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Uraizee F and Narsimhan G (1996) Effects of kinetics of Weijenberg DC, Mulder JJ, Drinkenburg AAH and
adsorption and coalescence on continuous foam concen- Stemerding S (1978) The recovery of protein from po-
tration of proteins: Comparison of experimental results tato juice waste water by foam separation. Journal of
with model predictions. Biotechnology and Bioengineer- Engineering and Chemical Processing, Design and
ing 51: 384. Development 17: 209.
Column Zones
Initial Design Data The Sotation column, as generally built, is composed
The feed transport Suid must be characterized in of a number of distinct zones. Under the spargers
terms of liquid Sow rate and chemical composition. there is a dead volume (underSow zone) which is only
Component solids or immiscible liquid Sow rate, used to remove slurry from the vessel. The volume
material composition and size distribution must between the spargers and the feed port is called the
also be known. In all cases, mean values, standard collection zone. The volume between the feed port
1522 II / FLOTATION / Froth Processes and the Design of Column Flotation Cells
Under]ow Port
Generally, the output port is designed to pull from the
cross-sectional centre at the base of the vessel in order
to minimize both the Sow differences within the
collection zone and large scale slurry circulation pat-
terns.
The spargers are placed at a level such that the
furthest descent of bubbles is above the highest ex-
pected solids settling point.
Collection Zone
The collection zone is characterized by a stream of
individual bubbles rising against a descending liquid
Figure 1 Column hydrodynamic zone.
or slurry. This is the zone in which the bubble}par-
ticle attachment occurs. The capacity of the column is
dictated in part by the intensity of bubble}particle
and the froth interface is called the cleaning (recollec- collision (number of collisions per unit time), the
tion) zone and above the interface is the froth zone. probability of attachment, and the bubble surface
The froth zone may be further divided into the wash- area Sux through the vessel (removal ability) in this
ing zone, if it is under the wash water distributor, and zone.
the free drainage zone, if it is above. These zones are When sizing a column, certain assumptions are
illustrated in Figure 1. made. These include that the column operates with
dispersed bubbles that rise as a swarm without slugs.
It is also assumed that the Sow of bubbles, liquid and
Under]ow Zone solids is uniform across the column, and that there are
The physical dimensions of this zone should be mini- no large scale vortices.
mized since its roles are to ensure that there are no There are four main collection zone design criteria
small bubbles entrained by the downward Sow to the which determine the vessel dimensions: Soatable
underSow stream, that sloughing of the solids par- particle residence time, mixing characteristics,
ticles does not occur, and that the outSow from the maximum gas rate and bubble loading. The resulting
base of the column does not create unwanted Sow volume can usually be achieved with a range of
patterns within the active zones of the vessel. Bubble height-to-diameter options. The Rnal dimensions
entrainment to the underSow is obvious, as in this are also dictated by layout and economic consider-
case frothing occurs in the tailing sump or in the next ations. It should be emphasized that this zone must
open tank downstream of the column. be designed in parallel with the sparging system
A zone underneath the spargers does not contribute and froth zone as each of these parts inSuences the
to the Soatation collection or separation. Design con- others. The placement of the column within the
II / FLOTATION / Froth Processes and the Design of Column Flotation Cells 1523
operating circuit will also impact on the Rnal design Rate Constant
and operation.
The Soating ability of a material is generally referred
Solids Settling to as a rate constant, similar to chemical processes,
and is assumed (for simplicity) to be of Rrst-order
Particles settle within the column system since there is kinetics for each mineral component and size frac-
no mechanical agitation to suspend them. As such, tion. The value of this term is dependent on a com-
each particle will have a speciRc hindered settling plex function involving the collision/attachment and
velocity dependent on size, density of the particle and detachment, as well as processes occurring in other
the effective density and viscosity of the suspen- zones of the Sotation column (see below). These data
sion with modiRcations due to bubble-induced mix- are generally determined through test work. As mech-
ing. Mixing enhances particle suspension, so small anism and intensities of subprocesses (collision, at-
and/or light particles do not have their own trajectory tachment, detachment, entrainment) in column and
and follow liquid Sow more than in two-phase sys- impeller Sotation can be substantially different,
tems. The settling velocity generally has little inSu- the lab and pilot tests for column design and scale-up
ence on residence time for particles smaller than should also be made in columns. First-order Sotation
about 20 m, but becomes an important design con- rates for the components can be determined from the
dition for larger particles. recoveries in a continuous lab Sotation column, or by
simulation of kinetic tests by recycling column tails
Particle Residence Time Distribution back to the feed line.
