Particle Technology Lab

Department of Chemical Engineering

Lab Report
Ch. E 203L Particle Technology A

Submitted to: Dr. Muhammad Shahzad

Assistant Professor
Mining Engineering Department
Submitted by: Muhammad Islam Amjad
Registration No: 2019-CH-47
Section: A

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Table of contents
Contents
 7.1 Objective/Abstract………………………………………………….3
 7.2 Related Theory……………………………………………………..3
 7.2.1 Introduction to machine…………………………………………3-4
 7.2.2 Types of machine ……………………………………………….4-5
 7.2.3 Construction and Working principle ……………………………5-6
 7.2.4 Performance indicators…………………………………………...6-7
 7.2.5 Parameters Affecting Performance ……………………………....7-9
 7.2.5.1 Feed Characteristics…………………………………………….9
 7.2.5.2 Design Parameters……………………………………………...9
 7.2.5.3 Operational Parameters……………………………………..….9
 7..2.6 Applications and Limitations…………………………………...9
 7.3 Procedure…………………………………………………………..10-11
 7.4 Observations and Calculations. …………………………………..11-12
 7.5 Discussion…………………………………………………………12-13
 7.6 conclusions ………………………………………………………………13

Figures: Page no.

Figure .1 (froth flotation cell with sensor) .................................................... 3
Figure .2(Flotation Machine an overview) ………………………………… 4
Figure .3 (Induced Flotation) ……………………………………………….5
Figure .4 (Aided Flotation )…………………………………………………5
Figure .5 (froth flotation working) …………………………………………..6

Tables:
Table 1 (Ash analysis of feed )………………………………………………11

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Experiment no.7
Froth Flotation

7.1 Objective/Abstract:
The fundamental reason/objective of the experiment is to review the "Lab Froth/flotation cell"
and to perform a test for observing the focus on the given coal test. We likewise decide the
presentation of buoyancy by the division proficiency, debris dismissal in coal, and the fixation
proportion. It is utilized for isolating hydrophilic material from a hydrophilic material. Numerous
immense applications from which some incorporate paper reusing, squander water treatment and
so on it has additionally worked on the recuperation of the important materials from the unuseful
ones.

7.2 Related theory:

7.2.1 Introduction to the machine:
A process that is essentially utilized for the partition of the particles that are hydrophobic to the
hydrophilic ones. It is used in the mineral handling industry, squander water treatment, and paper
reusing enterprises. Fundamentally it began from the mineral business. Likewise being known as "the
front-most significant activity utilized for the overhauling of the sulfide metals and their recuperation". It
has worked on the recuperation of important minerals, for example, copper-bearing minerals. Alongside
programmed mining, additionally empowered the monetary recuperation of significant metals from
much lower grade metal than already. It is profoundly adaptable for separating the particles by the
manner pockets of air follow and afterward, are does to the surface additionally eliminated, other than
those particles that stay wet will remain in the fluid phase.it can be utilized for various kinds of minerals
and it is likewise conceivable to utilize various sorts of substance medicines to change the outer layer of
the minerals so they can be isolated without any problem. Besides, it is additionally being utilized for the
handling of the fine-grained metals that don't so be it to the gravity fixation. Flotation is utilized for both
hard rock and coal mineral handling activity.

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Figure.1 (Froth flotation cell with sensor)

Figure.2(Flotation Machine an overview)

7.2.2 Types of machine:

There are three main types of Flotation machines through which different types of
processes can be handled.

 The Pneumatic type flotation machine

 The Centrifugal type flotation machine (Ruth, Groch, Hebbard)
 The Janney Mechanical flotation machine

There are three types of Flotation by which the process of flotation takes place and these
three types are following.

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 Natural floatation
 Induced flotation
 Aided flotation

Natural flotation:

Natural flotation is mostly used for oil separation processes. It is usually occurring as a
result of gas leakage or release from fermentation. It is useful if the difference in density is
suitable for separation. It creates froth that is easily separate from the solution.

Induced gas flotation:

It is an interaction that explains the water that is treated squandered by the elimination of
the suspended particles in it, for example, the oil or solids this is finished by a basic
technique

Which is the expansion of the air pockets into the flotation tank or the water. Then, at that
point, the following thing that happens is that the air pockets stick to the particles that cause
them to drift, and afterward they can be effortlessly eliminated by the skimming gadget.
What happens is that the tank is loaded up with the coagulant to flocculate the particles and
afterward eliminate them

Figure.3(Induced Flotation)

Aided flotation:

It is essentially a sort of regular flotation however it is improved by blowing a few air

pockets into the suspension and generally it is helpful for the partition of the oil in the fluid
suspension.

