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International Journal of Mineral Processing 106-109 (2012) 70–77

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International Journal of Mineral Processing


journal homepage: www.elsevier.com/locate/ijminpro

The effect of flotation variables on the recovery of different particle size fractions in
the froth and the pulp
Reza M. Rahman, Seher Ata ⁎, Graeme J. Jameson
Centre for Multiphase Processes, University of Newcastle, University Drive, Callaghan NSW 2308, Australia

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

Article history: This paper is concerned with the flotation behaviour of different particle size fractions in a flotation cell and
Received 25 November 2011 their response to changes in flotation variables. The flotation behaviour of a particle size range can be esti-
Received in revised form 27 February 2012 mated by using a common tool, flotation recovery versus particle size curve. However, interaction between
Accepted 4 March 2012
the pulp and froth phases makes it difficult to differentiate the performance of the collection zone from the
Available online 9 March 2012
froth zone. In this study, a unique device has been used to measure the flotation efficiency of different particle
Keywords:
size ranges in both the collection and froth zones simultaneously. Mixtures of fine (60 G silica, d80 = 72 μm)
Mineral processing and coarse (50 N silica, d80 = 299 μm) silica were used as feed. The influence of collector concentration, air
Flotation flow rate, froth depth, and the ratio of fine to coarse particles in the feed on both the collection and the
Particle size froth zone behaviour with respect to particle size has been investigated. The results show that the overall
Froth recovery fine particle recovery is much higher than for coarser particles and less favourable conditions for optimum
Flotation rate flotation efficiency are sufficient. The significance of the froth barrier to coarse particle flotation is also estab-
lished. The important finding of this study is that the presence of fine particles can enhance the collection of
coarse particles both in the collection and froth zones.
© 2012 Elsevier B.V. All rights reserved.

1. Introduction this range, recovery drops significantly (Anthony et al., 1975; King,
1982; Klimpel, 1997; Lynch et al., 1981; Markovic and Milosavljevic,
Froth flotation is one of the most widely used separation processes 2002; Shannon and Trahar, 1986; Trahar, 1976; Trahar and Warren,
in the mineral processing field, because of its ability to treat complex 1976; Wills, 1998). This results in an inverted U shape flotation recovery
and low grade ores where the mineral particle size is too small for versus particle size curve.
other separation techniques to be efficient. The flotation process utilises The flotation rate depends on variables such as cell hydrodynamic
the physicochemical surface properties of particles of different minerals conditions, chemical environment and the froth zone behaviour. Differ-
to effectively separate the valuable particles from the gangue compo- ent size ranges respond differently to these variables. Cell turbulence
nent. During the flotation process, hydrophobic particles are attached significantly affects the particle flotation efficiency and a suitable hydro-
to air bubbles and float upward into a froth layer where they are collect- dynamic condition in the pulp zone should prevail to provide a high rate
ed as concentrate. The hydrophilic gangue particles are left behind in of collision between bubbles and particles. Fine particles exhibit low
the pulp and finally removed as tailing. Large amounts of sulphide, collision efficiencies because of their lower mass and inertial force. Re-
oxide and phosphate ores are beneficiated using this process. Flotation cently Jameson (2010) suggested that from theoretical analysis, shear
has also been applied in some other areas like de-inking of recycling rate and bubble size in flotation vessels are the most important param-
paper, removal of oil from water and waste water treatment. eters for flotation of ultrafine particles. For coarse particles however, the
The successful operation of a flotation process depends on a number detachment process controls the maximum floatable particle size (King,
of variables. The size of the mineral particles is one of the important pa- 1982; Öteyaka and Soto, 1995; Schulze, 1984). While high shear rates
rameters and its significance in the flotation process was recognised at and turbulence provide favourable conditions for fine particle collection
an early stage (Gaudin et al., 1942; Morris, 1952; Spedden and Hannan, in the pulp zone, it has an opposite effect on capturing of coarse parti-
1948; Trahar, 1981). It is generally found that for a particular flotation cles due to the high probability detachment of particles from the sur-
system there is an optimum particle size range, usually 10–100 μm, faces of bubbles (Schulze, 1984).
where high flotation response and efficiency are observed. Outside The chemical environment in the collection zone also has an influ-
ential role. The collector is one of the major chemical reagents that is
used in the flotation process. It renders the mineral surface hydropho-
⁎ Corresponding author. Tel.: + 61 2 4921 5881; fax: + 61 2 4960 1445. bic which facilitates the attachment of the mineral particle to the air
E-mail address: Seher.Ata@newcastle.edu.au (S. Ata). bubble. However, the response of mineral particles with change in

