Minerals Engineering 23 (2010) 877884

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Minerals Engineering
journal homepage: www.elsevier.com/locate/mineng

A novel scale-up approach for mechanical otation cells

J. Yianatos a,*, F. Contreras a, P. Morales b, F. Coddou b, H. Elgueta b, J. Ortz b
a
Chemical and Environmental Engineering Department, Automation and Supervision Centre for Mining Industry, CASIM, Santa Maria University, P.O. Box 110-V, Valparaso, Chile
b
Chilean Copper Corporation, CODELCO, Santiago, Chile

a r t i c l e i n f o a b s t r a c t

Article history: Planning industrial otation operation and earlier otation equipment sizing are commonly based on
Available online 1 June 2010 batch otation testing, where ideal operating conditions can be provided. Each plant has its own batch
otation standards and typically uses a time scale-up factor in order to compare laboratory and plant o-
Keywords: tation performance. However, otation scale-up is more complex, and it is not yet completely under-
Flotation cells stood.
Modeling In this work, a novel scale-up approach was developed, where the effects of the hydrodynamic regime
Scale-up
(mixing), solid segregation (effective residence time) and froth recovery on the plant otation rate were
Simulation
Flotation rate
identied and evaluated. Each effect was then described by means of correction factors applied on the
batch otation rate, which was considered the optimal condition. These factors can be determined from
laboratory and plant experimental data. This methodology was successfully applied at the rougher cop-
per otation plant of Codelco Norte Division, Codelco-Chile, for cells of 160 and 300 m3.
2010 Elsevier Ltd. All rights reserved.

1. Introduction processes occurring in the collection zone of large industrial ota-

In recent years, industrial otation cells have shown a consider-
able increase in size related to the large increase in mineral treat-
ment by otation worldwide. Due to their greater size, fewer cells
are now necessary for larger otation capacities, and lower specic
power consumption and more efcient control can be provided
using large otation cells, with signicant economical benets
(economy of scale).
1.1. Cell sizing criteria
Scale-up methods for otation cell design have been mainly
based on geometrical similitude and dimensional analysis with
the use of dimensionless numbers (air ow number, power num-
ber, specic power, etc.) in order to reach similar solid suspension
and similar pulp mixing conditions at different scales (Gorain,
2007).
At the laboratory or pilot scale, signicant effort has been ex-
pended to describe and model the collection process (e.g., Duan
et al., 2003; Nguyen and Evans, 2004), the pulp and gas dispersion
(e.g., Koh and Schwarz, 2007; Evans et al., 2008) and the froth
performance (e.g., Stevenson, 2007; Lee et al., 2005; Neethling
and Cilliers, 2003) from a fundamental point of view. Most of these
models have a large number of parameters, and they are not
directly applicable for scale-up purposes. The mass transport
* Corresponding author. Fax: +56 32 2654478.
E-mail address: juan.yianatos@usm.cl (J. Yianatos).
tion cells have been modeled by CFD in order to develop a more
fundamental description of liquid and solid dispersion (Weber
et al., 1999; Lichter et al., 2007) without gas dispersion, froth
effects and particlebubble collection processes.
1.2. Kinetic approach
Robust scale-up methods are necessary for the earlier steps of
design and the prediction of industrial otation circuit perfor-
mance from batch tests. From a metallurgical point of view, how-
ever, the scale-up problem has not been completely solved yet.
Harris and Raja (1970) found that by scaling up from the labo-
ratory to industrial cell performance, the otation rate constant
can decrease up to one order of magnitude.
Kalapudas (1985) and Arbiter (2000) have quantied the effect
of the mixing regime, i.e., from batch (plug ow equivalent) to
plant (N-perfect mixers in series), on the otation time necessary
to reach the same recovery by considering the same otation rate
constant on both scales.
Gorain et al. (1997a,b) and Alexander et al. (2000) suggested the
use of the bubble surface area ux as the scale-up criterion by con-
sidering a linear relationship with the otation rate. This approach
was tested for cells over 50 L, where they believe the hydrody-
namic effect (turbulence) to be less signicant.
Yianatos et al. (2003) suggested that a comparison between
batch and plant operation can be made for the optimal mineral
separation point observed from the corresponding separability
curves. This approach was validated using plant and batch test

