Minerals Engineering 18 (2005) 1373–1377

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Collection zone kinetic model for industrial flotation columns

J. Yianatos *, R. Bucarey, J. Larenas, F. Henrı́quez, L. Torres
Department of Chemical Engineering, Santa Marı́a University, P.O. Box 110-V, Valparaı́so, Chile

Received 12 January 2005; accepted 24 January 2005

Available online 9 March 2005

Abstract

The collection zone recovery of a flotation column was modeled using a rectangular distribution function for the kinetic rate
constant and a tank in series model with different vessel sizes for the residence time distribution. It was demonstrated that an ana-
lytical expression can be obtained and that data from large industrial columns fits well, keeping the parsimony principle by using a
simple and practical solution. An example for the estimation of the maximum kinetic rate constant, useful for scale-up purposes, is
shown using data from industrial flotation columns.

2005 Elsevier Ltd. All rights reserved.

Keywords: Modelling; Column flotation; Flotation froths; Flotation kinetics

1. Introduction hydrodynamics, particle size, pulp density and chemical

reagents.
A model is required to predict the metallurgical per- During the early years of flotation, Garcia-Zuñiga
formance of a flotation column. It should be able to link (1935) proposed a first order kinetic model to describe
the main operating conditions with mineral recovery, to the batch flotation process, foreseeing the exponential
help engineers in design, control and scale-up of flota- nature of the overall process,
tion devices.
R ¼ R1 ð1
e
kt Þ; ð1Þ
The sub-processes involved in flotation are complex
and are generally not understood well enough to pro- where R represents the mineral recovery at time t, R1
pose a mathematical model from theory which can be represents the maximum mineral recovery at infinite
easily applied to the process. Therefore, most of the time, and k is the kinetic rate constant which includes
mathematical models proposed are empirical and can all the microscopic sub-processes.
be classified as kinetic or non-kinetic models (Tuteja Many authors have proposed different models to de-
et al., 1994). Kinetic models, as the name suggests are scribe the mineral recovery of a continuous flotation
models, which are based on flotation kinetics, and will process (Ek, 1992; Tuteja et al., 1994), the general ki-
be the kind of model used in this approach. netic equation for this kind of processes (Polat and
Flotation kinetics brings together the influence of all Chander, 2000) is represented by
the factors that take place during a flotation process Z 1Z 1
(Lazić and Ćalić, 2000), some of the most important R ¼ R1 ð1
e
kt ÞF ðkÞEðtÞ dk dt; ð2Þ
factors required to achieve a good separation are: ore 0 0

characteristics, machines and equipment involved,
*
Corresponding author. Fax: +56 32 654478.
E-mail address: juan.yianatos@usm.cl (J. Yianatos).
where the term (1
e
kt) represents the mineral recov-
ery of a first order process with invariant kinetic con-
stant k, as a time function. F(k) is the kinetic rate
constant distribution function for mineral species with

0892-6875/$ - see front matter
2005 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mineng.2005.01.014
1374 J. Yianatos et al. / Minerals Engineering 18 (2005) 1373–1377

different flotation rates, and E(t) is the residence time
distribution function for continuous processes with dif-
ferent mixing characteristics. Thus, according to Eq.
(2), the mineral recovery depends on the mixing level
and the actual mean residence time that is related to
the effective pulp volume in flotation equipments
(Yianatos et al., 2003). Rearranging Eq. (2), yields
Z Z
1 1
R lytical solution is commonly not possible. Therefore,
¼1
e
kt  F ðkÞEðtÞ dk dt:
R1 0 0
2. Process modelling
The column flotation modelling distinguishes the col-
lection and froth zones in order to calculate the overall
recovery RG, according to Finch and Dobby (1990),
RC  RF
RG ¼ ; ð4Þ
ð1
RC þ RC  RF Þ
where, RC represents the collection zone recovery and
RF represents the froth zone recovery.
2.1. Collection zone model
The flotation model for the collection zone will be de-
rived from Eq. (3), assuming a rectangular rate constant
distribution function F(k) and a tank in series model to
process (Boutin and Tremblay, 1962) where the plug
flow with axial dispersion model was the most widely
used by researchers (Sastry and Fuerstenau, 1970; Dob-
by and Finch, 1986; Laplante et al., 1988; Finch and
Dobby, 1990; Luttrell et al., 1993; Tokoro and Okano,
2001). This kind of model suits the hydrodynamic
behavior in pilot scale columns well, but the selection
of proper boundary conditions is difficult and the ana-
ð3Þ
numerical solutions must be considered (Xu and Finch,
1991; Mavros, 1992).
Another shortcoming for the use of this model is that
under axial dispersion conditions the dimensionless ves-
sel dispersion number must be lower than 0.2 (Leven-
spiel, 1966), however the literature reports vessel
dispersion numbers significantly higher (0.3–2.7) for
industrial columns (Laplante et al., 1988; Goodall and
OÕConnor, 1991; Yianatos and Bergh, 1992; Yianatos
et al., 2005).
On the other hand, with the help of radioactive tracer
technology, it was shown that large size flotation col-
umns perform closer to a perfect mixer. Plus a model
consisting of two small reactors (residence time sS) in
series with a larger one (residence time sL) gave the best
fit for a number of large size industrial columns, both
for liquid and solid (Yianatos et al., 2005). This model
is represented by the following equation:

 
t  

t

t

sS

a  e sS
þ a  e sL
describe the mixing condition of industrial size columns. EðtÞ ¼ ; ð6Þ
ðsL
sS Þ
2.1.1. Kinetic constant distribution F(k)
where
In flotation processes, it is common to observe miner-
als with different characteristics and sizes floating at dif- sL
a¼ ð7Þ
ferent rates. Thus, several models including normal, ðsL
sS Þ
gamma or rectangular distributions have been used to
make the description of the flotation phenomena more and
flexible. t ¼ treal
sP ð8Þ
In this study the rectangular distribution was used for
the kinetic constant distribution F(k) in order to keep with treal being the real time and sP the time delay of the
the parsimony principle in the sense of using the mini- model.
mum number of parameters. Thus, the model has only The conceptual diagram of the mixing model for the
one parameter, which corresponds to the maximum collection zone in large size industrial columns is pre-
kinetic constant kM sented in Fig. 1.

1 2.1.3. Model development

F ðkÞ ¼ for 0 < k < k M : ð5Þ
kM Replacing the rate constant distribution Eq. (5) and
the residence time distribution Eq. (6) in the general
2.1.2. Residence time distribution E(t) recovery Eq. (3) the next expression was obtained
It is well known that the flow condition in a labora- R
tory flotation column approaches plug flow, while in R1
large size industrial columns the flow regime is between 
    

t
t

t
plug flow and perfect mixed (Dobby and Finch, 1986). Z 1 Z kM
kt sS

a e sS
þae sL
e
Thus, several models to describe the flow conditions in ¼1
 dk dt
0 0 kM sL
sS
flotation columns have been developed. Column flota-
tion was originally thought to be a counter current flow ð9Þ
 J. Yianatos et al. / Minerals Engineering 18 (2005) 1373–1377 1375

Wash water If sS is equal to zero, Eq. (13) reduces to the solution

of a single perfect mixer with rectangular kinetic distri-
bution as it shown in Eq. (14)
 
RC 1
¼ 1
 lnðk M sL þ 1Þ : ð14Þ
R1 k M sL
Feed Concentrate Eq. (14) represents the lower recovery condition for the
τS column flotation model, which can also be derived from
Eq. (2) considering the following residence time distribu-
tion of a perfect mixer:
 
1
t
τL EðtÞ ¼  esL : ð15Þ
sL
On the other hand, the maximum recovery condition for
the column flotation model corresponds to the operation
Air
τS closer to plug flow observed in a pilot size column, and it
is shown in Eq. (16)
 
RC 1  
¼ 1
 1
e
kM t : ð16Þ
τP R1 kMt
Eq. (16) was derived from Eq. (2) considering the fol-
lowing residence time distribution of the batch flotation
Tails operation:
Fig. 1. Conceptual model for mixing in large size columns. EðtÞ ¼ dðtÞ: ð17Þ

2.2. Froth zone recovery

and rearranging Eq. (9) yields,
2 The froth zone recovery RF can be estimated using a
Z Z  
t model based on industrial column operating variables
RC 1 6 1 kM
t
ktþs
¼1
6
a e S
dkdt (Yianatos et al., 1998)
R1 k M ðsL
sS Þ 4 0 0 s S  
|fflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflffl{zfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflffl} H F ð1þ3J w Þ
A
0:0144
J3
3 RF ¼ 95  e g
; ð18Þ
Z 1 Z kM


ktþst 7 where HF is the froth depth, Jg and Jw are the superficial
þa e L
dk dt7 5: ð10Þ
0 0 air and wash water rates, respectively.
|fflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflffl
ffl{zfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflfflffl}
B

The integrals A and B in Eq. (10) have analytical solu- 3. Case example
tions and can be solved using the integration by parts
method (u dv = uv
v du). The actual or effective mean residence time in an
industrial column can be calculated from Eq. (19), where
1 VEff is the effective pulp volume and Q the pulp flowrate
A¼
1
a  lnðk M  sS þ 1Þ; ð11Þ
k M  sS þ 1 V Eff
s¼ : ð19Þ
B ¼ a  lnðk M  sL þ 1Þ: ð12Þ Q
From plant experience, it was shown that the effective
Replacing Eqs. (11) and (12) in Eq. (10), the result is volume in industrial columns was around 77% of the
   columns total volume VT (Yianatos et al., 2003). Thus,
RC 1 1 k M sL þ 1 the following relation will be considered for this
¼1