0301-7516/$ – see front matter © 2012 Elsevier B.V. All rights reserved.
doi:10.1016/j.minpro.2012.03.001
R.M. Rahman et al. / International Journal of Mineral Processing 106-109 (2012) 70–77 71

collector concentration varies from size to size. Gaudin et al. (1931) coarse particles. This was attributed to the increase of froth stability
were the first to investigate the effect of collector adsorption for differ- in the presence of fine particles. Vieira and Peres (2007) found similar
ent particle sizes on flotation of sphalerite. They found that different results; with the addition of fine particles in the flotation system, the
particle sizes exhibited different flotation kinetics in the same chemi- recovery of medium and coarse quartz was increased. It was also
cal environment. Trahar (1981) reported that the flotation recovery of found that presence of fine particles affects the froth, decreasing the
coarse particles is more sensitive to the chemical environment than bubble size and improving the froth stability.
the fine particles. Work by Shannon and Trahar (1986) and Klimpel This study aimed to investigate the flotation response of particles in
(1997) suggested that a small amount of collector dosage is sufficient the pulp and froth zones with respect to the cell hydrodynamics and
to float the fine and intermediate size particles, whereas a high degree chemical environment. A unique device was used to measure pulp
of surface coverage by collector is required for coarser particle flotation. and froth zone efficiency simultaneously. Special attention was focused
Crawford and Ralston (1988) performed experiments with quartz par- on understanding the role of fine particles on the flotation behaviour of
ticles in the size range of 15 to 125 μm and reported that particles with coarse fractions.
an average diameter of 71 μm require only 35% of surface coated with
the collector for around 80% recovery whereas coarser 121 μm particles 2. Experimental section
need 60% of the surface to be coated to achieve the same recovery. Sev-
eral other works reported a similar result for different collector mineral 2.1. Materials
systems (Moudgil and Barnett, 1979; Robinson, 1959; Santana et al.,
2008; Suwanasing and Salman, 1970). In a recent study, Muganda et Commercial silica samples, designated 60 G and 50 N, were supplied
al. (2011) investigated the influence of particle size and surface hydro- by Unimin, Australia. The d80 sizes as measured by Malvern Mastersizer,
phobicity on flotation rates of chalcopyrite. The hydrophobicity of dif- were 72 and 299 μm respectively. A flotation feed consisting of 60 G
ferent particle sizes, as measured through contact angle, was obtained (fine) and 50 N silica (coarse) in different proportions was used in the
by thermal oxidation. It was shown that for each size fraction tested experiments. The fraction of fine in the feed was varied from 40% to
(−20+ 300 μm) there is a critical contact angle below which flotation 95%. Table 1 shows the measured particle d80 for the feed mixture
is not possible. Interestingly, an inverse relationship between the criti- containing 40%, 70%, 80% and 95% finer 60 G silica, respectively.
cal contact angle and flotation recovery was observed. The critical con- A cationic collector, dodecylamine (DDA) (>99%) obtained from
tact angle was lowest for the particle size ranges that have relatively Aldrich Chemicals was used to float silica particles. Methyl isobutyl
high flotation recovery, approximately 45° for 20–75 μm particles, and carbinol (MIBC; 4-methyl-2-pentanol) was employed as a frother
it increases significantly outside this size range. without further purification. NaOH or HNO3 was added during the
Particle size also has been reported to have an effect on froth experiments to keep the pH at 7. The concentration of dodecylamine
phase behaviour. Livshits and Dudenkov (1965) proposed that there used was well below the critical micelle concentration which is
is an optimum particle size range that promotes bubble coalescence. reported to be 0.013 M at 25 °C (Smith and Scott, 1990).
Coarse and very fine hydrophobic particles may not destroy froth
because coarse particles retard the bubble coalescence through 2.2. Experimental arrangement
slowing down the drainage of liquid present in the thin film, while
very fine particles would drain back with liquid to the pulp phase. A unique experimental device was designed and built to investi-
Tao et al. (2000) used pulverised coal in laboratory flotation experi- gate the flotation behaviour of different particle sizes, as shown in
ments and showed that particles b150 μm destabilized froth at Fig. 1(a). The apparatus consists of a cylindrical Perspex column. The
lower concentrations and stabilized it at higher concentrations, lower part of the column has a wider section, 150 mm in diameter
while particles b30 μm always exhibit froth-destructive behaviour. and 140 mm in height. This section has a tailing outlet to assist the
On the other hand, Szatkowski and Freyburger (1985) found that non-floatable particles to leave the flotation system and a radial im-
fine quartz particles rendered bubbles more resistant to coalescence peller of Rushton turbine type to prevent the particles from settling.
and promoted the production of a stable froth. Moudgil (1992) also The wider section gently tapers down to a column of 70 mm in diam-
found that coarse particles are more likely to destabilize the froth. eter at an angle of 30º with the vertical. Feed is introduced to the
Wiegel and Lawver (1986) investigated the influence of the froth column at a height of 850 mm from the base, from a cylindrical baffled
zone on coarse phosphate particle selectivity and recovery. It was vessel of volume 40 l by a peristaltic pump. To maintain the feed slurry
found that both selectivity and recovery of coarse phosphate de- in suspension, an axial impeller is mounted in the feed vessel. The
creased with an increase in froth height. Soto (1992) reported that clearance between the impeller and the bottom of the storage vessel
the froth zone was the barrier to coarse particle collection. By using is maintained T/3, with T being the diameter of the feed vessel.
a short collection zone column, it was shown that the absence of a As shown in Fig. 1(a), at the height of 1050 mm above the base,
froth zone improved the coarse phosphate recovery significantly. the flotation column widens to accommodate a dropback collector.
Use of negative bias which eliminates the froth also enhanced coarse Bubbles rise through the annular gap between the collector and the
particle collection. widened section of the column. The cross-sectional area of the annulus
In a real flotation system, a wide range of particle sizes exists from is the same as the area of the column maintaining a constant superfi-
very fine to coarse. Particles of different sizes interact with each other cial gas velocity in the device. The top of the column connects to a
and influence the flotation recovery. Lange et al. (1997) investigated froth column by a flange not shown. The height of froth layer is main-
the fine - coarse particle interaction and aggregation in the flotation tained by the height of the froth column, so a series of interchangeable
of sphalerite in a modified microflotation unit. Two size ranges of
sphalerite particles, fine (b20 μm) and coarse (38–75 μm) were
used. After conditioning with collector, fine and coarse particles ag-
Table 1
gregated to form groups of particles as large as 100 μm. The recovery
Particle size (d80) of feed mixtures for different percentages of 60 G silica.
of fine particles was significantly enhanced by such a particle aggre-
gation which is sometimes referred to as “piggy back” flotation. The Percentage of 60 G silica Particle size d80 (μm)
recovery of coarse particles was reported to be higher in the presence 40 240
of fine particles than for the system without the fine. Similarly, 70 150
Moudgil and Gupta (1989) showed that the addition of different pro- 80 119
95 80
portions of fine particles to coarse particles increased the recovery of
72 R.M. Rahman et al. / International Journal of Mineral Processing 106-109 (2012) 70–77