0892-6875/$ - see front matter 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mineng.2010.05.004
878 J. Yianatos et al. / Minerals Engineering 23 (2010) 877884
data, obtained over a period of 9 months at Salvador concentrator,
Codelco-Chile. Yianatos et al. (2006) estimated a scale-up factor
from batch to plant data by considering the hydrodynamic (mix-
ing) effects separately. Results showed that the most signicant ef-
fect on the scale-up factor was attributed to the change in the
otation rate constant, and a good agreement was found with
other results from the literature. However, in their study, the time
estimation for high recoveries can introduce a larger uncertainty in
both scales.
Dobby and Savassi (2005) presented the Flotation Economic
Evaluation Tool (FLEET) modeling technique for scale-up from
batch otation using the MinnovEX Batch Flotation Testwork
(MFT). In this approach, the otation rate distribution (k-distribu-
tion) at the laboratory scale was characterized by a Weibull (Ro-
sinRammler) distribution, which is commonly used for particle
size distribution modeling. Each class in the k-distribution contains
particles of different sizes and different mineral liberation. Savassi
(2005) reported a compartment model describing the mass trans-
port in an industrial otation cell. The model considers three zones
(collection, quiescent and froth) and two transport mechanisms
(true otation and entrainment). The otation rate distribution in
the collection zone was represented by the same rate constant dis-
tribution obtained from the standard batch test MFT. Additionally,
three parameters were used to characterize the cell performance:
the effective collection volume VC to represent the effective collec-
tion zone residence time, the entrainment factor ENT to describe
the solid entrainment, and the froth recovery RF to quantify the
froth zone performance. For plant modeling, a sensitivity analysis
of the froth recovery and gangue entrainment, as a linear relation-
ship of the water recovery, must be performed. Nevertheless, the
use of linear relationships and three empirical parameters con-
strain the model prediction for other conditions different than
those observed during the model calibration.
Amelunxen and Amelunxen (2009a,b) recently reported a
methodology that considers a batch otation sampling (global
and per size classes) similar to MFT. The industrial cell model con-
siders two zones: collection and froth. In this approach, the batch
otation is conducted to obtain the maximum rate constant by fast
removal of the froth zone. Additionally, an entrainment factor de-
rived from literature data (Savassi, 2005) was used to evaluate the
mineral entrainment per size class. Thus, the mineral recovery by
true otation and that by entrainment were estimated separately.
However, the entrainment characteristics can change signicantly
from one system to another (Yianatos and Contreras, 2010).
In both approaches (Amelunxen and Amelunxen, 2009a,b, and
Dobby and Savassi, 2005), the batch otation rate (true otation)
was directly applied to calculate the collection zone recovery at
the industrial scale. This procedure is not strictly valid because
the gas dispersion and collection efciency are different on the
batch and industrial scales, so the collection rate constant is also
different. The mixing condition in large cells is not perfect, and so-
lid segregation occurs, so these aspects must be taken into account
Fig. 1. The scale-up approach.
separately. To compensate for these differences, a scale-up meth-
odology is required.
In this work, a scale-up approach based on the identication of
physical dimensionless parameters to account for the effects of
froth performance, cell mixing regime and solid segregation was
developed. The scale-up model was applied for comparison be-
tween the collection efciency of two large cells (160 and
300 m3) of the copper concentrator at Codelco Norte Division,
Codelco, Chile. The hydrodynamic and metallurgical characteriza-
tion of industrial cells was performed by the diagnosis and evalu-
ation procedure for otation plants (Yianatos et al., 2010).
2. Scale-up approach
The development of a scale-up methodology is necessary for
planning the industrial otation operation and earlier equipment
sizing, which are usually based on batch otation tests. The use
of scale-up factors is required because the knowledge and mea-
surement technologies are still insufcient for a reliable prediction
of the otation plant performance from laboratory tests using
physical variables alone. The operating conditions (gas dispersion,
particle size distribution, chemical conditioning, etc.) in the labora-
tory otation tests are typically different than the plant operating
conditions.
In order to identify and evaluate the scale-up factors, the perfor-
mance of the rst cell in a rougher otation bank was compared
with the batch otation of the industrial cell feed pulp with other-
wise similar reagent conditioning and mineral characteristics. The
rst cell of the bank is more sensitive because it represents the
largest rate of change (a higher recovery in a shorter time). In this
sense, the following scale-up approach is proposed, as shown in
Fig. 1.
The scale-up relationship was developed based on dimension-
less parameters. First, a scale-up factor (n) was dened as the ratio
between the actual otation rate (kAC) of the collection zone in a
perfectly mixed industrial cell (N = 1) and the otation rate (kB)
in a laboratory batch cell,
kAC
n 1
kB
The apparent otation rate constant for the overall cell (kAPP) is
described in terms of the actual otation rate constant (kAC) in the
collection zone, the froth effect (a), the cell mixing effect (b) and
the particle segregation effect (c), by Eq. (2).
kAPP kAC  a  b  c 2
Combining Eqs. (1) and (2), the ratio between the apparent otation
rate constant (kAPP) and the batch otation rate constant (kB) can be
described by Eq. (3).
kAPP
nabc 3
kB
 J. Yianatos et al. / Minerals Engineering 23 (2010) 877884
The ratio between the plant otation time sP and the batch otation
time sB is described by Eq. (4) (Yianatos et al., 2006).
sP k B
uN; g
sB kAPP
where u represents the effect of mixing in terms of batch otation
considering N perfect mixed cells in series (for a single cell, typically
N = 0.81.3) with dimensionless recovery g = R/RMAX, and RMAX is the
maximum recovery.
2.1. Froth recovery effect: a
The froth effect, a factor, is dened as the ratio between the
apparent otation rate constant (kAPP) and the collection zone rate
constant (kC) in an industrial otation cell, assuming perfect mix-
ing (N = 1),
kAPP
a 5
kC
Notice that other authors (e.g., Finch and Dobby, 1990; Gorain et al.,
1998) assume that the factor a, i.e., the ratio of kAPP to kC (Eq. (5)), is
equivalent to the froth recovery, RF. However, this approach is not
valid when the maximum recovery, RMAX, is different than 100%,
which is the case, for example, for coarse particles.
2.2. Cell mixing effect: b
The cell mixing effect b, Eq. (6), is described by the ratio be-
tween the u function of the cell operating as a perfect mixer
(N = 1) and the u function corresponding to the equivalent number
of perfect mixers representing the actual cell (N 1) at the same
dimensionless g recovery.