Taking into consideration separate Rrst-order kin-
(RTD) etic models for individual subprocesses and taking
Material residence time depends upon the inherent into account free bubble surface reduction in the
mineral settling velocity under the conditions within upward direction would lead to complicated nonlin-
the column and the superRcial velocity of the slurry. ear kinetic equations. These are important in under-
The total collection zone height divided by the sum- standing the physics of the process, but cannot be
mation of the hindered settling and slurry velocities used for scale-up or control, due to unavoidably high
gives a total average residence time for each particle error in determining their coefRcients from ex-
size and density. More precisely, the particle resi- perimental data.
dence time is a stochastic parameter inSuenced by the
turbulent mixing and potential macrocirculation pat- Carrying Capacity
terns within the column. The removal capability of the bubbles is called the
carrying capacity and is the general term which char-
Elementary Processes
acterizes the maximum amount of solids carried by
Flotation depends on the elementary processes of the air bubbles (either in reference to the maximum
collision and attachment. In columns the probability capacity of the column, or to the maximum capacity
of collision between a particle and a bubble remains per air volume). This refers to the fact that only
virtually constant within the collection zone. There is a speciRc amount of particles can be attached to and
a higher probability of attachment at the bottom of removed by a certain bubble area. Thus, the max-
a countercurrent column since bubble surface cover- imum Soatable solids removal or the surface area of
age by particles is low for newly formed bubbles. This attached particles is related to bubble surface area
maximizes the recovery of the small proportion of Sux.
particles targeted for Sotation that are still present in Typically, the distance between spargers and the
the lower parts of the zone. slurry}froth interface is between 6 and 12 m. This
The relative movement of slurry and rising bubbles leads to a substantial mass of particles attached to
is the main source of mixing energy in columns. This a bubble (bubble loading).
results in a low intensity of the turbulence (low energy As bubbles become loaded by collected particles,
dissipation and large internal scale of turbulence) and, the contact time between particle and bubble reduces
therefore, low relative bubble}particle velocities and due to the shortening of particle trajectory along the
accelerations. Bubble}particle collision efRciency free bubble surface. This means that the rate of collec-
is due to gravitational and inertial particle drift from tion slows as loading increases, especially when the
the liquid streamlines around the rising bubble and lower section of a bubble is virtually covered by
due to the interception. The probability of particle attached particles. Detachment probability is also
detachment from bubbles is limited since the velocity much higher for particles attached to the upper hemi-
gradient around the bubble is minimized. sphere of a bubble.
1524 II / FLOTATION / Froth Processes and the Design of Column Flotation Cells
Smaller bubbles can carry more solids than larger several approximation formulae. D ranges from 0,
bubbles, assuming an equal gas rate and that the for perfectly mixed systems, to inRnity, for plug
loaded bubbles have sufRcient buoyancy to move Sow. The following variables have an effect
against slurry Sow. A smaller weight of Rne particles on the Peclet number: bubble size and number
can be carried at a constant gas rate and bubble size of bubbles (which are dependent on gas rate and
distribution than that of coarse particles. surface tension), slurry rate, particle settling
Carrying capacity limitations should be taken into velocity, collection zone height and diameter. At
account when estimating height-to-diameter ratio for a constant collection zone volume, a taller column is
columns working at high overSow (froth) yield. Typi- better from a Sow structure perspective as less mixing
cal carrying capacity per unit column cross-sectional is induced. Peclet number can be estimated using one
area for base metal minerals Sotation is 2.5 t/(m2 h) of the experimental relationships, or from particle
and for coal Sotation 1.5 t/(m2 h). residence time distribution (RTD) similar to that in
chemical reactors or separation equipment. RTD can
Gas Rate and Bubble Size be directly measured using a tracer method. Disper-
sion of the RTD can be used to calculate turbulent
Column cells are operated in the bubbly region where
diffusion D and other column Sow structure
bubbles rise in a swarm. The Sow regime in the
criteria.
