Some Considerations in Column Flotation Pilot Plant Testwork
A J H NEWELL 1 , R A CANTRELL 1 AND G A DUNLOP 1
ABSTRACT
The metallurgical and engineering requirements that fonn the basis for
planning column flotation Pilot Plant testworlc are reviewed.
Pilot plant operating issues are discussed and a basis for the testworlc
program fonnulated.
The application of the testworlc results to engineering design and
scale-up is briefly reviewed.
INTRODUCTION
The attractiveness of flotation columns lies in three main areas:
1. significant capital and operating cost benefits,
2. improved metallurgy, usually concentrate grade, and
3. circuit simplicity and operating stability.
Not only are columns individually cheaper to install and
operate, the improvement in metallurgy, particularly in roughing
applications, results in a simpler circuit that is significantly more
cost-effective.
Many operators have reported the benefits of column cleaner
installations. However the application of columns to roughing
duties has not been widely documented.
The authors have extensive experience in this type of
application, collectively being associated with all Rougher
columns installed in Australia to-date.
An example of a hybrid column/conventional flotation circuit
is schematically presented in Figure 1.
The major advantages of columns in roughing duties concem
improved metallurgy and substantial capital and operating
savings.
In column roughing with base metals, a final grade concentrate
recovering between 50 to 70 per cent of the desired metal may be
typically achieved, removing the need for extensive cleaning
circuits. Because this material is extracted at the head of the
flotation circuit, overall recovery is maximised, obviating the risk
of subsequent loss which can occur with each retreatrnent step in
a conventional multi-stage circuit.
Further, the roughing circuit generally treats the largest slurry
volume in the flotation circuit, so any reduction in rougher
flotation equipment costs is more significant.
The impact on the overall flowsheet and subsequent capital
requirements is impressive when column roughing applications
are analysed (Newell, 1990). Notably, similar or better
metallurgy than that from the conventional option forms the basis
of the comparison.
For a number of base metal operations, a comparison between
the conventional option and a hybrid Rougher
column/conventional scavenger circuit demonstrated substantial
savings in terms of power (average of 66 per cent, 2 MW in some
cases), equipment (average of 72 per cent, drives, pumps, ete),
area (average of 66 per cent) and therefore overall capital
(average of 45 per cent).
Nonetheless, while columns are generally applicable to any
flotation separation it is important to undertake some pilot plant
testwork to confirm the suitability of this technology.
1. Float Tech ( A Division of New Met Services Pty Lld), PO Box
641, Nedlands WA 6009.
Extractive Metallurgy of Gold and Base Metals Kalgoorlie. 26 - 28 October 1992
Recently, some examples of column pilot plant testwork
undertaken at certain Chilean operations has been documented
(Crozier, 1992). While the general methodology is sound, the
testwork approach reflects North American experiences and omits
what the authors consider to be a particularly significant variable
(concentrate carrying capacity) while emphasising a somewhat
less important variable (bias).
Pilot plant testwork with columns is essentially about
equipment selection and circuit configuration, proving metallurgy
with this equipment and configuration on a reproducible basis as
well as generating engineering design criteria.
As with all pilot plant testwork, it is important that sufficient
bench scale testwork has been undertaken to identify the
metallurgical criteria and operating conditions for a desired
separation. Prerequisites, notably, include the following:
1. Laboratory bench scale tests have defined the
metallurgical separation in terms of grind, reagent types
and quantities, conditioning requirements and standard
process variables (rate of flotation, residence time, ete).
2. Metallurgical separation targets are clearly defined for
each potential column application.
3. A process flowsheet has been established (for example,
column roughing followed by conventional scavenging).
In considering a potential flowsheet, rate data from laboratory
testwork are particularly useful for selecting likely flotation
equipment duties.
Pilot plant testwork utilising columns is more cost-effeCtive
than conventional flotation equipment due to the simplification of
the flowsheet as previously outlined. Consequently, there is less
equipment to set up, to operate and to maintain. There are less
flotation streams, lower sampling needs and therefore less assays
(and other tests, eg sizings ).There are fewer reagent addition
points while there is less information to be recorded.
Significantly fewer people are generally required to operate the
pilot plant. Overall, this amounts to a more cost-effective and
efficient pilot plant testwork program.
ENGINEERING AND TESTWORK
CONSIDERATIONS
The major testwork considerations are based on demonstrating
reproducible metallurgy over extended runs during pilot plant
testwork. Consequently, the representative nature of both the
sample and water are important in achieving meaningful results
that can be used in a bankable feasibility document or
engineering design.
Depending upon the complexity of the metallurgical
separation, a minimum of ten tonne (and preferably 25 to 50
tonne) of sample is required. Where site water is needed during
pilot planting, some 18000 to 40 000 litres will be used.
Based on laboratory bench scale testwork results, preliminary
testwork conditions can be selected, viz, grind, percent solids,
reagent type and quantity, conditioning requirements, flotation
residence time as well as metallurgical separation targets (grade,
recovery, concentrate mass recovery, ete).
These conditions form the basis for the exploratory, qualitative
phase of the pilot plant program.
An important advantage of pilot plant testwork is the
opportunity to mill and classify on a continuous basis, providing
253
A J H NEWELL. R A CANTRELL and G A DUNLOP