uN 1
b 6
uN 1g
2.3. Solids segregation effect: c
The solid segregation c effect, Eq. (7), is dened as the ratio be-
tween the effective solid residence time (sS) and the effective li-
quid residence time (sL) in the industrial cell.
sS
c 7
sL
3. Experimental procedure
3.1. Hydrodynamic characterization
3.1.1. Flowrate distribution measurement
In order to estimate the actual residence time in a large opera-
tion with several rougher lines, the actual owrate distribution of
the feed pulp on the parallel otation lines must be evaluated. This
was the case in the otation plant where the present study was
developed. The owrate distribution was evaluated by the radioac-
tive tracer technique. Liquid and solid tracers were injected into
the common rougher distribution box, and on-line data acquisition
from the tailings stream of each rougher line was simultaneously
recorded; see Fig. 2 (Yianatos et al., 2009a).
3.1.2. Residence time distribution measurement (mean residence time)
The residence time distribution of single cells and a bank of
cells, were obtained by the radioactive tracer technique for global
solids, solids at three size classes (+150; +75 150; +45 75; and
45 lm) and liquid, as described by Yianatos et al. (2008a,
2009b). From the RTD measurements, the effective mean residence
time was calculated for the industrial cells.
879
4
Fig. 2. Sensor locations for owrate distribution measurement in a rougher circuit.
3.1.3. Effective cell volume estimation
The mean residence time, s, for single cells or banks of cells can
be obtained from residence time distribution (RTD) measurements.
Applying the radioactive tracer technique, the residence time was
calculated by deconvolution between the input and output signals
(Yianatos et al., 2009a). The effective cell volume VEFF was calcu-
lated by Eq. (8) from plant measurements (solid feed tonnage
and pulp density), where the volumetric pulp ow Q (m3/h) was
estimated, while the mean residence time s was determined from
RTD measurements.
V EFF Q  s 8
3.1.4. Solid segregation measurement
The solid segregation factor (c) was obtained as the ratio be-
tween the mean residence time of global solids and liquid, as cal-
culated from residence time distribution (RTD) measurements.
For comparative purposes, the RTD measurements for solids and li-
quid were normalized by considering the same volumetric feed
owrate.
3.2. Metallurgical characterization
3.2.1. Batch and plant otation tests
For batch kinetic evaluation, otation tests were carried out in
the metallurgical laboratory of the otation plant under standard
batch procedures. In order to estimate the scale-up factor, samples
from the plant feed stream were taken and immediately used for
batch otation tests, keeping the same pulp conditioning and the
same particle size distribution of the plant feed.
For the plant otation tests, the short-cut method was applied
(Yianatos and Henrquez, 2006). This method consists of sampling
ve points in the rougher otation circuit in order to determine the
recovery of the rst cell as well as the total otation line recovery.
The rst cell of the line was characterized to compare the collec-
tion rate with that of the batch otation tests.
Flotation rate constants were obtained for laboratory batch
tests and a single industrial cell from experimental data adjust-
ment using Eqs. (9) and (10), respectively, which consider a rectan-
gular otation rate distribution (Yianatos et al., 2006).
 