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Figure.4(Aided Flotation)

7.2.3 Construction and Working Principle:

Flotation is an interaction that includes blending and scattering the air in the metal while
the item is the slurry and all of this is an expansion to its science. Presently these machines
are connected by the individual machines to shape a bond/circuit so the item can be
effortlessly cleaned. Presently the old customary flotation cells which fundamentally
contained the tank which had a fomenter intended to scatter the air into the slurry. They
were exceptionally basic machines that had a wide scope of oscilloscopes took care of into
the froth with the water, which made the air pockets more strong or much less complex for
the hydrophobic particles which emerged from the froth and were killed in route.
hydrophilic particles. Then, at that point, it is gathered into a multi-stage circuit with the
coarser cells which can be effectively organized in an unexpectedly occurs in froth flotation
is that it begins from the condemnation which is fundamentally used to build the surface
space of the mineral so that further handling and separating the stone depending on the
situation and includes a cycle called freedom. which should then be isolated from the
material you need. Presently the following thing occurs as the metal is currently ground
into a fine powder and afterward blended in with the slurry and the ideal material is thought
by adding the synthetic gatherer. Presently the science relies upon the refined mineral to
frame the item. Assuming we take a model, pine oil is utilized to remove copper. The
suspension of the hydrophobic mineral and the gangue is then positioned in a water shower
which assists with making the air pockets.

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Figure.5 (froth flotation working)

7.2.4 Performance Indicator:
A. Feed Rate: When a molecule and an air pocket come into contact, the air pocket should be
enormous enough for its lightness to lift the molecule to the surface. Particles and air pockets
should stick to the highest point of the cell when they enter the froth layer. The froth layer should
stay set up long enough to stream over the release edge of the cell by gravity or to be taken out
by mechanical froth scrubbers. Assuming that the froth isn't adequately steady, the air pockets
burst and the hydrophobic particles are rashly resuspended. Notwithstanding, the froth ought not
to be entirely steady, to the point that it turns into an obstinate froth because the froth is hard to
move and siphon through the system. The surface space of the rises in the froth is likewise
significant since the particles are moved into the froth by sticking to the surfaces of the air
pockets; expanding the surface space of the bubbles empowers the particles to move quicker.
carries more water into the froth as a film between the air pockets. Since fine particles that not
will undoubtedly air bubbles are unselectively moved into the froth with the water (entrainment),
unnecessary measures of water in the froth can prompt significant pollution of the item with
gangue minerals.
B. Reagent: The properties of raw mineral mixtures suspended in tap water are sometimes
adequate for flotation. Synthetic substances are needed both to control the overall hydrophobicity
of the particles and to keep up with the legitimate properties of the foam.
C. Collectors: Collectors are reagents that are utilized to specifically adsorb onto the
surfaces of particles. They structure a monolayer on the molecule surface that ager film of
non-polar hydrophobic hydrocarbons. The collector significantly increments the contact
point so that air pockets will hold fast to the surface. Determination of the right authority is
basic for a successful partition by foam buoyancy. Authorities can either artificially attach
to the mineral surface (chemisorption), or be hung on a superficial level by actual powers
(actual adsorption).

D. Activator: Activators and regulators are also known as modifiers or regulators of the
flotation process. These reagents help the collector in modifying the surface and as a result,
it helps in the selection of the flotation process.

7.2.5 Parameters Affecting Performance:

7.2.5.1 Feed characteristics:
A. Impeller Speed:

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The mean bubbling formation speed is directly proportioned to the impeller speed and by
increasing the impeller speed the formation of bubbling is increased. Mean bubbling is largest at
near to the shaft of the impeller and smallest to the discharge of the impeller. This extends the
rate constants of each of the mineral particles to a point where the fomentation is extraordinary to
the point where the mixtures of bubble molecules are disturbed by the strong ripple and the
flotation rates drop again.
B. Particle size
The likelihood of a molecule crashing and getting stuck in an unreservedly moving air
pocket must vary with the size of the molecule, taking into account:
A. Its projected region
B. Its inactivity, which checks whether a molecule is surrounding Streamlines may or may
not intersect the airbags
C. The likelihood that you will lose the airbag due to a problematic malfunction even after
the attack
D. The extent to which the impact could twist the airbag and change the contact time. ,
and the influence of the molecule size on the acceptance time
7.2.5.2 Design Parameter

C. Air Flowrate: Increasing the airflow rate from 2 liters/min to 6 liters/min increased the
concentrate flow rate. At a given impeller speed, one can rely on an increase in the amount of air to a
cell to provide the constant speed value for an animal species. At the point at which more air is throttled
by the impeller, its start time in the exclusion zone is shortened, so that although air convergence builds
up in the cell, this air is converted into larger air pockets. and the value of the constant rate of the
remaining parts is practically unaffected.

