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The Froth Stability Column Measuring Froth Stability at an
Industrial Scale
N Barbian1, K Hadler1 and J J Cilliers1
ABSTRACT
Froth structure and stability are known to play important roles in
determining mineral flotation recovery and selectivity. However,
measuring froth stability in a consistent manner remains a significant
challenge, especially at an industrial scale. Following preliminary tests on
a copper concentration plant, a quantitative dynamic stability measure is
investigated in this study in order to extend the results over a wider range
of conditions and on a different orebody. The technique is based on the
Bikerman foam test and uses a non-overflowing froth column to quantify
froth stability.
Experiments were carried out using an automated version of the froth
stability column under different operating conditions. Air flowrate was
the key operating variable. Tests were reproduced on a single flotation
cell of a Platinum Group Metals concentrator. The froth stability factor,
, was measured for each operating condition, and compared with the air
recovery in the cell, , which was measured using image analysis. The
froth stability column results gave the same trends as image analysis. In
particular the froth stability factor was found to be linearly related to the
actual fraction of air overflowing the cell.
The metallurgical results clearly indicated that changes in air flowrate
result in variations in flotation performance that can be attributed to
changes in froth stability. The results showed that high froth stability
conditions occur at intermediate air flowrates, and result in improved
flotation performance. It is found that the froth stability column is a
simple, cost-effective and reliable method for quantifying froth stability,
and for indicating changes in flotation performance.
INTRODUCTION
Froth structure and froth stability are known to play a significant
role in determining the grade and recovery achieved from a
flotation operation. Previous studies (for example Banford et al,
1998, Ventura-Medina and Cilliers, 2002) have attempted to
quantify various stability and structure measures, and to link
these to the flotation recovery and selectivity. Ventura-Medina et
al (2003) recently related changes in the fraction of air
overflowing the weir, or air recovery, to variations in the
performance of a copper flotation process. This confirmed the
importance of froth stability on flotation performance and
established the need for the direct measurement and monitoring
of froth stability.
A multiplicity of dynamic and static methods have been
proposed to measure the stability of foams. These were reviewed
and evaluated by Bikerman (1973), who also proposed a simple,
dynamic method in which the foam rises in an open column and
the rise rate is measured. This test was adapted for mineral
flotation froths by Barbian et al (2003) and tested on laboratory
scale, before being introduced to industrial scale on a copper
sulfide flotation cell (Barbian et al, 2005). Although results
showed that the froth column was an effective method for
predicting variations in froth stability, the range of operating
conditions remained limited. As a result, the small changes
observed in froth stability on a single cell could not accurately be
related to variations in flotation performance.
1. Froth and Foam Research Group, Chemical Engineering, The
University of Manchester, PO Box 88, Manchester M60 1QD, United
Kingdom.
Centenary of Flotation Symposium Brisbane, QLD, 6 - 9 June 2005
THE FROTH STABILITY COLUMN
Background
Barbian et al (2005) introduced the principles and experimental
procedure for using the froth stability column at an industrial
scale. They carried out their measurements using a square
vertical transparent column, constructed of Perspex. The column
was inserted through the froth to below the pulp-froth interface
in the flotation cell, adequately low to avoid froth leakage from
the bottom. Once inserted, the froth rises up inside the column
and the froth height, H, is measured as a function of time, t,
using the pulp-froth interface as the reference. After some time,
depending on the froth stability and operating conditions, the
froth rise stops and it reaches a constant height, Hmax.
The froth height in the froth stability column was recorded
visually as a function of time and was fitted by an exponential
model of the form:
t
H( t ) = Hmax 1 e (1)
Finally they defined a factor (H) representing the fraction of
air remaining in the froth at a given froth height H:
dH(t) A ( Hmax H( t )) A
( H ) = = (2)
dt Q Q
The stable fraction, , can then be determined as a function of
the froth height, while the relationship between H(t) and Hmax
depends on frother concentration, air flowrate or even the
position of the flotation cell down the bank.
Preliminary tests at industrial scale
Barbian et al (2005) tested the froth stability column on the
second cell of the rougher bank circuit (Module 2) at
Northparkes Mine, north eastern Australia. The ore processed in
Northparkes contains copper as sulfide minerals (mainly bornite
Cu5FeS4, and chalcopyrite CuFeS2).
The experimental set-up allowed them to measure the froth
rise rate and ultimate height, while confirming the importance of
air flowrate on froth stability previously observed at laboratory
scale (Barbian et al, 2003). The authors also showed in
laboratory experiments that the air recovery in the cell at a
specific froth depth could be very accurately estimated from the
stability factor . However, the froth stabilities experienced in the
single cell were restricted to a narrow range and no clear
relationship could be established between the air recovery and
the stability factor . In addition the range of operating
conditions on plant remained limited and the small changes
observed in froth stability on a single cell could not accurately be
related to variations in flotation performance.
This work presents the application of a newly automated
version of the froth stability column to an industrial scale. The
aim of the study is to test the technique over a wider range of
operating conditions, and to confirm the relationship between
operational variables and flotation performance as a result of
changes in froth measured stability.
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N BARBIAN, K HADLER and J J CILLIERS