1  ekt
R RMAX 1  9
kt
 
ln1 kscell
R RMAX 1  10
kscell
For the plant cell modeling, RMAX was estimated by considering the
overall kinetics obtained by the short-cut method.
3.2.2. Overall cell recovery estimation
The overall cell recovery (ROV), Eq. (11), was obtained by ad-
justed mass balance of the sampling points around the rst cell
of the rougher line.
C  xC
ROV 11
F  xF
880 J. Yianatos et al. / Minerals Engineering 23 (2010) 877884

where C and F correspond to the solid mass owrate in the concen-
trate and feed streams, while xC and xF are the copper grades in the
concentrate and feed mass owrate, respectively.
3.2.3. Froth recovery estimation
The froth recovery, RF, can be obtained from bubble load mea-
surement (Yianatos et al., 2008b) by
C  xC
RF
k B  Q G  xB
where kB is the bubble load, QG is the volumetric gas owrate at the
pulpfroth interface, and xB is the copper grade of the collected
minerals (true otation) at the pulp/froth interface.
The mineral transport from the pulp to the froth by true ota-
tion was calculated using a USM-Bubble Load Sensor (Yianatos
et al., 2008b). This equipment allows the estimation of the bubble
load, kB, from samples of bubbleparticle aggregates taken below
the pulpfroth interface and the local gas ow measurement.
3.2.4. Collection zone recovery estimation
After the froth zone recovery (RF) was quantied, from the min-
eral transport across the pulpfroth interface, and the overall
recovery (ROV) was calculated by mass balance around the cell,
the collection zone recovery of oatable minerals (RC) was esti-
mated with Eq. (13) (Yianatos et al., 2008b).
ROV
RC
RF  ROV 1  RF
The hydrodynamic performance of both cells was also evaluated
and is described in Morales et al. (2009).
4.2. Industrial hydrodynamic characterization
For cell hydrodynamic characterization, liquid RTD for TC-300
cell and OK-160 cells were obtained by the radioactive tracer tech-
nique. For comparative purposes, data from both cells were tted
by the N mixer in the series model (Eq. (14)), and the theoretical
12
equivalent number of perfect mixers was estimated for each cell.
t N1 etN=s
Et 14
s=NN CN
Fig. 3 shows the experimental data obtained from TC-300 and OK-
160 cells and the good agreement with the RTD model (Eq. (14)).
4.3. Batch metallurgical characterization
Fig. 4 shows the batch data (triplicate) for feed samples taken
from rougher Lines 1 and 3 and the model adjustment (Eq. (9)).
4.4. Industrial metallurgical characterization
The maximum mineral recovery, RMAX, was obtained from the
total cells performance of each line by tting the tank-in-series
model, Eq. (15), as shown in Fig. 5.
!
13
1  1 kscell 1N
R RMAX 1  15
N  1kscell

