207

特 別
Recent Deister Flotaire Column Flotation
講 演
Cell Developments

John A. Christophersen

INTRODUCTION

Column flotation is rapidly becoming a well developed method of mineral processing for im-
proving recovery and grade of non-metallic minerals, coal and metallic sulfide minerals. In
column flotation cells, as in mechanical flotation cells, hydrophobic (water-hating) particles attach
to air bubbles and gather as a frothy layer on top of the pulp in the cell and discharge as a
concentrated overflow product. Hydrophillic (water-loving) particles remain in solution and dis-
charge out the bottom of the cell as tailings. The similarity between column flotation cells and
mechanical flotation cells stops here.
Mechanical cells require rotating parts to create solids and air dispersion within each com-
partment. To obtain a necessary retention time of a certin feed volume, typically more than one
mechanical cell is required. As the number or volume of mechanical cells increases , so do their
air, power and maintenance requirements.
Column Flotation Cells, on the other hand do not require mechanical agitation to suspend
solids or disperse air. After a column flotation cell is properly sized for a specific rate and reten-
tion time, additional retention time can be obtained by simply adding column heighth. No in-
crease in air flow volume is required. Bubble size and distribution can be controlled and opti-
mized in a column flotation cell to obtain maximum recovery of the entire cell cross-sectional area .
These facts, proven in lab, pilot and commercial Flotaire Column Flotation Cell installations
in a wide variety of flotation applications, support the lower maintenance and operating costs in
improved mineral recovery obtained by applying column flotation .
Besides having a deep, non-turbulent collection zone, defined as that area between the lowest
aeration inlet and the feed well, column flotation cells have a deep cleaning zone comprised of the
froth layer above the pulp and that area of the pulp above the feed well.
The froth layer, typically 1'-3' (0.3-0.9 m) deep, allows use of another important feature of
column cells, namely froth washing. In a froth washing system, an evenly distributed volume of
water is introduced inside the froth near the top discharge level. The volume of froth wash water
used is determined by the volume of froth water in the froth overflow. It is desireable to obtain a
counter current flow of wash water by exceeding the rising froth water volume.
Froth washing enhances the grade of the final product obtained. Some of the gangue parti-
cles which entered into the column with the feed become entrapped with the floatable minerals or
are suspended as slimes in the water between the mineral-laden bubbles. Froth washing causes
these gangue particles to be flushed back into the pulp and eventually report to the tailings.
Several criteria are used for the design of column flotation cells, including froth loading,
*昭 和63年11月16日 本 会 第81回 例 会 に お い て 発 表
**The Deister concentrator Co., Inc.社 長 昭 和63年10月27日 受理

Vol.35,No.4('88•\“~)
(17)
208 John A. Christophersen

downward pulp velocity and retention time. These are just a few of the major factors which
play a part in obtaining the optimum level of metallurgical performance and efficiency.
The effect of bubble size on column flotation performance has been an ongoing research
subject at The Deister Concentrator Company since the first commercial Flotaire Column Flota-
tion Cells were installed. Past methods of bubble generation using aspirated air in surface
tension lowered water gave way to newer, novel methods using compressed gas and lower water
volumes. Various air distribution methods have also been extensively researched.

BACK GROUND HISTORY

The Flotaire Column Flotation Cell was first commercialized in 1977 to recover coarse and
hard-to-float phosphate minerals. In the first three years following it's introduction, fifteen com-
mercial size (8.0' dia.) as well as various diameter laboratory and pilot size units were installed
in the phosphate industry alone. These units employed hydraulic water to generate less than
.05 mm dia, air bubbles through aspiration into surface tension lowered water. These units
require at least 10 GPM (40L/min) of hydraulic water at 40 PSIG or more for each SCFM of
air. These units were not provided with froth washing. Phosphate flotation feed requires high
solids conditioning with fatty acid and collectors. In these cases, the high percentage of hydraulic
water used for air aspiration assisted in internal pulp dilution which gave the proper pulp density
for flotation and tailings pumping.
The successful application of the Flotaire in the non-metallic minerals area lead to research
and development work in coal and metallic mineral flotation areas. Due to the low solids feeds
available in metallic sulfide, coal and metallic oxide applications, the Flotaire underwent complete
redesign of the aeration methods employed. These Flotaires are known as second generation
Flotaires.
This new generation Flotaire Column Flotation Cells employs two types of aeration for the
generation of fine (less than 0.05mm dia.) bubbles : externally mounted compressed air aspirators and
internally supported porous microdiffusers. In the aspirators, pressurized, surface-tension lowered
water is aspirated into a compressed air stream to generate the majority of the fine bubbles,
which are distributed through several discharge outlets into the pulp near the bottom of the
column. The microdiffusers, using compressed air only, provides additional bubbles in the 0.1 mm
range directly into the pulp, at two levels. The intermediate level of aeration provides additional
fine bubbles in the upper recovery zone of the Flotaire.
In the second generation Flotaires, froth washing began to be utilized to further improve the
concentrate grade in the metallic sulfide applications. Froth washing has since expanded into coal
and non metallic flotation applications as well. This generation of Flotaire Column Flotation
Cells are 24'-50' (7m-15m) tall with volumes as large as 2200 cu, ft. (62 cu.m.). Pilot testing of
the these systems began in 1985. Since 1986, 28 commercial size Flotaires were installed for the
flotation of sulfide minerals such as copper, molybdenum and gold, along with coal, lithium, mica
and other minerals. During this period, numerous lab and pilot flotaires were also installed with
these aeration systems.
The use of the compressed air aspiration system permits any necessary external maintenance
to be done without disrupting the Flotaire operation. In the case of the microdiffusers, which
have an operating life of approximately 6 months before replacement, shut down of the Flotaire is

