978
0.0913
0.0872
0.0851
0.0983
0.1004
0.0981
0.096
0.0871
0.1023
0.0872
0.0585
0.0911
0.0961
0.0556
0.0737
0.1028
0.0778
0.0962
0.1013
0.094
0.0847
0.0848
0.0878
0.0881
0.0774
0.0672
0.0756
1.47
2.04
1.80
1.92
1.02
2.02
1.44
1.07
1.39
1.40
1.35
1.24
1.73
1.10
1.77
1.22
1.26
1.46
1.48
1.59
1.84
0.64
0.57
1.02
1.66
1.27
0.98
1.65
1.38
1.43
1.30
0.88
1.58
D32 (cm)
(Pasn)
Mean
STDEV
CoV (%)
0.9536
0.0020
0.21
0.90
0.06
6.12
0.0115
0.0012
10.87
0.0923
0.0060
6.52
1.39
0.10
6.99
Fig. 8. Relationship between froth bubble size and the froth consistency index.
62
Fig. 9. Characteristics of a foam as the air fraction increases (a) low air fraction, (b) medium air fraction and (c) high air fraction.
distorts the ow eld and can therefore be expected to increase the energy dissipation during ow, and hence the viscosity. For such cases,
Einstein [49] developed a relationship between suspension viscosity
and the volume fraction of solids as shown in Eq. (16).
r 1 2:5s
16
where r is the relative viscosity dened as a ratio of suspension viscosity to the viscosity of suspension medium, and s is the volume fraction
of solids.
When the solids volume fraction increases to a moderate level of
about 10%, the average distance between particles becomes approximately equal to their average diameter. The interaction between pairs
of particles starts to inuence the suspension rheology by dissipating
shearing energy. The effect of particle interactions on suspension rheology is complex and can be generally expressed as a Taylor expansion in
powers of the solids volume fraction as shown in Eq. (17) [8], where ci
are expression coefcients.
r 1 2:5s c2 s 2 c3 s 3
17
Above a certain solids concentration, the suspension viscosity increases sharply due to the signicant energy dissipation resulting
from friction between particles. The suspension viscosity tends to innity when the solids volume fraction is close to the maximum where the
suspension stops owing and behaves like a solid body. In general, the
suspension viscosity increases slightly with increasing solid volume
fraction below solids concentration of about 0.50; above this value,
the suspension viscosity increases much more rapidly with increases
in solids concentration [8,46,50].
In this study, the solids concentration in the plateau borders was low
and varied in a narrow range between 5.56% and 10.75% (Fig. 13).
Therefore, it is believed that the contribution of solids concentration to
the viscosity of the suspension in the plateau borders and consequently
to the whole froth phase was low. This will result in any effect of the
solids volume fraction in the plateau borders on froth viscosity being
masked by the solids surface coverage and bubble size effects. Therefore
no clear trend was observed in Fig. 13.
5.2. Modelling froth rheology
According to the above analysis, bubble size and the fraction of lamellae covered by solids are the two important froth properties affecting the
Fig. 10. A schematic of the processes determining the lamella dynamics in sheared froth.
Fig. 11. Effect of the fraction of lamellae covered by solids on the froth consistency index.
froth rheology. Based on these ndings, the literature was reviewed with
the objective of determining an appropriate model structure that could be
used to predict froth rheology based on the underpinning mechanisms.
Princen and Kiss [10] was found to have developed a model for foam
and highly concentrated emulsions that predicts apparent viscosity as a
function of the foam or emulsion properties.
y
32:0 f 0:73 0 Ca0:5
_
18
0 R32 _
19
where R32 is the Sauter mean bubble radius and is the interfacial
tension. By substituting Eq. (19) into (18), gives:
R32 _ 0:5
0
32:0 f 0:73
:
_
0
20
63
Fig. 13. Effect of solids concentration in the plateau borders and vertices on the
consistency index of the froth.
D32 _
f 0:73
2k0
!0:5
21
Fig. 14. Comparison between the experimental and calculated apparent viscosity when
n = 0.5.
64
Fig. 15. Comparison between the experimental apparent viscosity and that predicted at
various shear rates for all the tests.
D32 _
2:44
!0:5
22
6. Conclusions
The effects of froth properties on froth rheology were investigated
under various otation conditions. The froth properties were calculated
based on several assumptions.
The froths exhibited shear-thinning behaviour that can be described
well using a power law model dened by a consistency index and a
ow index. No statistical difference was found between the tted ow
indices in the different tests. Therefore, the consistency index, which is independent of shear rate, was used to evaluate the froth rheology.
The understanding of the rheology of two-phase uids (i.e. aqueous
foams or suspensions) was consulted (and expanded upon) with the
objective of understanding the rheology of three-phase otation froths.
The results showed that the measured froth rheology could be related to
the estimated froth properties in each experiment. Bubble size had a
negative correlation with froth viscosity, which is in line with that observed in two phase dry foams. In a sheared froth, relative motion between bubbles occurs, which results in bubble deformation. The
energy dissipation rate is determined by the friction between bubbles
and the bubble surface dilatational modulus, both of which are negatively correlated to the bubble size. The fraction of lamellae covered
by solids was found to positively inuence the froth viscosity. The presence of solid particles stabilizes froth and consequently generates small
bubble sizes. In addition, the presence of particles on the lamellae will
be expected to increase the surface rigidity and bubble interfacial tension and therefore more energy will be dissipated as the bubbles are
sheared, increasing viscosity proportionally with bubble loading. No
clear relationship between froth viscosity and the solids volume fraction
in the plateau borders and vertices was observed and this was attributed to the percent of solids being low and not varying signicantly.
A model structure was developed which enables prediction of the
apparent viscosity of a three phase otation froth based on froth bubble
size, the proportion of the lamellae covered by particles and the shear
rate applied. This model was able to adequately predict the froth rheology measured in the tests performed in this study. It is hoped that this
model structure can be tted to any otation system to enable prediction of froth rheology. More work, however, is required to validate
this hypothesis. There may also be the potential to further rene this
Nomenclature
A
cell cross-sectional area (cm2)
Ca
capillary number
Sauter mean bubble diameter in the pulp (cm)
D32
D32
Sauter mean bubble diameter in the froth (cm)
G
copper concentrate grade (%)
h
froth height above discharge lip (cm)
supercial gas velocity (cm/s)
Jg
k
constant that accounts for the velocity prole of the
overowing froth
regression constant (PasNcm1)
k0
bubble loading in the froth (g/cm2)
LB
n
ow index ()
P50
mean particle diameter of chalcopyrite measured in the concentrate (m)
R
otation recovery (%)
Sauter mean bubble radius in the froth (cm)
R32
pulp recovery (%)
Rc
froth recovery (%)
Rf
bubble surface area ux in the pulp (cm2/cm2s)
Sb
velocity of the upper surface of the overowing froth (cm/s)
vf
volumetric ow rate of air overowing the lip (cm3/s)
Va
volumetric ow rate of air entering the cell (cm3/s)
VA
volumetric ow rate of chalcopyrite that is entrained in the
Vc
plateau borders and vertices (cm3/s)
concentrate slurry ow rate (cm3/s)
Vcs
volumetric ow rate of silica overowing the discharge lip
Vs
(cm3/s)
volumetric ow rate of water overowing the discharge lip
Vw
(cm3/s)
w
lip width (cm)
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