CONVENTIONAL SCAVENGER

COLUMN ROUGHER

FIG I - Hybrid column/conventional flotation circuit.

valuable data for scale-up considerations when analysing the TABLE 1

standard batch milling studies and selecting classification Summary a/variables.
equipment.
The major testwork considerations concern the following
DESIGN VARIABLE MEASURED CALCULATED
variables: VARIABLE VARIABLE
1. interstitial slurry velocity (Vi. should be identified as INTERS1TI1AL COLUMN SLURRY Vi =QslXAc*
superficial slurry velocity). SLURRY VELOCTIY FOLUMEN1RIC
(Vi, cm/S) FEED RATE:
2. superficial air flow rate (jg). Os l/min
3. concentrate Carrying capacity (Ca). SUPERFICIAL AIR COLUMN AIR Jg =QafXAc*
VELOCTIY (Jg, cmJS) VOLUMEN1RIC
4. frother requirements. and FLOW RATE:
5. wash water. Oa lImin (NTP)
A summary of all the pertinent variables in a column pilot plant FROTII DEPTII DISTANCE EFFECTIVE
BE1WEEN COLUMN HEIGHT -
testwork program is given in Table 1. FROTIlLIP AND FROTII DEPTII-
The interstitial velocity of the slurry is used directly to size the FROTIl-SLURRY AERATOR HEIGHT
recovery zone of the coluJIUl and consequently rates as an INTERFACE: cm ABOVE
important variable. DISCHARGE
In many slurry systems. a range of interstitial velocities exist WASH WATER LOCATION: ABOVE EQUIVALENT
where there is little change in metallurgical performance of the FROTII (5 cm), CONCENTRATE
column. However, for a number of ore types. where the slurry BELOW FROTH (5 BED/DISPLACEMEN1
an) QUANTITY: VOLUMES FROM
viscosity or co-agglomeration of gangue species is significant, VOLUMEN1RIC MASS BALANCE
interstitial velocity needs to be carefully examined. FLOW RATE (l/min)
At the other end of the scale, the ability to remove concentrate CARRYING CONCENTRATE BASED ON A
from the coluJIUl is an important design criteria. Analogously to CAPACITY (Ca, MASS (Mc)! SMOOTHED FULL
2
lip length considerations with conventional cells. the concentrate g/an /min) VOLUMETRIC (Qc) MASS BALANCE
carrying capacity needs to be clearly identified. FLOW RATE AND
PER CENT SOLIDS Ca =McfXAc*
It should be noted the concentrate carrying capacity is
influenced by the flotation duty. such as roughing, scavenging or (NB SOLID AND
cleaning. Higher concentrate carrying capacities are possible WATER SG NEED
with finer sized mineral particles (eg Cleaning). however it is also TO BE KNOWN)
dependent on the mineral specific gravity as well as the
concentrate mass recovery. • XAc = cross-sectional area of column
In particular, a minimum carrying capacity as well as a
maximum carrying capacity needs to be established and related to coluJIUl. A satisfactory compromise can be found with the use of
the separation conditions (concentrate mass recovery. grind size. at least a 100 mm diameter unit or preferably 150 mm.
etc). It is important to appreciate the possible fluctuations in head In the evaluation of coluJIUls, it has become traditional to
grade as well as the resultant variations in grind size so that there operate with a positive bias (that is. the ratio of the slurry
are no limitations during full scale operation. volumetric feed rate to the coluJIUl tailings volumetric flow rate is
Notably. due to side wall effects, both interstitial velocity and less than one) with a slurry volumetric increase being produced
carrying capacity do vary with the diameter of the pilot plant by wash water additions. The role of wash water. when applied