(18) 資源処理技術
 Recent Deister Flotaire Column Flotation Cell Developments 209

necessary for their removal.

Recognizing the need formicrobubble generation system which would be completely external

to the Flotaire other than the bubble distributionmeans, the Deister Concentrator Company re-

seached, developed and patented this year the new Deister Flotaire Bubble Generator System .
Additional information on the Deister Bubble Generator System will be covered later in this

paper.

APPLICATIONS AND PERFORMANCE

COPPER SULFIDE FLOTATION

The first application for the large volume second generation Flotaire Column Flotation Cells

was for copper sulfide cleaner and recleaner flotation. Nine Flotaire Cells either 8.0'dia.•~40'

tall (2.4m dia.•~12.2m tall) or 8.0'dia.•~48'tall (2.4m dia.•~14.6m tall) were installed at Copper

Mines in Arizona and Newmexico.

The operating parameters for the Flotaire Column Flotation Cells installed at plants A, B, C,
D and E are shown in the attachments. The volume feed rate to these column cells ranges from
800 GPM (3000 LPM) to 2,100 GPM (8000 LPM).
In all of these installations, froth washing water showed a concentrate grade improvement of
1-4% when the water volume increased from 0-170 GPM (645 LPM). Increasing the froth wash
water flow above this volume show little grade improvement while recovery rapidly decreases .

PLANT A COPPER RECLEANER FLOTATION

Plant A installed one 8.0'dia.•~40'tall (2.4m dia.•~12.2m tall) Flotaire Column Flotation

Cell in their plant in Arizona as a copper recleaner. This Flotaire replaced 200-300 cu, ft. (8.5

cu.m.)mechanical cells. Recovery has beenmaintained as previous levels, but the final concen-

trate grade is increased on the average of 3% copper.

Plant A Flotaire operating and design parameters are as follows :

FEED RATE 36.5 STPH (33.1mTPH), 864 GPM (3270 LPM)

TAILS RATE 16.9 STPH (15.3mTPH), 588 GPM, (2230 LPM)
CONC. RATE 19.6 STPH (17.8mTPH), 476 GPM (1800 LPM)
WASH WATER RATE 100 GPM (378 LPM)
ASPIRATOR WATER RATE 100 GPM (378 LPM)
CELL VOLUME 1800 cu, ft. (51 cu.m)
CELL AREA 50 sq, ft. (4.6 sq.m)
AIR VOLUME FLOWRATE 200 SCFM (5.7 SCMM)

PLANTS C/D COPPER CLEANER/RECLEANER FLOTATION

The Flotaire Column Flotation Cells installed at this plant (actually two columns were in-

stalled on the original side and two columns installed on the extension side) were installed to re-

place a total of 90mechanical first and second cleaner cells. The Flotaires installed were one

8.0'dia.•~48'tall (2.4m dia.•~13.4m tall) and one 8.0'dia.•~40'tall (2.4m dia.•~12.2m tall)

as shown on the schematic drawings.

Vol.35,No.4('88•\“~)
(19)
 210 John A. Christophersen

COAL FLOTATION

In a coal preparation plant in Pennsylvania, a 8.0'dia.•~17'tall (2.4m dia.•~5.2m tall)

Flotaire Column Flotation Cell is operating a single stage for the recovery of -28mesh coal.

The operating parameters for this Flotaire are shown in the attached schematic.