D. Pulp Density:
Pulp density plays an essential role in determining the size distribution and flotation cells
number.

E. Temperature :
As we know that by increasing the temperature density of different materials is decreased
so those materials whose flotation is affected by the density must be affected by the
temperature.

F. Agitation
Agitation of the pulp must be vigorous enough to keep all the solids in suspension, without
breaking up the mineralized froth column.

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G. Flotation tank size: A float tank (also called an isolated tank or a sensory tea tank) is
essentially the perfect bathtub.
7.2.6 Applications

7.2.6.1 Flotation of iron ore:

The process of flotation with foam is widely used in the world as an important technique
for non-magnetic iron ores and for further upgrading of magnetic minerals. It can be
achieved in mechanical flotation cells or columns and nowadays it has become very
common in industries for many applications. The flotation of iron ore was first introduced
in America in 1931. The routes of this process can be divided into two categories. These
are:

7.2.6.1.1 Direct Flotation of Iron Ore

This was the first method employed in the industry in an alkaline medium. In this process,
through flotation, on is formed into foam. and the pH was adjusted to 910 by using
sodium carbonate.

7.2.6.1.2 Reverse Flotation of Iron Ore

Currently, this is the most accepted methodology for the concentration of iron ores. Here
in this process, the gangue particles are caused to rise and into the foam while the mineral
particles remain at the bottom of the cell. This is exactly the opposite of the direct flotation
method. Based on the differences in using collectors, this reverse flotation method is
roughly divided into two categories.

It is currently in use for many diverse applications, with a few examples being: separating
sulfide minerals from silica gangue (and from other sulfide minerals); separating potassium
chloride (sylvite) from sodium chloride (halite); separating coal from ash-forming
minerals; removing silicate minerals from iron ores; separating phosphate minerals from
silicates, and even non-mineral applications such as de-inking recycled newsprint. It is
particularly useful for processing fine-grained ores that are not amenable to conventional
gravity concentration.

7.2.6 Limitations:

Devour the reagent and effectively purpose contamination to the climate In the froth
flotation technique, the utilization of flotation reagents assumes a significant part in the last
improvement list. Intense usage of reagents will prompt higher buoyancy costs, hence
influencing the financial advantages of the establishment. It is recommended that the
concentrator embraces the severe dressing framework as indicated by the aftereffect of the

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mineral dressing test, rigorously control the material molecule size and the centralization of
the suspension, keep the buoyancy machine on schedule, to diminish the general utilization
of the buoyancy reagent and work on the amount and quality record of buoyancy items.
Moreover, flotation specialists are on the whole compound specialists, which will cause
differing levels of harm to the natural climate.

Severe crushing size

The crushing size is one of the significant elements to get a better foam flotation record, the
intention is to cause the drifting material and gangue minerals to accomplish monomer
separation. But assuming the crushing size is too coarse, the mineral can't accomplish
monomer partition. On the off chance that the crushing size is too fine, the separated
mineral is not difficult to be worn, which will likewise expand the power utilization of the
crushing machine, and produce fine mud effectively, subsequently influencing the impact
of foam buoyancy.

Hence, a get the better-spbetterdecord and financial markers, we should allude to the
consequences of the metal dressing test.

7.3 Procedure:
• Perform a carbon test with a span of - 0.5 + 0.044 mm. •
Mix the charcoal test properly and separate it with guns for a revealing example of feeding. •
Dry the sample in an oven at 110 ° C and examine it for its dirt content. •
Study every part of the machine.
• Fill the tank with refined water to a point not many inches below the tank opening and insert
the impeller into the water tank.
• Turn on the machine and pour the charcoal test into the water.
• Let the charcoal mix with water for 5 minutes.
• Inject collector (lamp oil), measured at 400 g / t and give a molding time of 5 minutes.
• Inject 100 g / t Vaporizer (MIBC) and open the air valve shortly after 10 to 20 seconds.
• Collect the foam on a foam board until the foam does not rise to the top.
• Switch off the machine and collect the dirt from the water tank on the dirt plate. • Filter the
water with a vacuum sewer siphon and dry the cake on a skewer.
• Shred objects independently of one another to 250 µm and examine them for deposits.
• Determine the fastening ratio, the gap effect, and the removal of dirt.