254 Kalgoorlie, 26 - 28 October 1992 Extractive Metallurgy of Gold and Base Metals
 CONSIDERATIONS IN COLUMN FLOTATION PILOT PLANT TESTWORK
carefully to the froth phase, is to assist in the disengagement of
entrained gangue species from the froth zone and thereby
improve the concentrate grade, as well as removing penalty
species (eg silica). Under ideal conditions, the grade may be
improved by up to one per cent. However in practice, with the
presence of many interfering variables, the effect of bias is offset.
Many flotation columns, particularly in roughing applications,
operate successfully with a negative bias, without the use of wash
water.
Consequently, bias is not regarded as being a significant
variable and there are a number of more important parameters
that must be addressed before bias is considered.
The wash water flow rate is an important consideration where'
wash water has been shown to be beneficial. It should be noted
that not all applications require wash water and that where it is
applicable, there is an upper limit to the quantity which can be
added.
Excessive wash water flow rates may wash out fine sulphide
particles from the froth and in some cases, destroy the stability of
the froth zone. In these cases, frother may be added to the wash
water to maintain the integrity of the froth zone.
Thus, the effect of wash water flow rate needs to be ex~ed
in terms of metallurgy and froth structure. The location of the
wash water addition may be important and this can be tested
during this qualitative testwork phase. Most installations apply
wash water below the froth. However some operators prefer to
locate the wash water above the froth, in order to visually monitor
the wash water addition. In this situation, more wash water does
report to the concentrate.
There are a number of engineering aspects that are outside the
scope of this paper that require consideration after successful
pilot plant testwork (Newell, 1989),
The design of the wash water system is an important aspect of
the column engineering, as is the method of concentrate removal.
Note that the area of the wash water system in a submerged
application needs to be considered when designing the froth zone.
This must be allowed for when considering the concentrate
carrying capacity.
The internal design of,both the reCovery zone and the froth
zone are important in the full scale application. The slurry feed
system and distribution within the column is also a critical design
issue. It should be noted that for a full scale column, slurry
should be fed under gravity wherever possible to avoid feed
surges associated with pumping.
Finally, the nature of the aerator needs to be considered. A
number of bubble production methods are available, varying from
high pressure systems (600 kPa) to low pressure systems (100
kPa).
The high pressure systems include the CESL and control
international air spargers, while perforated rubber/plastic sleeves
represent the major low pressure system.
All methods do generate an adequate bubble size range for
successful flotation. However the quality of the engineering and
installation is crucial to the satisfactory operation of the
proprietary high pressure aerators.
Notably, it has been suggested that column aerators do produce
more smaller bubbles than conventional machines, thereby
assisting the flotation of finer sulphide minerals. Nearly all pilot
plant columns employ a low pressure aerator, since small scale
high pressure system aerators cause excessive dilution of the
slurry. These high pressure systems incorporate an air-water
aspiration process in their operation.
The high pressure systems do offer a number of benefits,
including the option of adding frother to the aerl).tor as well as the
ability to remove the sparger tubes from the column during
operation. On the other hand, they do require more auxiliary
Extractive Metallurgy of Gold and Base Metals Kalgoorlie, 26·28 October 1992
equipment, including a high pressure air compressor and a high
pressure water pump.
The control philosophy is particularly important to the
successful operation of a column. Specifically accurate control
over the level of the slurry - froth interface is required.
The use of bias to control II column operation, with variable
wash water addition rates to maintain a constant slurry level, is
not generally considered conductive to consistent metallurgi~al
performance. Additionally, this approach necessitates substantlal
and expensive instrumentation.
A number of other variables, such as air hold up and air flow
rate, can be incorporated in the column control philosophy.
A general comment concerning scale-up is warranted.
Columns are the one piece of flotation equipment that is custom
designed and manufactured to suit the application. As mentioned
previously, columns are significantly cheaper to install and
operate than conventional cells.
It is strongly recommended that pilot plant testwork be
undertaken if a column flotation circuit is considered. Although
columns can be designed without pilot plant testwork, there is a
high risk factor associated with this approach.
In the early days of column flotation, an apparently successful
application at one plant was copied without much consideration
to the requirements of the technology of that particular slurry and
separation.
For example, a larger number of site built cleaner columns in
both North America and Australia simply have not addressed the
carrying capacity needs of the separation. There would appear to
be considerable scope to improve the metallurgical performance
of many of these installations.
Nonetheless, a number of successfully operating columns have
been installed without the benefit of pilot plant testwork
(Boddington, WA and Three Mile Hill, WA). However, this
design approach relies heavily on experience as well as an
extensive data base, and depends on the nature of the flotation
separation and the associated complexity.
Scale-up from pilot plant testwork data is well established and
has been successfully demonstrated in a large number of
operating columns around the world.
Notably, the scale-up techniques associated with rougher
column applications in Australasia and Africa reached a mature
and low risk status many years ago.
METHODOLOGY
Pilot plant testwork falls into three stages:
1. exploratory, qualitative stage,
2. quantitative, testwork matrices, and
3. demonstration phase.
The column pilot plant testwork methodology is summarised in
Figure 2, noting the outcomes at the end of each subsequent
phase of testwork.
During the exploratory stage, the slurry and flotation system
requirements are explored based on the preliminary operating
conditions formulated from Bench scale metallurgical testwork.
Basic operating variables are identified and their influence on
the column performance noted.
It is important to determine the useful range of interstitial
slurry velocities (Vi, inversely related to residence time) and
airflow rates Jg ).
With highly viscous slurries, it may be difficult to disperse air
bubbles and so slurry dilution may be required.
Although columns may be sensitive to viscosity, pilot plant
testwork on a viscous slurry has indicated that columns can
255
A J H NEWELL, R A CANTRELL and G A DUNLOP