column may change to the churn-turbulent condi-
The absence of an agitator limits the formation of
tion when coalescence is caused by gas entering a re-
large scale Sow loops unless the column is operated in
gion faster than it can leave as small bubbles. As
a high air rate, churn-turbulent Sow or the feed distri-
smaller bubbles have lower swarm rising velocity, the
bution of either air or slurry is not even. Low mixing
Sooding occurs at a lower gas rate for Rne bubble
intensity and lack of circulation contours cause par-
dispersions. Thus, there is a link between maximum
ticle residence times to be highly dependent on the
gas rate at the Sooding point and bubble size. Also,
particle settling velocity. Reduced mixing leads to
Sooding is enhanced by countercurrent slurry Sow;
lowering of local upward Sow intensities which min-
the higher its superRcial velocity, the lower the gas
imizes particle entrainment to the froth. Thus, at
rate at the Sooding point. At bubble size ranges used
a constant collection zone volume (slurry retention
for column Sotation, Sooding occurs typically at
time), its increased height leads to lower mixing
a superRcial air velocity of 2.5}3 cm s\1. More pre-
intensity and improved (due to this) metallurgical
cise values can be calculated from the drift Sux
results up to the point when restrictions in carrying
model.
capacity limits concentrate (Soat product) yield.
It is also possible for uniform countercurrent
Also, higher superRcial slurry velocity reduces
froth Sow to occur in the column even at lower
negative inSuence of mixing and slime entrainment
superRcial air and slurry rates when the bubbles are
intensity.
very stable (gas hold-up at both bubble and froth Sow
Careful design and positioning of any bafSes
regimes can also be estimated based on the drift Sux
(horizontal or vertical), the feed system, and any
model).
internal piping that may be needed minimize local
turbulence. The feed pipe must be located high
Mixing
enough in the column to maximize the collection zone
Columns are commonly sized with a dispersion length but also low enough to limit turbulence at the
method which uses the Peclet number, a dimension- slurry}froth interface.
less criterion, to characterize mixing. It is assumed
that an axial dispersion model adequately reSects
Entrainment
Sow structure in the collection zone. It is also possible
to use a tanks-in-series Sow model. The Peclet num- Fine and/or light hydrophilic particles may pass up-
ber reSects the ratio between the downward path of wards through the collection zone by entrainment.
particle and the average length of its stochastic drift There are two forms of entrainment. In the Rrst,
due to mixing (diffusion). It is equal to UL/D, a portion of feed water containing suspended Rne
where U is the mean velocity of the phase of interest particles passes into the froth. This type of entrain-
(for particles it is the sum of downward liquid velo- ment can be minimized by maintaining a net down-
city and a hindered settling velocity), L is the charac- ward Sow of water through the upper column zones.
teristic length scale for the apparatus (collection zone The second form of entrainment is the capture of
height of the column), and D is the turbulent disper- particles in the eddies behind a rising bubble. These
sion (diffusion) coefRcient. The latter can be particles are also rejected in the froth zone operating
determined by a tracer technique or by using one of with positive bias.
II / FLOTATION / Froth Processes and the Design of Column Flotation Cells 1525
and possible froth collapse. Care must be taken in ing; uniformity of air hold-up across the vessel, min-
the design of the distributor to ensure even cross- imization of scale formation, resistance to wear, re-
sectional wash water Sows. quired air pressure and maintenance considerations.