7.4 Observation and Calculations:

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Observations:
Ash analysis of Feed:

Ash analysis of feed and all the calculations are given to the next page.

Sr. Weight of Weight of

Weight of
No. Crucible with sample after
Empty Combustion
coal sample
Crucible (gm) (gm)
(gm) (A) (B) (C)
1 Feed 23.93229 24.9318 24.3308

2 Concentratio 23.2014 24.2039 23.4490

n
3 Tail 22.4243 23.4233 23.0723
Table.1 (Ash
analysis of feed)

Calculations:
A. Separation Efficiency, concentration ratio, and ash rejection

Concentration = 40 grams
Tail = 52 grams
Feed = 92 grams
FA =(C-A/B-A ) x 100
FA= 39.8%

CA= 33.7%

𝑌(𝐹𝐴 − 𝐶𝐴)
𝑆𝑒𝑝𝑎𝑟𝑎𝑡𝑖𝑜𝑛 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = × 100
(100 − 𝐹𝐴)

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Thus,

Y = Concentration /Feed

Y= 40/92= 0.4347

0.4347(39.8 – 33.97)
𝑆𝑒𝑝𝑎𝑟𝑎𝑡𝑖𝑜𝑛 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = × 100
(100 – 39.8)

Separation Efficiency= 0.11%

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐹𝑒𝑒𝑑
𝐶𝑜𝑛𝑐𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑖𝑜 =
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝐶𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑒

92
𝐶𝑜𝑛𝑐𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑖𝑜 =
40

𝐶𝑜𝑛𝑐𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑅𝑎𝑡𝑖𝑜 = 2.3

0.4347(100− 33.97)
Recovery = × 100
(100 −39.8)

Recovery = 47.7%

𝐹𝐴 − 𝐶𝐴
𝐴𝑠ℎ 𝑅𝑒𝑗𝑒𝑐𝑡𝑖𝑜𝑛 = × 100
𝐹𝐴

39.8−33.97
𝐴𝑠ℎ 𝑅𝑒𝑗𝑒𝑐𝑡𝑖𝑜𝑛 = × 100
39.8

Ash Rejection = 14.6%

7.5 Discussion:

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The whole experiment is used to check the ashes metals (Na, K, Ca) in the feed
water. As we know that ores are decreasing day by day so the separation f valuable
minerals from ore are very important. Due to this phenomenon, the demand for this
experiment is also increasing. Flotation is a process to separate the valuable
minerals from the gangue based on the difference in its surface properties that can
be modified by the outer factors. In this experiment, we also perform a flotation
process on a given feed sample to check the ash percentage in the sample and to
recover ashes from the sample. The collaboration between strong particles of
various sizes with added reagents has been perceived as the most significant and
critical perspective in the flotation response of the material. This connection makes
a reasonable surface quality for the strong particles, which empowers them to be
consumed via air bubbles and shipped over the cell edge. This is the way to
powerful drift detachment and has been the subject of broad exploration
throughout the long term. The necessary level of hydrophobicity accomplished by
adding the gatherer portion is vital because the measure of authority should be
adequately exact to frame a monolayer on the outer layer of the molecule. In this
experiment, we, first of all, find Yield which is the ratio of centration to feed. Yield
is required in the calculation of separation efficiency. The separation efficiency of
froth flotation is the measure of its ability to separate different metal minerals from
the sample or ores. We calculate the separation efficiency which is almost 0.11%
which shows that its ability to separate solid particles is very low. This will be
related to ash rejection of the machine because if the separation efficiency of a
machine is low it indicates that its ash rejection will be high so the same is the case
in our experiment the ash rejection is much higher than the separation efficiency.

7.5 Conclusion:
The product of flotation is consequently the result of numerous interactions. The strong
interaction of the reactants is the main factor as it leads to the selective modification of the soil
and causes the separation. The other interactions, your personal property, are important and
casual. Hence, the froth flotation form is a multi-interaction phenomenon, and knowing these
interactions could be of paramount importance for high-performance, first-class particulate
removal. The experiment was very useful and it provides all the necessary information. In this
experiment, the recovery is almost 50 % which is almost a good efficiency of any machine. The
ash rejection is almost 15% which depends upon the ashes metals in the feed.

References:

1. Wills mineral processing technology

2. Mineral processing design and operating parameters

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