EXPERIMENTAL SYSTEM Froth stability column

Experiments were carried out on a Platinum Group Metal (PGM)
ore in the rougher cells of the primary flotation circuit at BRPM,
South Africa. The rougher cells are Outokumpu cells with twin
crowders and a donut launder in the middle. One froth crowder is
from the impeller outwards and the second one is from a position
half way to the outer wall outwards. The cell dimensions are
given on Figure 1. It is possible to increase or decrease the
amount of air introduced into each cell. All changes and
measurements were done on the second cell of the rougher bank
under steady state. A time of 20 minutes was allowed to reach
steady state between each experiment. A solids feed tonnage of
340 t/hr was used in all experiments, with the feed to the rougher
bank containing a solid content of 45 per cent by mass. Samples
of feed to the bank and concentrate and tails in the first two cells
were taken for each experiment. In addition, the design of the
first two cells allowed for the concentrate mass flowrates to be
measured. After filtering and drying, samples were analysed at
the plant laboratory for solids content, and assayed for PGM FIG 2 - Position of the froth stability column in the flotation cell.
content.

4.5 m cell standard aeration rate. The froth depth was fixed at 24 cm
3.2 m and the reagents concentration was kept constant at the plant
standard level for the duration of the study.

RESULTS AND DISCUSSION

Froth stability column

Figure 3 illustrates a typical measurement of the froth height
2.6 m 2.2 m over time using the froth stability column in the second flotation
Launder
cell of the rougher bank. The data points were obtained for an air
Froth flowrate of 9 m3/min. Also shown on Figure 3 is fit to the
experimental data using Equation 1. Note that the amount of
noise on Figure 3 is relatively high due to the high frequency of
Impeller measurements. However, Equation 1 remains a good fit to the
experimental data as found previously in Northparkes (Barbian
et al, 2005) allowing Hmax, and to be estimated after a short
FIG 1 - Dimensions of a primary rougher flotation cell in BRPM,
time.
South Africa.

The froth stability column was used for measuring froth 0.6
stability in the second cell of the bank. Measurements were
Froth height in column (m)