(a) (b)
60
froth
removal
water
froth zone

froth zone

concentrate
36

dropback
froth dropback particles
collection
chamber

dropback

dropback catcher

feed

230
840

80

pulp zone
100

70

stirrer
140

tailing

air
60
150

Fig. 1. (a) - Schematic diagram of the set-up; and (b) dropback collection chamber.

froth columns was constructed. The mouth of the dropback collector is 2.3. Experimental procedure
located just below the pulp-froth interface, so there is a clearance of
20–30 mm approximately between the interfacial zone and the top The steps that have been taken during the flotation experiment
of the collector. are similar to our previous work (Rahman et al., 2010).
The dropback collector consists of three parts (Fig. 1(b)). The In operation, particle laden bubbles arrive at the base of the froth
bottom of the device is an annular shaped collection tube which is layer and distribute themselves across the column. The bubble parti-
60 mm in diameter and works as an entrance for the bubble particle tioning in the interfacial layer is quite open, allowing froth drainage
aggregates into the device. This collection tube then diverges into a liquid to fall out of the froth and flow to the dropback collector, carry-
wider cylindrical chamber through a conical transition section. The ing particles that had disengaged from the froth layer. The height of
cylindrical chamber has two concentric tubes. The internal diameter the froth was maintained in such a way a minimal distance (20–
of the outer and inner tubes is 100 and 80 mm, respectively. The 30 mm) existed between the pulp-froth interface and the top of the
inner tube, dropback collector, collects the particles that drop off the dropback catcher. After the column reached steady state condition,
froth. The conical transition zone in between the collection tube and dropback particles were collected from the dropback collector by
the cylindrical chamber has an angle of 30º to the vertical to ensure use of a peristaltic pump, whereas the concentrate was collected by
smooth transition of bubble particle aggregates from collection tube a launder which is attached to the top of the column. A water sprin-
to the cylindrical chamber. The cylindrical chamber then converges kler system was used to assist the transfer of froth from the launder
into a froth column with 60 mm diameter at the top of the device. to sample tray. The feed, dropback, concentrate and tailing samples
The advantage of this set up is that the collection and froth zone that were collected for each experiment were dried in an oven and
recovery can be measured simultaneously. Also by conducting the the weights of the dried samples were noted. The dried samples
size analysis of dropback, concentrate, tailing and feed particles, flota- were then sieved using a series of 20, 53, 75, 106, 150, 212, 300 and
tion response of different particle sizes to the changes in chemical, 425 micron sieves. A combination of both wet and dry sieving was
hydrodynamic and other flotation parameters can be investigated. used. Wet sieving was used with a 20 micron screen to remove
R.M. Rahman et al. / International Journal of Mineral Processing 106-109 (2012) 70–77 73

ultrafines as these particles have tendency to agglomerate and block the superficial gas velocity in the froth column was 1 cm/s. The measured
opening of the sieve. Particles that were smaller than 20 micron were froth recovery and collection zone values at three collector concentra-
collected, dried and weighed. The oversize particles were dried and tions are shown in Table 2 along with the recovery of drop-back. The
screened in a mechanical vibration machine for at least 30 minutes. ratio of fine to coarse in the feed is 40%.
The retained particles on each screen were collected and weighed. The From Table 2 it is seen that the collection zone recovery increases
froth recovery and collection zone recovery were calculated as a func- with an increase in collector concentration. At 50 g/t the collection
tion of particle size. zone recovery is 58% increasing to 78% when the concentration in-
Once the weights of dried samples are known, a mass balance is creases to 200 g/t. At the same time, the froth recovery drops from
applied to calculate the overall froth and collection zone recovery 73 to 45%, for the corresponding collector dosages.