There are many types of spargers used in column
Froth Zone Dimensions cells. Pneumatic (porous media or perforated) spar-
Although the froth zone usually has the same cross- gers form bubbles at small oriRces. Pneumohydraulic
sectional area as the collection zone, it may be necked spargers break up an air stream into bubbles by
to promote crowding which increases the upward a water jet as an air-water mixture is distributed into
velocity in the froth. This may be done when small the column. The air jet spargers form bubbles through
amounts of froth are generated, reagent conditions the high velocity injection of air into the column.
dictate that the froth will not be stable, or the size There are also a class of spargers termed external
distribution of solid particles in the froth promotes spargers that aerate the feed slurry, or portion of the
coalescence of bubbles. It is more common to pre- underSow, and use the column as a de-aeration or
serve the overall area and apply internal bafSing bubble separation vessel rather than for particle col-
and launders. Internal bafSes may be added to lection. Combination of external spargers for slurry
support the froth, or to contain or localize froth pre-aeration with microbubbles and/or dissolved air
collapse. with internal spargers to facilitate microbubble buoy-
ancy by adding larger bubbles is optimal for a wide
Internal Launders range of applications (see below). In recent years, the
general trend among major column suppliers is to use
Syneresis and coalescence occur within the froth air jet and external types of spargers, although speci-
zone. Thus, relative to a localized section of froth, Rc circumstances dictate the use of other types.
bubble surface area is lost with time as that section Care must be taken when designing the bubble
travels from the slurry}froth interface to the overSow distribution system to ensure that an even Sow of
points. Furthermore, analysis of particle RTD in froth bubbles is generated. Poor air distribution can cause
indicates that horizontal transport to the froth large scale Sow patterns in the column that are detri-
launder is very slow. For larger diameter columns, mental to performance. Macrocirculation zones can
dead zones can form in the central part of the vessel. also be caused by a misalignment of the column either
Columns normally do not have froth skimmers or by bows along the length or by offsets from the
paddles. Therefore, fast froth removal is critically vertical.
important for operation and is often achieved by
a series of internal froth launders.
Pre-Aeration
Organic Pad Columns, by nature, have low turbulent momentum
between the bubbles and particles, meaning that
Liquid}liquid column applications may be operated smaller particles have slow Sotation kinetics in these
with an organic pad on the top of the vessel. Organics vessels. The column is, however, a good separator of
Soated in the collection zone gather at the surface of bubbles from the feed slurry, especially if wash water
the vessel. These may overSow a weir continuously if is added. This feature virtually eliminates hydrophilic
the organics concentration is sufRcient or if low entrainment. In order to improve the collection of Rne
concentrations of organics in the overSow stream are particles, a pre-aeration system or intense Sotation
acceptable. Otherwise, the pad accumulates and is device can be used. These devices act by creating
dumped on a regular basis. If some or all of the a turbulent zone, where the inertial momentum of
organic compounds present in the system are volatile, both bubbles and particles is high (due to high inten-
a pad may not be suitable or dumping must be fre- sity turbulence and velocity gradients) enabling high-
quent to prevent excessive stripping. er recovery of the smallest Soatable particles by
microbubbles. If the pressure in the pre-aeration de-
vice is substantial, a portion of air is dissolved and
Air-Sparging Systems then released in a column; normally, nucleation of air
The purpose of the sparging system is to distribute bubbles occurs at a solid surface, thus a collision stage
evenly the appropriate-sized bubbles near the bottom of Sotation process is eliminated for the cavitation
of the column. The sparging system is critical and bubbles.
must be designed taking into consideration many Pre-aeration devices then feed a modiRed column
elements, including bubble size distribution, max- which acts as a recollection device for the larger
imum air rate, bubble coalescence and induced mix- particles and a bubble coalescence/separation system.