carried out using a cylindrical (0.3 m diameter), vertical (1.5 m) 0.5

column. The column was secured onto the main railing on top of
the cell and inserted into the outer froth crowder, and to a depth 0.4
of approximately 0.25 m below the pulp-froth interface (Figure
2). The froth level in the column was measured electronically via
0.3
an ultrasonic sensor and recorded as a function of time. The -t/4.7
device allowed for measurements to be taken every second and H = 0.43(1-e )
logged on the plant online monitoring system. After some time, 0.2
3
depending on the froth stability and operating conditions, the 9 m /min
froth reaches a constant height when the growth and bursting 0.1
rates are equal. The method gives estimations on froth growth fit
rate, maximum froth height and bubble lifetime. 0
A digital video camera was set up near the lip of the outer 0 10 20 30 40
crowder and above the froth surface of the second cell. Under
steady state conditions and in each experiment the top surface of Time (min)
the froth was video recorded and subsequently processed. Images
were grabbed and analysed to estimate bubble size distribution,
FIG 3 - Typical variation of froth height with time in the second cell
average bubble size and froth velocity of the overflowing froth.
of the rougher bank at BRPM.
The image processing was performed using Smartfroth (Sweet et
al, 2000; De Jager et al, 2003). These parameters were obtained
by processing the recorded videos over a period of 20 minutes Table 1 summarises the estimated values for Hmax, and for
from which average values were produced. the different air flowrates studied. The stability factor, , was
The key operational variable manipulated during the study was calculated from Equation 2 using the froth rise velocity dH/dt at
the air flowrate Q introduced in the cell. The operating the operating froth depth. Figure 4 shows the variations of in
conditions were varied from 6 to 12 m3/hr, with 9 m3/hr as the the second cell with air flowrate. The plot clearly illustrates the

316 Brisbane, QLD, 6 - 9 June 2005 Centenary of Flotation Symposium

 THE FROTH STABILITY COLUMN MEASURING FROTH STABILITY AT AN INDUSTRIAL SCALE

influence of air rate on froth stability. The froth stability factor

first increases with air rate, reaches a maximum for 8 m3/min and 70%
finally decreases for values above 8 m3/min, indicating a drop in
froth stability at high air rates. This confirms the observations 60%
previously made at Northparkes (Barbian et al, 2005) where a
drop in froth stability was also observed at high air rates. In 50%
addition, the range of stabilities observed here on a single cell are

Air recovery
significantly wider than the ones obtained in Northparkes, 40% intitial
providing a higher degree of confidence in the effect of air rate 30% repeats
on froth stability. Additional experiments were performed on the
same rougher cell in order to confirm the peak in froth stability 20%
observed at 8 m3/min. The repeat experiments were carried out
on a different day, and results have been added on Figure 4. 10%
Although there is some scatter in the data plotted in Figure 4, the
trends clearly match the previous observations; the condition of 0%
high froth stability is met at 8 m3/min, while a higher air flowrate 0 2 4 6 8 10 12 14
results in a significant drop of the stability factor, . 3
Air flowrate Q (m /min)

TABLE 1
Estimated froth stability parameters from froth stability column FIG 5 - Variations in with air flowrate.
data.

Air flowrate Q Hmax be performed down the rougher bank to be able to establish a
(m3/min) (m) (min) (%) relationship between and . Figure 6 summarises the results
6 0.33 3.1 4.7 obtained in Northparkes. Although no clear relationship could be
7 0.51 7.19 5.1 established on the single cell studied in Northparkes (cell B), it
was shown that the two stability parameters were positively
8 0.34 1.63 7.3
correlated down the rougher bank, and that a decrease in could
9 0.43 4.7 4.2 be related to a drop in the fraction of air overflowing, which was
12 0.42 3.67 3.8 consistent with the depletion of material down the bank.

18%
8% 16%
= 1.7873
7% 14%
R2 = 0.7419
Froth Stability Factor

6% 12%
Air recovery

Cell A
5% 10% Cell B
initial
4% 8% Cell C
repeats
3% 6% Cell D
2% 4%

1% 2%
0%
0%
0 2 4 6 8 10 12 14 0% 2% 4% 6% 8% 10%

Air flowrate Q (m 3/min) Froth stability factor

FIG 6 - Air recovery ( ) as function of the froth column stability

FIG 4 - Variations in with air flowrate. parameter ( ) in Northparkes (Barbian et al, 2005).