MOLYBDENUM SULFIDE FLOTATION

The first application of the Flotaire Column Flotationmachine for rougher sulfide flotation

utilized a 2.5'dia.•~24'tall (0.76m dia.•~7.3m tall) Flotaire operating as amoly rougher in

Arizona. This cell was enclosed for inert gas recirculation to reduce sodium hydrosulfide con-

sumption. An 8" (0.2m)•~24'(7.3m) column cell was used as a first cleaner on the Flotaire

concentrate.

molybdenite rougher recovery averaged 79.4% while ranging from 66.5 to 90.2%. Rougher
concentrate grade averaged 17.9%moS2. The cleaner cell upgraded the Flotaire concentrate to
between 58 and 78%moS2 at recoveries ranging 60 to 91%. Sodium hydrosulfide plus ammonium
sulfide depressant consumption averaged 8 lbs/ton. Prior operation ofmoly plant roughermechan-
ical cell in 1982 consumed 181bs/ton of sodium hydrosulfide copper depressant.
The second application of the Flotaire Column Flotationmachine for rougher sulfide flotation

was the operation of a 8'•~40'high (2.4m dia.•~12.2m tall) highmoly rougher in Utah. A 2.5'

dia. X25'high (0.76m dia.•~7.6m tall) Flotaire was used to clean the rougher concentrate. Both

cells are enclosed for inert gas recirculation to reduce sodium hydrosulfide depressant consumption.

Comparison of this circuit withmechanical roughers and cleaners is as follows :

FLOTAIRE CELLS MECHANICAL CELLS

%MoS2 %MoS2
Feed 1.5 1.5

Rougher Concentrate 21.8 9.2

Cleaner Concentrate 38.1 14.1

Operating parameters for this Flotaire installation are shown in the attached flowsheet.

LITHIUM CLEANER FLOTATION

One 8'dia.•~17'high (2.44m dia.•~5.18m tall) Flotaire Column Flotationmachine is operating

as a third cleaner in North Carolina. This additional cleaning upgrades final spodumene

(LiAlSi2O6) concentrates from approximately 62.5% to 66.25% spodumene for an increase in Li2O

content from 5.0 to 5.3%.

Operating parameters for this Flotaire column installation are shown in Table on page 222.

GOLD CLEANER FLOTATION

Two 3.0'dia.•~2.5'tall (0.9m dia.•~7.6m tall) Flotaire Column Flotationmachines are operat-

ing in Nevada to clean rougher concentrate containing indigenous carbon and gold contained in

pyrite and other iron sulfides. Rougher concentrate is upgraded from 0.72 oz/st Au to 3.0 oz/st

(20) 資源処理技術
 Recent Deister Flotaire Column Foltation Cell Developments 211

Au.

A third Flotaire is operating at this plant to upgrade cleaner scavenger concentrate from 0.71
oz/st to 3.0 oz/st.
Operating parameters for this plant Flotaire installation are shown in the attached flowsheet.

LEAD SULFIDE CLEANER FLOTATION

A 2.5'dia.•~24'tall (0.76m dia.•~7.3m tall) Flotaire Column Flotationmachine, operating as a

third stage lead cleaner in Sweden, gave the following results compared to conventional flotation.

FLOTAIRE CELL
LEAD % ZINC
FEED 55.5-64.0 2.0-3.8

CONCENTRATE 77.5-83.8 0.6-1.5

TAIL 36.2-58.8 2.8-5.7

RECOVERY 26.2-69.4 5.4-22.8

CONVENTIONAL CELLS
% LEAD % ZINC
FEED 62.1 3.8

CONCENTRATE 75.3 2.1

TAIL 50.4 5.44

RECOVERY 57.0 25.3

Operating parameters for Cleaner Lead Flotation

FEED RATE
Volume 5-12m3/h (22.53 GPM)
Weight 3.4-7.8mTPH (3.7-8.6 STPH)
% Solids 42%
Froth Depth 40-75 cm (16-30")
Wash Water Rate 1.5-3.6m3/h (6.6-15.9 GPM)
Aspirator Air Rate 31.4 Nm3/h (18.5 SCFM)
Aspirator Water Rate 3.4 LPM (13.0 GPM)
Frother rate 18-66 G/h (0.3-1.1ml/min)

ZINC SULFIDE CLEANER FLOTATION

A 2.5'dia. (76cu,m) Flotaire Column Flotationmachine, operating as a third stage zinc

cleaner in Sweden gave the following results compared to conventional cells :

FLOTAIRE CELL
% ZINC % LEAD
FEED 1.14 0.31

CONCENTRATE 59.4 1.08

TAIL 0.20 0.31

RECOVERY 82.70 -

Vol.35, No.4 ('88•\“~)

(21)
212 John A. Christophersen

CONVENTIONAL CELL
% ZINC % LEAD
FEED 1.05 0.31

CONCENTRATE 57.3 0.90

TAIL 0.19 0.29

RECOVERY 82.2%0 -

Operating parameters for Cleaner Zinc Flotation

Feed Rate 43.5-55.0 GPM (9.9-12.5 M3/h)

6.2-8.5 STPH (5.6-7.7 MTPH)
43% solids
Froth Depth 13-16" (33-40cm)
Wash Water Rate 4.8-7.0 GPM (1.1-1.6 M3/h)
Aspirator Air Rate 20.1 SCFM (34.2 Nm3/h)
Aspirator Water Rate 9.7 GPM (2.6 LPM)
Frother rate 30 g/h (1.0ml/min)

AERATION DEVELOPMENTS

As previously mentioned, Deister has developed and patented a new bubble generator system.

