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Flotation Process (Sometimes Called Flotation Separation) Is A Method of Widely Used in The Treatment and Industries
Flotation Process (Sometimes Called Flotation Separation) Is A Method of Widely Used in The Treatment and Industries
air bubbles
Being carried by the water in the floth
Caught b/w particles in the froth
In flotation concentration mineral is
transferred to the froth leaving the gangue in
the pulp. This is direct flotation.
In reverse flotation, gangue is separated into
malachite,cerussite;non metallic-
fluorite,phosphate,fine coal;sulphides-
copper,zinc,lead
The flotation process is also widely used in
industrial waste water treatment plants, where it
removes fats, oil, grease and suspended solids from
waste water. These units are called
Dissolved air flotation (DAF) units. In particular,
dissolved air flotation units are used in removing oil
from the wastewater effluents of oil refineries,
petrochemical and chemical plants,
natural gas processing plants and similar industrial
facilities.
Froth flotation is one of the processes used
to recover recycled paper. In the
paper industry this step is called deinking or
just flotation. The target is to release and
remove the hydrophobic contaminants from
the recycled paper. The contaminants are
mostly printing ink and stickies. Normally the
setup is a two stage system with 3,4 or 5
flotation cells in series[4]
Chemicals for deinking of recycled paper
pH control: sodium silicate and
sodium hydroxide
Calcium ion source: hard water, lime or
calcium chloride
Collector: fatty acid, fatty acid emulsion, fatty
acid soap and/or organo-modified siloxane[6]
Froth flotation commences by comminution (that is, crushing
and grinding), which is used to increase the surface area of
the ore for subsequent processing and break the rocks into
the desired mineral and gangue in a process known as
liberation, which then has to be separated from the desired
mineral. The ore is ground into a fine powder and mixed with
water to form a slurry. The desired mineral is rendered
hydrophobic by the addition of a surfactant or collector
chemical. The particular chemical depends on which mineral
is being refined. As an example, pine oil is used to extract
copper (see copper extraction). This slurry (more properly
called the pulp) of hydrophobic mineral-bearing ore and
hydrophilic gangue is then introduced to a water bath which
is aerated, creating bubbles. The hydrophobic grains of
mineral-bearing ore escape the water by attaching to the air
bubbles, which rise to the surface, forming a foam or a scum
(more properly called a froth). The froth is removed and the
concentrated mineral is further refined.
To be effective on a given ore slurry, the surfactants are chosen based
upon their selective wetting of the types of particles to be separated. A
good surfactant candidate will completely wet one of the types of
particles, while partially wetting the other type, which allows bubbles to
attach to them and lift them into a froth. The wetting activity of a
surfactant on a particle can be quantified by measuring the
contact angles that the liquid/bubble interface makes with it. For
complete wetting the contact angle is zero.
Another consideration, especially important for heavy particles, is to
balance the weight of the particle with the surfactant adhesion and
buoyant forces of the bubbles that would lift it.
For typical values of metal densities and surface tensions, if the bubbles
are larger than the ore particles, and the particles are equal to or less
than 1 mm radius, then particles will rise into the froth layer if:[5]
where is the radius of the particles, is the average surface tension
between the three pairs of phases (particle, flotation solution, air), is the
mass density of the particles, and is the acceleration of gravity (9.81
m/s2).
For particles larger than the bubbles, they too can rise into the froth,
each buoyed by a swarm of bubbles, under similar conditions as those
expressed in the inequality.[5]
Diagram of froth flotation cell. Numbered triangles show direction of
stream flow. A mixture of ore and water called pulp [1] enters the cell
from a conditioner, and flows to the bottom of the cell. Air [2] or nitrogen
is passed down a vertical impeller where shearing forces break the air
stream into small bubbles. The mineral concentrate froth is collected
from the top of the cell [3], while the pulp [4] flows to another cell.
Flotation can be performed in rectangular or cylindrical mechanically
agitated cells or tanks, flotation columns, Jameson cells or deinking
flotation machines.
Mechanical cells use a large mixer and diffuser mechanism at the bottom
of the mixing tank to introduce air and provide mixing action. Flotation
columns use air spargers to introduce air at the bottom of a tall column
while introducing slurry above. The countercurrent motion of the slurry
flowing down and the air flowing up provides mixing action. Mechanical
cells generally have a higher throughput rate, but produce material that is
of lower quality, while flotation columns generally have a low throughput
rate but produce higher quality material.
The Jameson cell uses neither impellers nor spargers, instead combining
the slurry with air in a downcomer where high shear creates the turbulent
conditions required for bubble particle contacting.
s
The following steps are
followed:
Grinding to liberate the mineral particles
Reagent conditioning to achieve hydrophobic surface
charges on the desired particles
Collection and upward transport by bubbles in an
intimate contact with air or nitrogen
Formation of a stable froth on the surface of the
flotation cell
Separation of the mineral laden froth from the bath
(flotation cell)
1) pneumatic machines either use air
entrained by turbulent pulp addition(cascade
cells), or more commonly air either blown in
or induced, in which case air must be
dispersed either by baffles or some form of
permeable base within the cell. It gives low
grade concentration &little operating trouble.
The davcra cell is used for roughing or
cleaning operations.
Most resent is floatation column.
Mechanical floatation characterized by a
mechanically driven impeller which agitates
the slurry and disperses the incoming air into
small bubbles.