using Rf = [C/(C + D)]× 100 and Rc = [(C + D)/(C + D + T)] × 100 where Recovery in the collection and froth zones are given in Figs. 2 and 3,
C, D and T are the mass flow rates of the concentrate, dropback and respectively as a function of particle size. Fig. 2 shows that particles up
tailing streams respectively. to 50 μm can be floated at high rates, beyond which the recovery de-
creases rapidly with an increase in particle size. It is also evident that
2.4. Viscosity measurements with the increase in collector concentration the recovery in the pulp
phase increases, indicating that coarser particles can be removed
The rheological behaviour of the slurry containing different fine to from the cell if the particles are sufficiently hydrophobic. Despite
coarse particle ratios was measured using a Brookfield rotating type considerable improvement in the collection zone recovery of coarse
viscometer. The viscosity measurement is based on sensing the torque particles at higher collector concentrations, the froth recovery appears
required to rotate a spindle at constant speed while immersed in the to drop significantly (see Fig. 3). At high dodecylamine concentrations,
slurry. From the torque, which is proportional to the viscous drag on the particles are expected to be more hydrophobic which probably
the spindle, the slurry viscosity can be calculated. As the samples in cause the froth to destabilise to such an extent that the particles
the present study contain coarse faster settling particles, some modifi- start to fall down through the froth layer. This is consistent with pre-
cations are given to the viscosity measurement set up. The modified vious studies by Dippenaar (1982a, 1982b) and Johansson and Pugh
set up consists of a stirrer and a baffle which allows a relatively accurate (1992) which suggest that extremely hydrophobic particles can lead
measurement of slurry viscosity by keeping the particles in suspension to froth destabilisation. It is also possible that the presence of coarse
and reducing the radial flow rises from the stirring operation. The particles in the froth contributes in part to the froth instability since
beaker was equipped with four baffles equally spaced around the vessel sufficiently heavy particles can easily initiate film rupture due to
and aligned perpendicular to the vessel wall. The width of baffle was 1/ their mass. Once the particles drop out of the froth and return to the
10 of the vessel diameter. During the experiment a 500 ml beaker was liquid zone, they may be picked up by rising bubbles and re-enter
filled out with a slurry containing a mixture of coarse and fine silica the froth zone. In a continuous cell, this will lead to the establishment
particles where the slurry solid density was maintained at 20%. A partic- of an internal circulating stream between the froth and liquid phase,
ular amount of surfactant was added and the pH of the suspension was causing the cell to operate below its full capacity.
measured to ensure the slurry chemical conditions were as identical to Overall, the results strongly suggest that even though it is possible
the flotation experiment. Then the slurry was stirred by a magnetic to capture coarse particles in the collection zone, such particles possi-
stirrer for a period of time. The stirring speed was controlled in such a bly may not be retained in the froth zone. Froth phase management,
way that all the particles remained in suspension. Once the particles therefore becomes extremely important for the recovery of coarse
were in suspension the stirring process was switched off and the viscos- particles. Reducing the residence time of particles in the froth, such
ity meter spindle was allowed to rotate at a constant 12 rpm and at as by maintaining shallow froth or increasing superficial gas velocity,
steady state the viscometer dial reading was noted. While taking the might improve their survival chance. However, this would also in-
reading from the viscometer dial it is worth noting that the spindle crease more gangue recovery by entrainment which would contami-
was allowed to complete at least three complete rotations before nate the concentrate.
the dial showed steady state reading. Then viscometer dial reading
was multiplied by a conversion factor that takes into accounts the
spindle type and rpm of the spindle to estimate the viscosity in mPa.s
unit.
100
3. Results and discussion
collection zone recovery (%)