BENCH SCALE
DATA may exclude some parameters (eg wash water). However a
I firmer basis for the next testwork phase will have been
~
elucidated.

1
Reaglnt Suit.
Grind. % solids
R'l!Iic:hil~ Urn" (reagents, flotallon)
The outcome of this exploratory, qualitative phase should
M8ta!lurgical Performance Cf/teria (grad., riCOVlry) include the following:
1. frother type and quantity,
EXPLORATORY,
QUALITATIVE 2. range of slurry interstitial velocities,
PHASE
3. range of airflow rates, and
~ 4. the applicability of wash water.

1
QUANTITATIVE
Rang. of Vi. Jg
Froth,r type, quantity, addition point
Wash wat., applicability
The next stage of testwork involves formulating a testwork
matrix, essentially examining the relationship between interstitial
velocity and the air flow rate.
PHASE For this initial testwork matrix, the froth depth is fixed (say 30
(TESTWORK MATRICES) cm) while a ,constant wash water rate (if required, say 0.25
concentrate bed volumes) is applied in the preferred location
~ (above or below the froth).
R.lationship botwH" Vi and Jg

1 Frolh Dopth· optmum Vi. Jg

Wash walot· optimum Vi. Jg, Froth Depth
Concentrate mUI flowrataa . Ca min. Ca max
/>Jtholdup
An example of this matrix is shown. in Tabl~ 2, w~ere s~all
increments in the values of Vi and Jg are exammed m a
randomised fashion. The metallurgical performance of each
matrix condition is evaluated in terms of product grade, metal
DEMONSTRATION recovery and concentrate'mass recovery.
PHASE