Criterions for assessing cell performance are:
Metallurgical performance i.e. product
maintenance cost
Numbered triangles show direction of stream flow, Various flotation
reagents are added to a mixture of ore and water (called pulp) in a
conditioning tank. The flow rate and tank size are designed to give the
minerals enough time to be activated. The conditioner pulp [1] is fed to
a bank of rougher cells which remove most of the desired minerals as a
concentrate. The rougher pulp [2] passes to a bank of scavenger cells
where additional reagents may be added. The scavenger cell froth [3] is
usually returned to the rougher cells for additional treatment, but in
some cases may be sent to special cleaner cells. The scavenger pulp is
usually barren enough to be discarded as tails. More complex flotation
circuits have several sets of cleaner and re-cleaner cells, and
intermediate re-grinding of pulp or concentrate.
A composition and process are provided for the recovery of the
values of zinc, molybdenum, copper, lead, iron (pyrite), and iron-
containing small amounts of gold or uranium, or both, from ores
comprising these mineral sulfides. The aqueous composition is
the impure form of an alkali metal alkyl trithiocarbonate
compound. The process comprises employing said aqueous
composition as a collection agent for the above minerals in an
ore recovery process.
A process for the separation of zinc values from lead values from
an ore comprising both is provided by employing an alkali metal
alkyl trithiocarbonate compound as a collection agent for zinc.
In addition, both a composition and process are provided for the
recovery of the values of iron, copper, and lead from ores
comprising these values. The composition consists essentially of
a dispersant and an impure form of an alkali metal alkyl
trithiocarbonate compound. The process comprises employing
this composition as a collection agent for the above minerals in
an ore recovery process.
Collectors
Collectors either chemically bond (
Pine oil
Alcohols (MIBC)
Polyglycols
Polyoxyparafins|
Cresylic Acid (Xylenol)
Modifiers
Modifiers as activators, depressants or pH
modifiers. Alters selectivity of the collectors.
It intensifies or reduces their water repellant
effect on the mineral surface.
Activator-soluble salts which ionizes in solution
Eg activation of sphalerite by cu in solution
Depressant-are used to increase the selectivity of
floatation by rendering certain minerals
hydrophilic thus preventing their floatation.
Eg slime coating
Cationic modifiers:
Ba2+, Ca2+, Cu+, Pb2+, Zn2+, Ag+
Anionic modifiers:
SiO32-, PO43-, CN-, CO32-, S2-
Organic modifers:
Dextrin, starch, glue, CMC
pH modifier floatation is carried out at alkali
pH because most collector are stable at
higher pH & corrosion of cells, pipework is
minimized.
pH modifiers such as:
Lime CaO
Soda ash Na2CO3
Caustic soda NaOH
Acid H2SO4, HCl
Specific ore applications
Sulfide ores
Copper (see copper extraction)
Copper-Molybdenum
Lead-Zinc
Lead-Zinc-Iron
Copper-Lead-Zinc-Iron
Gold-Silver
Oxide Copper and Lead
Nickel
Nickel-Copper
Nonsulfide ores
Fluorite
Tungsten
Lithium
Tantalum
Tin
Coal
Ore Concentration by Froth Flotation
Remember that only 0.67% of the ore is copper.
The copper minerals and waste rock are
separated at the mill using froth flotation. The
copper ore slurry from the grinding mills is
mixed with milk of lime (simply water and
ground-up limestone) to give a basic pH, pine oil
(yes, it comes from trees -- a by-product of
paper mills) to make bubbles, an alcohol to
strengthen the bubbles, and a collector chemical
called potassium amyl xanthate (or the
potassium salt of an alkyl dithiocarbonate).
The xanthates are added to the slurry in relatively
small quantities. Xanthate is a long hydrocarbon
(5 carbons) chain molecule. One end of the chain
(the ionic dithiocarbonate) is polar and sticks to
sulfide minerals while the other end is nonpolar,
containing the hydrocarbon chain is hydrophobic
-- it hates being in the water and is attracted to
the nonpolar hydrocarbon pine oil molecules.
Raising the pH causes the polar end to ionize more
and to preferentially stick to chalcopyrite (CuFeS 2)
and leave the pyrite (FeS2) alone. Air is blown into the
tanks and agitated like a giant blender, producing a
foamy froth. The chalcopyrite grains become coated
with xanthate molecules with their hydrophobic ends
waving around trying desperately to get out of the
water.
They attach themselves to the oily air bubbles which
become coated with chalcopyrite grains as they rise
to the surface and flow over the edge of the tank. In
this manner through a series of steps the copper ore
is concentrated to an eventual value of over 28%
copper. Waste rock particles do not adhere to the
bubbles and drop to the bottom of the tank. The
waste material that comes out of the bottom of the
tanks at the tail end of this process is called
"tailings." It is nothing more than ground-up rock
with the copper minerals removed.
The bubbles that flow over the edge of the first set of
flotation tanks (inside the mill building) end up in
this thickener. By then the bubbles have broken and
the slurry is poured into the center of this round
tank. The solid material settles to the gently sloping
bottom and is pushed toward the center by a systems
of rakes that slowly revolve around the tank.
The thickened slurry is pumped back into the mill for
further processing. The clarified water flows under
the small dam, that you can see just inside the
perimeter of this tank, flows over the side, and is
pumped back to the mill for reuse.
That stuff floating on top is "almost money" - just
chalcopyrite that hasn't sunk in the tan yet. A water
spray on the opposite side of that radial walkway
helps sink it.
Text edited by Rob Vugteveen, Director,
Asarco Mineral Discovery Center
The graphic down shows an air bubble