80
3.1. Effect of collector concentration

To investigate the effect of collector concentration on both collection


60
and froth recovery, experiments were carried out at three dodecyla-
mine concentrations. A mixture of 60 G (particle size d80 = 72 μm)
and 50 N silica (particle size d80 = 299 μm) was used in the experi-
40
ments. The pulp solid density was maintained at 20% (w/w) and the

50 g per ton DDA


20 100 g per ton DDA
200 g per ton DDA
Table 2
Collection zone and froth zone recoveries with respect to collector concentration. 0
0 50 100 150 200 250 300 350 400
DDA concentration Collection zone Froth zone Drop back
(g/t) recovery, Rc (%) recovery, Rf (%) (%) average particle size in band (micron)
50 58 73 27
Fig. 2. Collection zone recovery as a function of particle size for three different collector
100 70 64 36
concentrations (40% 60 G silica in feed, Jg = 1 cm/s, froth depth = 250 mm, feed rate =
200 78 45 55
280 g/min, frother dose = 20 ppm).
74 R.M. Rahman et al. / International Journal of Mineral Processing 106-109 (2012) 70–77

100 100

80 80
froth recovery (%)

froth recovery (%)


60 60

40 40 Jg 0.5 cm/s
50 g per ton DDA Jg 1 cm/s
100 g per ton DDA Jg 2 cm/s
20 200 g per ton DDA 20

0 0
0 25 50 75 100 125 150 175 200 225 250 275 0 25 50 75 100 125 150 175 200 225 250 275
average particle size in band (micron) average particle size in band (micron)

Fig. 3. Froth recovery as a function of particle size for three different collector concentra- Fig. 4. Froth recovery as a function of particle size for three different superficial air
tions (40% 60 G silica in feed, Jg = 1 cm/s, froth depth = 250 mm, feed rate = 280 g/min, velocities (70% 60 G silica in feed, froth depth = 250 mm, feed rate = 280 g/min, collec-
frother dose= 20 ppm). tor dose = 100 g/ton, frother dose = 20 ppm).

