FLOTATION

Definition of flotation
The process of seperation of mixed liberated particles from each other if there are sufficent differences in their wettability is called flotation.

Principle Of Operation
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 (lacking affinity for water) by the addition of a surfactant. The particular chemical depends on which mineral is being refined. As an example, pine oil is used to extract copper. This slurry (more properly called the pulp) of hydrophobic mineral-bearing ore and hydrophilic (having a strong affinity for water 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.

INTRODUCTON
The floatation process operates by preparing a water suspension of a mixture of relatively fine sized particles (smaller than 150 micro meters) and by contacting the suspension with a swarm of air bubbles of air in a suitably designed process vessel. Particles that are not wetted by water (hydrophobic) tend to be attached to air bubbles levitate (float) to the top of the process vessel and collect in the forth layer. Thus difference in the surface chemical properties of the solids are the basis of separation by flotation. surfaces that do not have strong surface chemical bonds that were broken tend to be non-polar and are not readily wetted. e.g Graphite and Talc. These solids are naturally floatable.

Froth Flotation Cell

Effect of Variables on Flotation

Physical and chemical nature of the material Pretreatment (grinding etc.) Water chemistry Reagents added Type flotation cell

APPLICATIONS
Mineral applications: the floatation process is most widely
used in the mineral process industry to concentrate mineral values in the ores.most of the worlds copper, lead, zinc, molybdenum and nickel are produced from ores that are concentrated first by flotation. In addition, floatation is commonly used for the recovery of fine coal and for the concentration of wide range of mineral commodities including fluorspar, mica, sponueme, bastnaesite, calcite, granite and talc.

OTHER APPLICATIONS
Wastewater treatment: to remove particulate, organic and biological contaminants. Extraction of metallic values from hydrometallurgical streams by particulate floatation. Recovery of bitumen from tar sand. Deinking of waste paper.

APPLICATIONS
Recovery of solids from white water in paper making. Recovery of glass water from industrial wastes. Removal of impurities from peas. Separation of proteins from milk. Clarification of fruit juices. Extraction of soluble particles

Mechanics Of Flotation
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)

UNIT OPERATION OF FLOTATION

Unit operation of flotation is based on two major steps: Conditioning Separation

UNIT OPERATION OF FLOTATION

Conditioning: is basically a pre treatment step. the slurry or the
pulp, consisting of particles to be separated, is fed to the conditioning unit, to which the necessary flotation reagents are added. the main purpose of conditioning step is to create physical-chemical conditioning or the process of chemical changes necessary for forth flotation. The conditioner may be soluble, insoluble, and partially soluble.

UNIT OPERATION OF FLOTATION Separation: separation is then intended to generate and introduce
air bubbles into the process vessel for contacting them with particulate species. Particles attached to the air bubbles are in most applications removed from the process vessel as froth. accordingly the unit operation of flotation is referred to as FROTH FLOTATION. The froth overflow stream is called a concentrate in the mineral industry. the slurry underflow is called tailings. depending on the application, these two steps may be carried out in two distinctly different process units or in one combined unit.

FLOTATION PLANT OPERATION

Ores must be ground to a point of complete or nearly complete liberation. Even tough it might possibly be accomplished by coarse crushing., grinding. Grinding is done in closed circuit with classifier. In many instances, superior flotation is results are obtained by conditioning the ore with the reagents before the flotation step. Oily type collectors are sometimes added to the grinding circuit to ensure dispersion. Flotation machines are built in multiple units. Common practice is to feed the pulp to several cells known as roughers. Which produce a barren tailing. The conentrate is treated in cleaner cells and recleaner cells for final concentration.

Types of flotation
Ore flotation Macro flotation Microflotation Precipitate flotation Ion flotation Molecular flotation Adsorbing collide flotation

Macroscopic flotation
A type of flotation of flotation in which there is the removal of macroscopic particles is called macroscopic flotation

Microscopic flotation
A type of flotation in which there is the removal of microscopic particles particularly colloid or microorganisms is called microscopic flotation It is also called colloid flotation

Adsorbing colloid flotation

A type of flotation in which there is the removal of dissolved material in piggyback fashions by adsorbtions on colloidal particles is called adsorbing colloid flotation

Molecular flotation
A type of flotation in which there is the removal of surface inactive molecules through the use of collector (surfactant) which yields an insoluble product is called Molecular flotation

Ion flotation
It is the type of flotation in which there is the removal of surface-inactive ion via a collector which yields an insoluble product; especially a removal of scum is called ion flotation

Precipitate flotation
A type of flotation in which precipitate is removed by a collector which is not precipitating agent is called precipitate flotation.

Flotation Reagents
Three types of chemical reagents used during the froth flotation process Collectors Frothers Modifiers

Collectors
These are surface active agents that are added to the flotation pulp where they adsorbs selectively on the surface of the particles and render them hydrophobic. Collectors increase the natural hydrophobicity of the surface. and increase the separability of the hydrophobic and hydrophilic particles. Collectors are added in a certain amount. Addition of excess quantities of a collector is not desirable because it results in reducing the selectivity and increasing the cost.