TABLE 2

1
~
Reproducible and conlistent Initial testworkmatrixfor the two principal var~ables.
metallurgy ov.r signficlant period of timo
Metallurgical and Engineering Design Data Bast
SUPERFICIAL AIR VELOCITY al!, cm/s)
BANKABLE FEASIBILITY INTERSTITIAL
DOCUMENT SLURRY. 1.75 2.00 2.25 2.50 2.75
AND/OR VELOCITY
ENGINEERING DESIGN (Vi cm/s)
1.25 10 4 20 8 14
FIG 2 - Column pilot plant testwork methodology. 1.50 13 6 1 '15 12
1.75 3 16 11 19 5
2.00 7 2 18 9 17
handle higher per cent solids (20 per cent versus 12 per cent) than
conventional cells. * Fixed Froth Depth: Say 30 cm
Fixed Wash Water: Say 0.25 Concentrate Bed Volumes,
Further, the rougher column/scavenger conventional ~ell 5 cm below froth.
combination was particularly stable and easy to operate, unlike
Frother: Purified TEB, 5 glt,
the conventional pilot plap.t option, which required continuous
Addition to Conditioner
trimming and attention. At these l~w solid. de~ities, ~is
represents a significant and cost-effecnve reducnon m flotanon Randomised order of testing: 1 to 20
equipment volume.
The outcome of this testwork is the optinIum range of slurry
The measurement of slurry viscosity at various per cent solids interstitial velocities and air flow rates that achieve the desired
during bench scale testwork is advocated, since this information metallurgical target separations.
can be used. to formulate the preliminary operating conditions.
The typical range of residence tinIes that can be expected is
Further, perhaps more importantly, this data may also flag
between ten and 20 minutes and the column height can be varied
potential problems during classification with hydrocyclones.
to improve the stage recovery for the selected interstitial velocity
Preliminary metallurgical data can be generated based on range.
sampling the various flotation streams after three residence
Examples of possible testwork matrices for the other variables
periods once stable conditions are achieved.
is shown in Table 3. Note that strictly speaking, air hold up is not
The importance of the frother type needs to be examine.<!, since a variable but it has been included in the Table for reasons of
the froth zone exhibits a significant volume (unlike the rather completeness.
limited froth zone in a conventional cell).
With an understanding of the relationship between Vi and Jg,
Unfortunately, the old favourite MIBC is not particularly the effect of froth depth can be examined (say 15 cm, 45 cm, 60
suitable, unless outrageous quantities are applied. Glycols, cm and 90 cm). In some cleaning applications, injection of the
purified TEEs and MillC / glycol mixtures are recommended. slurry into the froth phase may be considered.
The development of a mobile, well draining froth structure is Under conditions of optimal Vi, Jg and frQth depth, the
vital to any successful flotation separation. The formation of a sensitivity of wash water additions (where applicable) is studied.
clear slurry-froth interface is usually desirable in the operation of Wash water settings may be varied in increments of 0.1
a column, although in some flotation systems such an interface is concentrate bed volumes, from zero to 1.2 if exploratory results
not developed. Nonetheless, even in this latter situation, the indicate that this may be beneficial.
flotation operation can still perform satisfactorily.
The final stage of testwork involves at least an eight hour
It is important during this stage of the testwork to identify the demonstration run under optimum conditions to prove the
parameters, as well as their range, that have a significant effect o.n metallurgy as well as the technology. In this case, samples of the
both the operation and performance of the column. Notably, thIS

256 Kalgoorlie, 26·28 October 1992 Extractive Metallurgy of Gold and Base Metals
 CONSIDERAnONS IN COLUMN FLOTAnON Pll..OT PLANT TESTWORK.