3.2. Effect of air rate depth. However a considerable improvement in overall froth recovery
is observed for shallow froth height, 10 mm. For froth depths of
Table 3 presents the recoveries of collection and froth zones for dif- 400 mm and 250 mm, the froth recovery is almost the same, around
ferent superficial air velocities (Jg). Three Jg, 0.5, 1 and 2 cm/s were 85% but it rises to 93% when the froth height is reduced to 10 mm.
used to understand the flotation behaviour of different sizes of parti- Figs. 6 and 7 show the collection and froth zone recoveries as a
cles with respect to variation in air rate. Experiments were carried function of particle size for various froth depths. From Fig. 6 it can be
out with 70% 60 G silica in the feed mixture. The froth height was seen that there is no significant change with the particle size in the
maintained at 250 mm and the concentration of collector was 100 g/t. collection zone efficiency for three froth depths. This is not surprising.
Table 3 clearly indicates that both collection and froth zone effi- In the current device the froth phase is separated from the collection
ciencies increase with an increase in superficial air velocity. At Jg zone in such a way that as soon as the particles fall out of the froth,
0.5 cm/s froth recovery was 73%. With an increase in Jg, the froth re- they are collected and removed before they have chance to go back
covery increases up to almost 90% at the highest Jg (2 cm/s) used in to liquid phase beneath it. Therefore, the concentration of particles
the study. The corresponding collection zone recovery values at 0.5 in this zone is the same at all froth thicknesses and is essentially inde-
and 2 cm/s are 77% and 95%, respectively. pendent of the phenomena occurring in the froth.
The recovery of froth and collection zones with respect to the par- The results in Fig. 7 follow the overall froth recovery result shown in
ticle size at different superficial air velocity is shown in Figs. 4 and 5, Table 4. The froth recovery curve as a function of particle size remains
respectively. It is clear from the figures that when Jg is increased there almost the same for 400 mm and 250 mm froth depth. However, for
is an improvement in the recovery of both fine and coarse particles, the 10 mm froth depth, there is a significant improvement in the recov-
although the increase is more towards the coarser size range. It is ery of coarser particles. It was observed that coarse particles tend to
also observed that the froth zone recovery responds relatively better accumulate at the base of froth in the device, presumably due to their
to the increase in Jg, which may suggest that the froth phase has a size, as they could not be retained in the upper levels of the froth. The
more determining role on the flotation behaviour of large particles
than the collection zone. The improvement in froth recovery with Jg
can be attributed to the reduction in the residence time of particles, 100
which can lessen the detachment of particles in the froth zone.
collection zone recovery (%)

3.3. Effect of froth depth 80

In order to investigate the effect of froth layer thickness on froth re-


covery and collection zone recovery, experiments were performed 60
with 10 mm, 250 mm and 400 mm froth depths while keeping other
experimental conditions the same as above. The feed consisted of Jg 0.5 cm/s
70% 60 G silica. Table 4 shows the overall collection and froth zone re- 40
Jg 1 cm/s
coveries for three different froth depths. It can be seen that there is no Jg 2 cm/s
significant change in collection zone recovery with a variation in froth
20

Table 3
Collection zone and froth zone recoveries with respect to the superficial air velocity. 0
0 50 100 150 200 250 300 350 400
Air velocity, Collection zone Froth zone Drop back
Jg (cm/s) recovery, Rc (%) recovery, Rf (%) (%) average particle size in band (micron)
0.5 77 73 27
Fig. 5. Collection zone recovery as a function of particle size for three different superfi-
1 83 85 15
cial air velocities (70% 60 G silica in feed, froth depth = 250 mm, feed rate = 280 g/min,
2 95 88 12
collector dose = 100 g/ton, frother dose = 20 ppm).
R.M. Rahman et al. / International Journal of Mineral Processing 106-109 (2012) 70–77 75

Table 4 100
Collection zone and froth zone recoveries for different froth depths.