4. Results and discussion
4.1. Industrial application
Metallurgical and hydrodynamic characterization of large ota-
tion cells was carried out in the rougher circuit at the copper con-
centrator of Codelco Norte Division, Chile. The concentrator
consists of two SAG mills, from which the mineral is fed to three
parallel rougher lines; each line consists of eight OK-160 cells
(160 m3) in a 2222 arrangement.
For comparative purposes, rougher Lines 1 and 3 were selected.
Rougher Line 1 was evaluated considering a single TC-300 cell in-
stalled as the rst cell of Line 1, followed by six TC-160 cells in
operation (total volume: 1260 m3), while Line 3 was evaluated
considering eight OK-160 cells (total volume: 1280 m3). Line 2
was not considered in this study.
In order to evaluate the new TC-300 cell performance, consider-
ing the OK-160 cell as the reference at the same plant conditions,
the novel scale-up approach (presented in this work) was applied.
Fig. 5 shows the otation recovery data and model adjustment (Eq.
(15)), where a good agreement was observed for both rougher o-
tation lines.
The RMAX estimation for Line 1 considered the single TC-300 cell
as an equivalent volume (Vol. TC-300 = 1.88 Vol. OK-160). The
apparent otation rate constants, kAPP, for the single TC-300 cell
(Line 1) and for the rst OK-160 cell (Line 3) were estimated by
considering perfect mixing conditions (Eq. (10)), using RMAX ob-
tained from Fig. 5 and Eq. (15).
The model parameters estimated from batch tests (using the
same feed of rougher Lines 1 and 3) and industrial cell data, consid-
ering the mean residence time per cell obtained from RTD mea-
surement, are shown in Table 1.
4.5. Estimation of dimensionless factors
4.5.1. Froth factor: a
In order to evaluate the a froth factor, the froth zone recovery
(RF) and the collection zone recovery (RC) were estimated from

0,010 0,014

Data 0,012
0,008 Data
Model 0,010 Model
0,006
E(t), 1/s

E(t), 1/s

0,008

0,004 0,006
N=0.81 N=0.79
0,004
0,002
0,002

0,000 0,000
0 200 400 600 800 1000 1200 0 200 400 600 800 1000
Time, s Time, s

Fig. 3. RTD data and adjusted models for TC-300 (left) and OK-160 (right) cells.
 J. Yianatos et al. / Minerals Engineering 23 (2010) 877884 881

100 100

80 80

Cu Recovery, %

Cu Recovery, %
60 60

40 Data L1 Data L3
40
Model Model
20 20

0 0
0 5 10 15 0 5 10 15
Time, min Time, min

Fig. 4. Batch kinetic for feed samples of rougher Lines 1 and 3 (triplicate test).

100 100

Cu recovery, %
80 80

.
Cu recovery, %.

60 60
Test 1 Test 1
40 40
Test 2 Test 2
20 20
1.88
0 0
0 2 4 6 8 0 2 4 6 8
Cell number Cell number

Fig. 5. Cumulative copper recovery in rougher Line 1 (left) and Line 3 (right).

bubble load measurements for the TC-300 and OK-160 cells. Table 2 ROV and RC, respectively. Thus, the a factor was determined accord-
shows the cell mass transport obtained from plant sample analysis ing to Eq. (5); see Table 3.
and adjusted mass balances.
Using the data presented in Table 2, the overall recovery (ROV) 4.5.2. Cell mixing factor: b
and the froth recovery (RF) were estimated using Eqs. (11) and The cell mixing factor (b) depends on the cell dimensionless
(12), respectively. Then, the collection zone recovery (RC) was esti- recovery (g) and the number of mixers (N) required to reach that
mated by Eq. (13). The apparent rate constant (kAPP) and the collec- recovery. Fig. 6 shows the relationship between the u parameter
tion zone rate constant (kC) were also estimated by Eq. (10) using and N tanks in series for two dimensionless recoveries; g = RC/RMAX.
For the TC-300 and OK-160 cells, dimensionless recoveries, g,
Table 1 were obtained from the collection zone recovery estimation. Thus,
Model parameters. the u parameter was estimated for N = 1 (ideal) and N 1 (actual)
Test Model parameters TC-300 cell OK-160 cell for both cells. Table 4 shows the dimensionless recoveries, u
Line 1 Line 3 parameters and b factor estimation (Eq. (6)) for each type of cell.
Batch 1 kB, min1 (Eq. (9)) 6.2 6.4
RMAX, % 95.8 93.7
4.5.3. Segregation factor: c
2 kB, min1 (Eq. (9)) 5.6 6.0
RMAX, % 94.6 90.7 The global solid residence time was about 90% of the liquid res-
idence time in both lines (Morales et al., 2009). Table 5 shows the
Plant cell 1 kAPP, min1 (Eq. (10)) 1.5 1.1
RMAX, % (Eq. (15)) 91.7 91.4 resulting c values according to Eq. (7).
Cell residence time, min 5.5 3.6
2 kAPP, min1 (Eq. (10)) 1.0 1.3
4.5.4. Scale-up factor: n
RMAX, % (Eq. (15)) 94.3 91.5
Cell residence time, min 4.6 2.9 The otation rate constants for batch (kB) and industrial (kAPP)
cells were obtained from kinetic tests, and the overall scale-up