TABLE 3 pilot plants utilise a pump for tailings removal, this also must be
Testwork matricesfor other variables. turned off. After a few minutes, the fall in slurry height is noted
(relative to the froth-slurry interface) and the ratio of this fall to
OTHER VARIABLE RANGE
the effective column height reflects the percent air hold up.
FlXED VARIABLE
FROTH DEPTH 15 to 90 cm, Optimum Vi, Jg,
Another approach employs pressure gauges located variously
(cm) increments of 15 cm Frother type, quantity above the aeration zone.
and addition pOint The concentrate carrying'capacity is determined from the
WASHWATER metallurgical data and column details , namely concentrate
production rate over the column cross-sectional area.
* Flowrate (l/m) oto 1.2 concentrate Optimum Vi, Jg, Froth As mentioned previously, somewhat analogously to the
bed volumes, Depth determination of the maximum interstitial velocity, tests to
increments of
0.1 specifically to establish the range of concentrate carrying capacity
'* Location (cm) Above Froth (5 cm) Frother type, quantity are strongly recommended.
Below Froth is cm) and addition ooint
CONCENTRATE Minimum Minimum Vi and CONCLUSIONS
CARRYING associated Jg, shallow
CAPACITY Froth Depth and high A reasonably thorough and planned approach to pilot plant
(Ca, g/cm2/min) Wash Water rate testwork columns has been presented. This approach reflects the
Maximum Maximum Vi and concerns and interests of both the metallurgist as well as the
associated Jg, deep design engineer.
Froth Depth and low
Wash Water rate
This approach to pilot plant testwork has been applied
Average Optimum Vi, Jg, Froth collectively to a large number of projects with considerable
Depth and Wash success by the authors.
Water rate Like all flotation testwork, fairly generic comments outling the
AlRHOLDUP Minimum As per concentrate testwork philosophy have been presented. The actual testwork
(%) carrying capacity program is highly dependent on mineralogy, metallurgical
Maximum As per concentrate parameters and flowsheet considerations, as well as the
carrying capacity metallurgical budget.
Average As per concentrate
canying capacity Hopefully the material presented will assist any metallurgist
considering the application of columns and, noting the
immortable words of Professor Taggart:
various flotation streams can be collected on a 20 minute basis Make your mistakes on the small scale, and make your profits
on the large scale.
and composited on an hourly or two hourly basis.
This raw data can be smoothed and used to generate a mass
balance suitable for engineering design. NOTATION
It should' be noted that a considerable amount of information Vi: Interstitial slurry velocity (should be Superficial
needs to be gathered, since engineering data needs to be extracted Slurry Velocity, Js ), cm/s
for design and scale-up purposes. A check list may be
summarised as follows: Jg: Superficial Air Flow rate, cm/s
~a: Concentrate Carrying Capacity, g/crn2/s
1. air flow rate (1/s) as well pressure and temperature at inlet
to column aerator; Qs: Slurry Volumetric Flow rate, 1/min
2. wash water flow rate (l/s) and location; Qa: Air Volumetric Flow rate, 1/min (NTP)
3. slurry feed rate (kg/min); Qc: Concentrate Volumetric Flow rate, 1/min
4. froth depth (cm); Mc: Concentrate Mass Flow rate, kg/min
5. concentrate mass recovery (kg/min); XAc: Column Cross-sectional Area ( cm2 )
6. column details: internal diameter (cm), effective height
(distance between aerator and feed inlet, cm), etc; REFERENCES
7. air hold up ( per cent); and Crozier, R D, 1992. Theory, reagents and ore testing, First Edition,
(pergamon Press: Oxford).
8. Metallurgical data for each matrix condition. Newell, A J H, 1989. Column Flotation - An Engineer's Perspective,
Note that air hold up can be determined a number of ways. Column Flotation Workshop, Adelaide, Tunra/Amira.
However the two best known methods are as follows. Newell, A J H, 1990. Column/Conventional Flotation Cost Comparison,
At the end of a particular testwork condition, the air, slurry The Flotation and Mineral Processing Seminar, Adelaide,
feed and wash water are simultaneously turned off. Since many Amdel/SAIT/AMP.

Extractive Metallurgy of Gold and Base Metals Kalgoorlie, 26 - 28 October 1992 257
258 Kalgoorlie, 26 - 28 October 1992 Extractive Metallurgy of Gold and Base Metals
HYDROMETALLURGY
1B -
Base Metals

J Fodor
New Celebration Gold Mine
Kalgoorlie J Western Australia

TTran
University of New South Wales
Kensington, New South Wales