II / FLOTATION / Historical Development 1527
Civil Engineering and Material Special attention should be paid to the carrying
of Construction capacity of air bubbles and to secondary upgrading in
the froth.
The Rnal column design must be site-speciRc. There Design of air-sparging systems, feed distributors
may be height and/or area considerations due to re- and also froth discharge systems is critically impor-
strictions of space, and weight and loading consider- tant for successful column operation.
ations due to foundation requirements. In addition, Unconventional design and use of pre-aeration sys-
some environmental considerations such as wind tems are the main trends in Sotation column develop-
load, earthquake zone and rainfall intensity will af- ment at present.
fect steel thickness, foundations and attachments,
braces and access platforms. As columns are normally See also: II/Flotation: Column Cells.
much taller than mechanical Sotation cells, they are
often located outside, and these factors can play an
important role in column design. There are also pro- Further Reading
cess considerations like per cent solids, wear factors, Clift R, Grace JR and Weber ME (1987) Bubbles Drops
chemical composition of the slurry (pH, etc.) and and Particles. New York: Academic Press.
particle size distribution which affect the phys- Dobby GS and Finch JA (1986) Flotation column scale-up
ical structure, pipe sizing and materials of construc- and modelling. CIM Bulletin 79: 89}96.
tion. In special cases, these units may be designed as Finch JA and Dobby GS (1990) Column Flotation. Oxford:
pressurized vessels or as enclosed systems. Pergamon.
Levenspiel O (1972) Chemical Reaction Engineering. 2nd
For example, many oil}water separation columns
edn. New York: Wiley.
are pressurized or some installations use circulating Lynch AJ, Johnson NW, Manlapig EV and Thorne CG
inert gases to minimize oxidation. When columns are (1981) Mineral and Coal Flotation Circuits, Their Simu-
installed for oil}water separation duties, mainly on lation and Control. New York: Elsevier.
offshore platforms, a circulating hydrocarbon gas Masliyah JH (1979) Hindered settling in a multi-species
(propane) is often used instead of air. particle system. Chemical Engineering Science 34:
1166}1168.
Ross VE and van Deventer JSJ (1988) Mass transport in
Conclusions Sotation column froths. Column Flotation 88. Proceed-
Despite its simple design, the scale-up and modelling ings of the International Symposium, Phoenix, Arizona.
of column Sotation is a complex problem. It includes Littleton, Colorado: Society of Mining Engineers.
Rubinstein JB (1995) Column Flotation, Processes, Designs
analysis of three-phase three-dimensional Sow in col-
and Practices. Basel: Gordon and Breach.
lection and cleaning zones and in the washed thick Schuhmann R. (1942) Flotation kinetics 1: methods for
froth layer. In the last few years, a technique for steady state study of Sotation process. Journal of Phys-
column design has been developed. Its adequacy has ical Chemistry 46: 891}902.
been conRrmed by many columns installed world- Zhou ZA, Xu Z and Finch JA (1994) On the role of
wide for a wide range of mineral and other applica- cavitation in particle collection during Sotation } a criti-
tions. cal review. Mineral Engineering 7: 1073}1084.
Historical Development
Z. Xu, University of Alberta, Edmonton, Alberta, liquid) to ions and molecules, while the most com-
Canada monly used carriers are air bubbles due to their ready
Copyright ^ 2000 Academic Press availability, easy handling and very low cost. Com-
pared to other light Suids (e.g. parafRn oil), air
has the highest hydrophobicity, and its low density
Flotation is a versatile, surface wettability-based sep- facilitates mass transfer of bubble-target aggregates
aration process, usually taking place in an aqueous from the bulk medium to the interface where froth
medium. In Sotation, a water-repellent (hydropho- forms and is collected/removed. Flotation was prac-
bic) target to be separated is attached to a carrier tised around a century ago, mainly for mineral separ-
lighter than the medium in which separation occurs. ation applications. It is difRcult, if not impossible,
The target varies from Rne particulates (solid or to pin down who should be given credit for the