Table 2
Cell mass transport at the pulpfroth interface.

Feed and concentrate Pulpfroth interface transport

Cell TC-300 OK-160 Cell TC-300 OK-160
Feed tonnage, tph 1378 1571 Sup. gas rate, JG (cm/s) 1.40 1.85
Feed grade, xF (%) 0.90 0.66 Bubble load, kB (kg/m3) 61.5 27.7
Cu feed, tph 12.5 10.4 Total mass ow, B (tph) 98.4 44.3
Cu concentrate, tph 8.0 5.2 % Cu in bubble load, xB 13.1 23.3
Conc. grade, xC (%) 25.2 21.5 Cu mass ow (tph) 12.9 10.3
882 J. Yianatos et al. / Minerals Engineering 23 (2010) 877884

parameter, kAPP/kB, was calculated. This parameter hinders the

froth, mixing and solid segregation effects, which have been quan-
tied through the dimensionless factors a, b and c. Now, isolating
these effects from the kAPP/kB relationship (Eq. (3)), the actual scale-
up factor, n = kC/kB, relating the true collection rate and the batch
otation rate, was obtained. Table 6 shows a summary of the
dimensionless factors, and the scale-up factor, n, obtained from
Eq. (3).

Table 3
Estimation of a factor.
Fig. 7. Contribution of different effects on the scale-up process.
Cell TC-300 OK-160
Overall cell recovery, ROV (%) 64.1 49.6
Froth recovery, RF (%) 62.2 50.1 Table 6. shows that the froth effect (a = 0.440.48) and then the
Collection zone recovery, RC (%) 74.2 66.3 mixing effect (b = 0.760.78) were the most signicant effects on
RMAX (%) 91.7 91.5 the nal scale-up factor.
kAPP (overall) min1 1.5 1.3
kC (collection) min1 3.2 2.9
Fig. 7 shows the contribution of each effect on the scaling up
process.
a Factor 0.48 0.44

4.6. Simulation

10 In order to evaluate the new TC-300 in comparison with the OK-

160, the novel scale-up approach was applied for simulating a
8 =0,83 (TC-300) rougher otation circuit consisting of eight OK-160 cells versus a
otation circuit consisting of ve TC-300 cells. Metallurgical per-
6 =0,74 (OK-160)
formance simulation was developed by considering the mineral
N=0.81 represented by the batch otation rate, kB = 6.1 min1 (rectangular
4
model). For this batch otation rate, the scale-up factor (n) and the
dimensionless factors (a, b, c obtained from plant data (see Table 6)
2 N=0.79
were applied to estimate the apparent otation rate constant (Eq.
0 (3)) for both types of cells. The same factors (a, b, c were used
0 1 2 3 4 5 for the rst cell of the bank (from the actual calibration) as well
N - tanks in series as for the following cells along the bank, but strictly these param-
eters could change downstream. Table 7 shows the resulting
Fig. 6. Estimation of the u parameter.
parameters used for the rougher otation simulation.
Fig. 8 shows the simulation results for both lines, consisting of
eight OK-160 cells and ve TC-300 cells, respectively. The use of
Table 4 time on the x-axis was required because of the different cell sizes
Estimation of b factor.
in both lines. It was observed that the line of TC-300 cells reaches
Cell TC-300 OK-160 a recovery similar to that of eight OK-160 cells near the fourth cell.
g = RC/RMAX 0.83 0.74
u, N = 1 (ideal) 2.93 2.35 4.7. Collection efciency analysis
N (actual) 0.81 0.79
u, N (actual) 3.86 3.02 Jameson et al. (1977) used a simplied theoretical analysis and
b Factor 0.76 0.79 derived a fundamental relationship for the rst-order otation rate
constant as a function of the supercial gas rate, JG, the bubble
diameter, dB, and collection efciency, EK,