1 þ a ln :
R1 k M ðsL
sS Þ k M sS þ 1 k M sS þ 1 purpose:
ð13Þ
V Eff ¼ 0:77  V T : ð20Þ
Eq. (13) is a new relation which allows for estimation of Also, the total residence time s is given by
the maximum kinetic rate constant from industrial col-
umn operating data. s ¼ sL þ 2  sS þ sP : ð21Þ
1376 J. Yianatos et al. / Minerals Engineering 18 (2005) 1373–1377

From plant experience, it was observed that sS is Table 1

approximately ten times lower than sL for the tank in Operating conditions of an industrial flotation column
series model (Yianatos et al., 2005). Then, it can be as- Feed rate (m3/h) 567 522 522 520 532 508
sumed that Froth 92.5 85.0 100.0 87.5 95.0 110.0
height (cm)
sL Superficial 1.7 2.0 1.6 1.6 1.9 1.8
sS ¼ : ð22Þ gas rate (cm/s)
10
Superficial 0.21 0.29 0.29 0.21 0.21 0.23
Assuming the time delay sP = 0, the total residence time water rate (cm/s)
Mean residence 12.7 12.3 13.8 13.9 13.6 14.2
s can be described in terms of sL by
time (min)

s  Global recovery (%) 38 41 43 40 54 52
6
L Collection zone 50 49 61 53 63 64
s ¼ sL þ 2  ¼ sL : ð23Þ
10 5 recovery (%)
Froth zone 63 71 48 59 68 61
Now, combining Eqs. (22), (23) and (13) the following recovery (%)
model relating the dimensionless recovery w = R/R1 Maximum rate 0.21 0.23 0.33 0.23 0.37 0.39
constant (min
1)
with the dimensionless term kMs, was derived

RC 4
w¼ ¼1

R1 3  kMs During these tests, the mineral quality was unstable
  
12 10 2ð5  k M s þ 6Þ and the global recovery was low, 40–50%, while the typ-

1 þ  ln : ð24Þ ical recoveries were 60–70%. Difficulties were also ob-
kMs þ 1 9 k M s þ 12
served to keep the final concentrate grade near the
From Eq. (24) the effect of pulp residence time and max- target value, 30% copper, for a typical chalcopyrite
imum rate constant on the dimensionless mineral recov- ore. Thus, from Fig. 2, it can be observed that despite
ery is shown in Fig. 2. Here, the exponential nature of the column which was operated at relatively constant
the recovery can be seen, approaching R1 at larger res- pulp flowrate with a mean residence time of 12–
idence times and larger rates constants. 14 min, and despite changes in the manipulated vari-
Also, the experimental data from an industrial col- ables which were less than 15%, the overall recovery
umn of 2 · 6 · 13 m in size, operating at El Salvador and then the maximum kinetic rate constant varied
concentrator in Chile, are presented in Fig. 2 in white more significantly, i.e., kM values in the range 0.21–
circles. For this purpose, a maximum collection zone 0.39 min
1 were found. This variation can be attributed
recovery R1 equal to 90% was assumed. to changes in mineralogy, feed grade, soluble copper
The operating conditions for the sampling points of a content and chemical conditioning, as well as the control
flotation column at El Salvador, with a total column system action trying to reach the final concentrate grade.
volume of 156 m3, are presented in Table 1.

4. Conclusions
1.0
τ=16 min The collection zone recovery of a flotation column
τ=14 min was modeled using a rectangular distribution function
τ=12 min for the rate constant and a tank in series model, consist-
Dimensionless recovery, ψ

0.9
Data ing of one large and two small size units, to account for
the residence time distribution. Thus, an analytical
0.8 expression relating to the dimensionless recovery
w = R/R1 and the dimensionless kinetic term kMs was
derived.
0.7
The column recovery can now be calculated in a more
flexible way considering the use of a rectangular rate
0.6 constant distribution while respecting the parsimony
principle, or the use of a minimum number of
parameters.
0.5 The model was applied to evaluate the kinetic rate
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
constant of an industrial column, and a range of kM val-
Maximum rate constant kM, 1/min ues 0.21–0.39 min
1 was found. Work is now under
Fig. 2. Dimensionless recovery versus kinetic rate constant at different development to explore the use of this model for scale-
residence time. up purposes.
 J. Yianatos et al. / Minerals Engineering 18 (2005) 1373–1377
Acknowledgements
The authors are grateful to El Salvador Division of
Codelco-Chile, for permission to present this work.
Funding for process modelling and control research is
provided by Conicyt, Project Fondecyt 1040100, and
Santa Maria University, project 270322.
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