Froth depth Collection zone Froth zone Drop back


(mm) recovery, Rc (%) recovery, Rf (%) (%)
80

froth recovery(%)
10 80 93 7
250 83 85 15
400 82 83 17 60

10 mm froth depth
40 250 mm froth depth
use of the shallow froth greatly helped the recovery of these particles. 400 mm froth depth
The implications for the flotation process are that coarse particles
should be removed as soon as they are transferred into the froth. The 20
observation that most particles detach at the interface region is in
agreement with the previous studies (Falutsu and Dobby, 1989;
Feteris et al., 1987; Vera et al., 1999). Falutsu and Dobby (1989) mea- 0
sured the particles that dropped out of the froth directly into a specially 0 25 50 75 100 125 150 175 200 225 250 275
designed flotation column using a single mineral (silica), and reported average particle size in band (micron)
that the froth recovery is independent of froth height. It is noted that
the lowest froth height employed in their study was 200 mm. Therefore, Fig. 7. Froth recovery as a function of particle size for three different froth depths
a strong relation between froth recovery and froth depth is not (Jg = 1 cm/s, 70% 60 G silica in feed, feed rate = 280 g/min, collector dose = 100 g/ton,
frother dose = 20 ppm).
expected, since detachment of particles predominantly takes place in
the narrow froth region immediately above the pulp, particularly if
the feed consists of a fully liberated single mineral. In practice, where
the flotation feed stream generally contains particles with various is 96%. Collection zone recovery also shows a similar increase with
degrees of liberation and ore types, the dependency of froth recovery increasing proportions of the finer 60 G silica. With an addition of 95%
on froth depth is expected to be more apparent. of the finer 60 G silica the collection zone recovery reaches up to 97%.
From Table 5 it is obvious that to achieve optimum flotation recovery
3.4. Effect of particle size on froth and collection zone recoveries a certain ratio of fine to coarse particles should be maintained.
The froth and collection zone recoveries with respect to the parti-
Another parameter studied here is the effect of particle size on the cle size are presented in Figs. 8 and 9, respectively. Fig. 8 shows the
froth and collection zone recoveries. Experiments were carried out froth recovery of different particle sizes as a function of finer 60 G sil-
with 40%, 70%, 80% and 95% fine, 60 G silica mixed with coarse 50 N ica in the feed. For relatively finer silica particles from 10 μm to 64 μm
silica at a constant superficial air velocity of 1 cm/s and a froth depth the froth recovery is very high and it hardly changes with a variation in
of 250 mm. The corresponding d80 of the mixtures are given in Table 1. the percentage of finer 60 G silica in the feed. However for particles
Table 5 shows the overall collection and froth zone recoveries for from 128 μm to 256 μm size, froth recovery seems to be sensitive to
different percentages of 60 G silica in the feed mixture. It can be the ratio of fine to coarse particles in the feed. With an increasing per-
seen that with an increasing percentage of finer 60 silica in the feed centage of finer 60 G silica in the feed, an increasing trend of coarse
the recovery in both zones increases. For the addition of 40% finer particles froth recovery noticeable. For example when the percentage
60 G silica in the mixture, which gives the feed particle size d80 of finer 60 G silica is 40% in the feed, only 40% of 128 μm particles are
240 μm (see Table 1) the froth recovery is around 60%. With a gradual collected as concentrate (see Fig. 8), whereas for the same experimen-
increase in the percentage of 60 G silica, an increasing trend in the tal conditions when the percentage of finer 60 G silica in the feed mix-
overall froth recovery is evident. Moreover for 95% 60 G silica (feed ture is as high as 95%, more than 90% of 128 μm particles that enter the
d80 is 80 μm) the froth recovery reaches the maximum value which froth phase are collected as concentrate. We note that the results
reported here not only include the particle recovery by attachment
or true flotation, but also those recovered by mechanical entrainment
100 which may contribute to the recovery of particles in the fine size
range. The entrainment process is more likely to apply to the fine par-
ticles as particles less than 50 μm are more prone to be carried over in
collection zone recovery (%)

80 liquid due to their relatively low mass (Smith and Warren, 1989).
The results in Fig. 8 clearly show that the presence of fine particles
is vital for the coarse particles to survive in the froth. They confirm that
60 the froth phase is responsible for the low recovery of coarse particles
observed in the present study. From flotation practice, it is known
that the stability of the froth depends significantly on the solids it
10 mm froth depth
40 250 mm froth depth contains. The presence of particles greatly affects the froth stability
400 mm froth depth by reducing bubble coalescence, thus maintaining more bubble

20
Table 5
Collection and froth zone recoveries for different percentages of 60 G silica in the feed.
0 Percentage of Collection zone Froth zone Drop back
0 50 100 150 200 250 300 350 400 60 G silica recovery, Rc (%) recovery, Rf (%) (%)
average particle size in band (micron)
40 70 64 36
70 83 85 15
Fig. 6. Collection zone recovery as a function of particle size for three different froth depths
80 91 89 11
(Jg = 1 cm/s, 70% 60 G silica in feed, feed rate = 280 g/min, collector dose = 100 g/ton,
95 97 96 4
frother dose= 20 ppm).
76 R.M. Rahman et al. / International Journal of Mineral Processing 106-109 (2012) 70–77

100 particles is concerned, it suggests that the presence of fines not only
90 affects the froth phase but also the collection zone.
The reasons for increase in the coarse particle collection rate in the
80 presence of fines are not immediately clear. One possibility is that
the presence of fine particles on the surfaces of bubbles may stabilise
70
froth recovery(%)