Table 5
JG
k 1:5EK 16
Estimation of c factor (duplicate). dB
Cell TC-300 OK-160 Eq. (16) has been successfully validated by experimental testing on
sS 4.9 4.1 3.2 2.6 the laboratory (Hernandez-Aguilar et al., 2005) and plant scale
sL 5.5 4.6 3.6 2.9
sS =sL 0.891 0.891 0.889 0.897
c Factor 0.89 0.89 Table 7
Simulation parameters.

Cell TC-300 OK-160

Nominal volume, m3 300 160
Table 6 Effective volume, m3 270.3 144.2
Dimensionless parameters and scale-up factors. Cell number 5 8
Effective total volume, m3 1351.5 1153.6
Cell kAPP/kB a Froth b Mixing c Segregation n = kC/kB scale-up
Time per cell, min 5.5 2.9
factor
Time per line, min 27.5 23.2
TC-300 0.24 0.48 0.76 0.89 0.75 kAPP (min1) 1.47 1.28
OK-160 0.21 0.44 0.79 0.89 0.68 RMAX (%) 92 92
 J. Yianatos et al. / Minerals Engineering 23 (2010) 877884
Fig. 8. Flotation circuit simulation: comparison between TC-300 and OK-160 cells.
Table 8
Scale-up factor n and SB.
Celdas n = kC/kB SB (m2/s/m2)
TC-300 0.75 44.5
OK-160 0.68 41.7
(Gorain et al., 1997a,b). The otation rate constant can be expressed
in terms of the bubble surface area ux, SB, by Eq. (17).
EK
k SB
4 2009, Chile (December), pp. 347355.
Considering the same mineral for the batch operation (equal kB) and
replacing Eq. (17) in Eq. (1) give Eq. (18).
nTC300 EK TC300 SBTC300
nOK160 EK OK160 SBOK160
Table 8 shows the scale-up factor and SB values (Morales et al.,
2009) estimated for the TC-300 and OK-160 cells using experimen-
tal plant data.
Substituting the values from Table 8 into Eq. (18), the collection
efciency ratio for both types of cell is
EK TC300
1:0
EK OK160
This result shows that both cells present similar behavior in terms
of collection efciency for the conditions tested.
The new scale-up approach has been successfully validated by
comparison of batch otation results with industrial single cell o-
tation performance (rst rougher cell) treating the same feed pulp.
Application of the scale-up approach in designing of a new circuit,
for which no industrial data are available, requires the knowledge
of the expected feed particle size distribution (considering the
hydrocyclon effect) and chemical conditioning in the future plant
feed, in order to prepare the batch feed pulp to perform the corre-
sponding batch tests. Finally, for otation bank design, the use of a
methodology consisting of the sequential calculation of each indi-
vidual cell is recommended (Yianatos et al., 2008c). For this pur-
pose, the dimensionless factors a, b and c, accounting for the
froth, mixing and segregation effects, must be estimated for each
cell downstream from the otation bank. At present, this evalua-
tion is under development in order to generalize the application
of the new scale-up approach.
5. Conclusions
A novel approach for the scale-up of batch otation results
for plant metallurgical performance has been developed and
validated.
883
The effects of froth recovery, cell mixing and solids segregation
were identied and described by means of dimensionless factors.
The actual scale-up factor, n = kC/kB, relating the true collection
rate (kC, industrial cell) to the batch otation rate (kB) was
quantied.
The scale-up method allowed the comparison of the TC-300 and
OK-160 cell performances, where similar collection efciency be-
tween both cells was found.
The froth recovery showed the most signicant effect on the
scale-up factor for both cells.
Acknowledgements
The authors are grateful to El Teniente Division CODELCO-Chile
for providing access to its plant and for valuable assistance in the
experimental work. The funding for process modeling and control
research was provided by CONICYT, project Fondecyt 1070106,
NEIM ICM-Mideplan, Santa Maria University, Project 270522, and
the Chilean Commission of Nuclear Energy.
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