Types of collectors:
1. 2. Ionizing collector Non ionizing collector

Collectors contd.
The non ionizing collectors are practically insoluble in water and cause the particles to become hydrophobic by covering them with a thin film. The ionizing collector adsorb either physically or chemically on the particles surface and can further b classified into anionic and cationic collectors depending upon the nature of the non polar hydrocarbon group. common examples of the ionizing collectors include Fatty acids Long chain sulphates Sulphonates Amines Xanthates Dithiophosphates

Frothers
These are also surface active agents added to the flotation pulp primarily to stabilise air bubbles for efffective particle bubble attachment and removal of the froth. The frother action is similar to the ionizing collectors except that thay concentrate primarily at air-liquid interface. Commonly used frothers are Pine Oil Short Chain Alcohol Polypropylene glycol Cresylic acid

Modifiers
Modifiers adsorb on the surface of particles or react chemically at the surface and prevent the adsorption of the collector or promotor. Flotation modifiers include several classes of chemicals Activator pH regulators Depressants Despersants and flocculants

Activators
Enhance the flotation by collectors that will not float in their absence e.g. calcium activated flotation of Quartz using oleate

pH Regulators
Regulators such as lime, caustic soda, soda ash and sulphuric acid are used to control or adjust pH , a very critical factor in many flotation separations.

Depressants
Depressants prevent the adsorption of collectors and help in selectivity or stop unwanted mineral from floating. Typical are sodium to depress pyrite, zinc sulphate to depress ZnS,lime to depress pyrite and lignin sulphonates to depress graphite.

Flotation Equipment
Various type of flotation machine designs can be classified into different categories on the methods used for the generation and introduction of air bubbles into the equipment . Each of the techniques has its own advantage and limitations. These must be considered carefully in selecting the equipment for a specific application. Following are some different flotation units used as flotation equipment.

Electrolytic flotation units

Electrolytic or electroflotaion is based on the generation of hydrogen and oxygen bubbles in a dilute aqueous solution by passing direct current between two electrodes.Electrical power to the electrodes is supplied at a low voltage potential of 5 to 10 volts. The power consumption is in the reage of 0.5 to 0.7kW/m of flotaion tank surface depending in the conductivity of the liquid and the distance between the electrodes.

Electrolytic flotation contd......

The main drawback of the electroflocation units is associated with the electrodes in terms of their fouling requiring mechanical energy and their consumption needing replacement at frequent intervals. Electroflocation is not expected to suitable for potable water treatment because of the possibly water treatment because of the possible heavy metals contamination that can arise due to dissolution of the electrodes.

Dissolved air flotation units

Vacuum flotation and pressure flotation are the two main types of dissolved air flotation processes,with the latter being most widely used.

Vacuum flotation
In vacuum flotation the process stream is saturated with air at atmospheric pressure and introduced to the flotation tank on which a vacuum is applied giving rise to the generation of the air bubbles. The process can be run only as a batch process and requires sophisticated equipment to produce and maintain the vacuum. By and large the amount of air released during flotation is limted by the vacuum achievable.

Pressure flotation
In contrast to vacuum flotation dissolved air flotation unit can be operated on continued basis by the application of pressure.this consist of pressurising and aerating process stream and introducing it into the flotation vesel that is maintained at low atmospheric pressure.the reduction of pressier resultys in the formaiton of fine air bubbles and the collection of fine pariculates to be floated and removed as sludge.

Pressure flotation cont...

Pressurisation could be carried out on the entire feed stream or a fraction of the feed stream while the remainder is introduced directly without aeration into the flotation tank.the split flotation system offers a cost saving over the full flow units.in both cases however is the solid particles in the feed stream are flocullated before introducing top the flotation tank,the high shear during pressurisation,aeration and pressre release can destroy flocs. The dissolved air flotation process is more commonly used for sewage and potable water treatment.it is gaining popularity for thetreatment of slaughter house,poultry processing,sea food processing and food processing in wastes.

Dispersed air flotation units

Dispersed air flotation involves the generation iof air bubbles either pneumetically Or by mechanical means.in both cases relatively large air bubbles are generated.in order to control the size and stability of air bubbles frothere are added to the flotation devices. Mechanical flotation machines are most commonly used in mineral industry while pneumatic column type unit are gaining popularity in recnt.

Mechanical Cells
In a typical installation a number of flotation cells are connected in series such that each cell output froth into a launder.and the underflow from one cell goes to the next one.The cell design may be such that the flow of slurry from one cell to another can neither be restricted by weirs or unrestricted. The mechanical cells that are most widely used today in sulfide,coal and non metallic flotation operation are made by Fagergren,Denver and Outokumpy.

Mechanical cells cont...

These machines provide mechanical agitation and aeration by means of a rotation impeller on an upright shaft.in addition the agitair and Denver cells also utilise air from a blower to help aerate the pulp.

.Large scale flotation machine offer advantages of lower installed cost, lower operating cost,lower floor space requirement.However it should be noted that large flotation cells do not permit a reduction in the number of cells in a series.The use of large flotation cells does enable a few number of parallel rows and therby permits a reduction in pumps piping and other auxiliaries.

Flotation columns
Flotations columns belong the class of pneumatic devices in that air bubble generation is accomplished by a gas sparging system and no mechanical agitation is employed.Inputs to the column include pre conditioned slurry feed and air and wash water spray which are introduced at about two third of height from the bottom,in the bottom region and at the top of the column respectively.The outputs are froth overflow consisting of hydrophobic particles from the top and underflow from the bottom of the tank,carrying the non floatable hydrophilic particles. The main advantages of the flotation column technology include : - Improved recovery - Optimized grade - Increased throughput

Column Flotation

COLUMN FLOTATION CELLS BETTER SUITED TO FLOTATION OF FINES

Flotation columns cont.... Advantages

Improved seperation performance particularly for fine materials. Low Capital cost. Low operating cost. Low plant floor space requirments Easy adaptability to automatic control Simplicity in construction Flexibility in operation.

Uses
It is used in Iron ore Copper,Lead Zinc and coal flotation processes.