After months of testing on both Flotaire Column Flotation Cells and homemade column cells, the

new bubble generator systems are being provided on all new Flotaires being manufactured by

The Deister Concentrator Company, and many retrofits are being installed on existing Flotaires.

In addition, several homemade column cells are being converted worldwide to employ the new

Deister Generator System.

Most recently, comparative testing was conducted at a United States copper plant on molyb-
denum flotation. At this time, a total of 12 homemade column flotation cells, ranging from 20"
(0.5m) dia. to 3.0'(0.9m) dia, are operating in the moly plant.
The bubble generation systems tested were the U.S. Bureau of Mines Generator System, in-
stalled on three of the 12 columns, one Deister Generator System installed on a 3.0' dia. cell, and
filter sock type spargers, installed on the balance of all of the columns in the plant.
Based on the test results conducted over a period of two months, the Deister Bubble Genera-
tor System showed superior performance results over both of the other aeration systems. In
addition, no maintenance was required on the Deister Generator during this time. Torn sparger
covers were a maintenance problem on the plant aeration systems, while scaling and wear from the
high pressure flows created problems with the U.S. Bureau of Mines Generator Systems. Improved
performance of the Deister Generator System lead to it's choice for the conversion of eight of the
homemade column cells at the plant. These units have been ordered and the conversions will be
made early next month.
The patented Deister Generator is the heart of the generator system, which produces a high
volume of micron size bubbles while requiring a low water volume of only 0.3-0.5 GPM/SCFM
(35-70 LPM/SCMM).
Water enters into the generator and flows rapidly past the interior surface of a porous tube
through which pressurized air flows. The water shears the air, creating millions of fine bubbles.
Water and air pressure requirements for the generator range from 40-70 PSI each. The flow of

(22) 資源処理技術
 Recent Deister Flotaire Column Flotation Cell Developments 213

water with the entrained bubbles flows through the distribution system into the Flotaire. The

stainless steel distribution tubes evenly discharge the fine bubbles into the column at two different

levels. On larger diameter Flotaires, individual generator systems are provided for each level of

aeration.

The generators are constructed entirely of stainless steel, with only the porous generator tube

and gaskets being of different material. There are no other parts which require replacement in the

generator. Maintenance intervals are expected to be a minimum of 6-12 months in most applica-
tions.

CONCLUSION

The new Deister Generator System, combined with the easy to install modular design of the

Flotaire Column, the responsive control of the Flotaire pneumatic level control system and the

efficient water distribution of the Flotaire Froth Washing Arrangement all play a part in making

the Flotaire one of the most efficient column flotation cells available.

Val.53, No.4('88•\“~)
(23)
214 John A.Christophersen

(24) 資源処理技術
 Recent Deister Flotaire Column Flotation Cell Developments 215

Vol.35,No.4('88•\“~) (25)
216 John A. Christophersen

Copper Recleaner flotation

Plant A

資源処理技術
(26)
 Recent Deister Flotaire Column Flotation Cell Developments 217

Copper Cleaner/Recleaner flotation

Plant B

Vol.35,No.4('88•\“~)
(27)
 218 John A. Christophersen

Copper Cleaner/Recleaner flotation

Plant C

(28) 資源処理技術
 Recent Deister Flotaire Column Flotation Cell Developments 219

Copper Cleaner/Recleaner flotation

Plant,D

Vol.35,No.4('88•\“~)
(29)
220 John A. Christophersen

Copper Cleaner/Recleaner flotation

Plant E

(30)
 Recent Deister Flotaire Column Flotation Cell Developments 221

Molybdenum Rougher/Cleaner flotation

Vol.35,No.4('88•\“~)
(31)
222 John A. Christophersen

Lithium Cleaner flotation

(32) 資源処理技術
 Recent Deister Flotaire Column Flotation Cell Developments 223

Coal flotation

Vol.35,No.4('88•\“~)
(33)
 224 John A. Christophersen

Gold Cleaner/Scavenger flotation

(34) 資源処理技術
 Recent Deister Flotaire Column Flotation Cell Developments 225

Vol.35,No.4('88•\“~) (35)