the air-liquid interface by restricting the surface movement or three


60 phase contact line on the particle surface. This would also reduce
the bubble surface deformation that may cause the particle to be
50
dislodged as the bubble rises up in the liquid, therefore providing
10 micron
40 36 micron more secure environment for the coarse particles to be carried out.
64 micron The particles, especially fine particles, are known to have the ability
30 90 micron to make the bubble surface rigid which resists the deformation that
128 micron may be caused by various reasons, such as turbulence or even bubble
20
181 micron
coalescence. This was recently shown by the work of Ata (2009) who
10 256 micron
analysed the effect of post rupture oscillation of a coalesced bubble on
0 the detachment of previously attached particles. The presence of par-
40 50 60 70 80 90 100 ticles, as well as frother molecules (Ata, 2011) on the interface were
percentage of finer 60G silica in feed found to largely dampen the oscillation, which in turn reduces the
number of particles detaching from the bubble surface. Theoretical
Fig. 8. Flotation response of different particle sizes in froth zone as a function of per- analysis by Stevenson et al. (2009) showed that the detachment of
centage of finer 60 G silica in the feed. Note that the froth recovery of 362 μm fraction particles during oscillation is largely due to the instability in the
does not appear in the graph due to negligible number of particles in the froth.
three phase contact line over the particle surface which is closely re-
lated to the bubble surface deformation. A similar dampening effect
is also expected with an increase in the viscosity of the fluid which
surface area throughout the froth zone. Coarse particles are believed surrounds the individual bubbles in the cell. In the present study, the
to rupture the thin films easily due to their higher mass, resulting in feed pulp density was kept constant at 20% w/w while the ratio of
froth collapse and destabilisation. In the present system the particles, fine to coarse particles was varied, possibly influencing the viscosity
especially fine particles, positioned at the air-liquid interface might of the suspension. The variation of the feed slurry viscosity with the
have made a rigid and strong structure, therefore providing a barrier percentage of fine fraction in the feed is shown Table 6. An increasing
for the coarse particles to drop out from the froth. This result is consis- trend in slurry viscosity is seen as the percentage of fine particles is in-
tent with the work of Moudgil and Gupta (1989) and Vieira and Peres creased in the slurry. The viscosity of the slurry is as low as 2.33 mPa.s
(2007) which showed that the recovery of coarse phosphate particles when the slurry has 40 percent fine particles, whereas the viscosity is
could be enhanced with the addition of fine particles which enhances increased to as high as 6.65 mPa.s when the slurry contains a signifi-
froth stability. cant proportion of fine, 95 %. Although the increase in the feed viscos-
Fig. 9 presents the collection zone efficiency for different particle ity is significant, we are not sure whether it is sufficient to lead to such
sizes. It can be seen that the recovery in this zone decreases with an a dramatic improvement in the recovery of coarse fraction in the pulp
increase in particle size, as expected. The most interesting feature of zone observed in the present work. In this regard, it is worthwhile
this graph is that the presence of more fine particles in the cell mentioning the work of Xu et al. (2010) who found that for fully liber-
appears to lead to more particles being transported to the interface ated quartz and complex locking hydrophobic particles, the detach-
level, as is also evident from the increase in the collection zone recov- ment force is higher in viscous glycerol-water than the less viscous
ery. This is very interesting, and as far as the recovery of coarse water medium, suggesting that the bubble-particle couplet is more
stable in a high viscosity environment.
Another reason for the high recovery of coarser particles in the
pulp zone observed in the present work is that the presence of fine
particles might have led to a different bubble structure in the collec-
100 tion zone that could assist the transport of coarse particles into the
90 froth layer. Indeed, in the present system it was observed that the bub-
bles arrived at the interface in the form of aggregates or clusters rather
80 than individually. A bubble cluster formation is a combination of two
collection zone recovery(%)

or more bubbles held together by particles. Thus, if a single coarse


70
particle forms a linkage between two bubbles, the net buoyancy
60 force acting on the particle is correspondingly greater than a single
particle attached to a single bubble. In the present system, fine parti-
50
10 micron cles might have played a role as binder in these bubble clusters,
40 36 micron which are more capable of transferring the attached coarse particles
64 micron to the interface easily due to their improved buoyancy in a secure
30 90 micron transporting structure. By decreasing the amount of fine particles in
128 micron
20 181 micron
256 micron Table 6
10 362 micron Slurry viscosity for different percentages of fine 60 G silica particles.
0
40 50 60 70 80 90 100 Percentage of fine 60 G silica Viscosity (mPa.s)

percentage of finer 60G silica in feed 40 2.33


70 3.48
80 5.23
Fig. 9. Flotation response of different particle sizes in collection zone as a function of
95 6.65
percentage of finer 60 G silica in the feed.
R.M. Rahman et al. / International Journal of Mineral Processing 106-109 (2012) 70–77 77

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