The corresponding fraction of air overflowing the weir, or air
recovery , was estimated using the froth velocities measured by
image processing for each experiment. Figure 5 shows the
variations in with air flowrate both for the initial tests and the
repeat experiments. The trends given by video image analysis are
clearly consistent with the information obtained with the froth
stability column. The variations in indicate a peak in froth
stability at 8 m3/min, followed by a significant decrease in froth
stability at high air rates.
The relationship between and
In the previous tests in Northparkes (Barbian et al, 2005) the
froth stabilities experienced on a single cell were restricted to a
narrow range and therefore, additional froth stability tests had to
Figure 7 shows the relationship between both stability
measures in BRPM, and confirms that and are closely
correlated in a single cell. The results presented in this study
indicate that since the linear relationship is valid over a wide
range of froth stabilities, a simple calibration would allow one to
accurately estimate the air recovery at a specific froth depth in a
single flotation cell.
Similarly to the results obtained in Northparkes, the reason
why and are not equal in BRPM is that was measured in a
particular point in the cell, whereas was averaged over the
whole cell which is experiencing different superficial gas
velocities. Nevertheless, the experiments carried out confirm that
by measuring the rising velocity of the froth column, the fraction
can be inferred and used as an indicator of the froth stability in
the cell.

Centenary of Flotation Symposium Brisbane, QLD, 6 - 9 June 2005 317

N BARBIAN, K HADLER and J J CILLIERS

The performance results are consistent with the changes in froth

80.0% stability measured under the different air rates studied. Note that
the lowest air flowrate represents the origin on Figure 8. The high
70.0% froth residence time associated with the lowest air flowrate
= 8.116 resulted in an unstable froth and was characterised by low values
60.0% for (from the froth stability column) and (from image
R2 = 0.8731
Air recovery

50.0% analysis). As a result, the concentrate displays a high grade due to

the low entrainment rates and possibly high mineral attachment
40.0% associated with low aeration conditions (Ventura-Medina et al,
2004). However, the high concentrate grade is obtained at the
30.0%
expense of the recovery of valuable material, which remains low
20.0% because unstable froths generally result in a low overflow of
bubble surface (Ventura-Medina and Cilliers, 2002).
10.0% Consequently, a small increase in air flowrate will result in an
0.0% improved froth stability ( >5 per cent), and improved overflow of
valuable material. Increases in the aeration of the cell are expected
0.0% 2.0% 4.0% 6.0% 8.0% 10.0% to increase the entrainment rates and yield higher recoveries (Tao
Froth stability factor et al, 2000; Engelbrecht and Woodburn, 1975).
However, if the aeration is increased further, the froth becomes
unstable as indicated by image analysis and froth stability
FIG 7 - Air recovery ( ) as function of froth column stability column measurements ( <5 per cent) and breaks before
parameter ( ) in BRPM. overflowing the lip of the cell, releasing the attached particles. The
resulting froth is not stable enough to carry the valuable material
over the weir, preventing any further improvement in recovery.
Most of the overflow of valuable material therefore is made
Froth stability and flotation performance through entrainment, and a poor separation is achieved. The
optimal flotation performance is consequently observed under
Flotation performance is described by the PGM grade in the medium aerations, when both the grade and recovery are at their
concentrate and the PGM recovery in the second cell of the highest. The point of maximum froth stability appears, therefore,
primary rougher bank. Both grade and recovery are given relative to correlate closely with optimal flotation performance.
to the grade and recovery obtained for the lowest air flowrate
investigated (6 m3/min).
CONCLUSIONS
The grade/recovery data are plotted in Figure 8 for two
different types of froth: the unstable froths, for which <5 per The automated froth stability column was tested on a new
cent, and the stable froths, for which >5 per cent. Figure 8 orebody and over a wide range of operating conditions. The
suggests a link between froth stability and flotation performance. stability factor was measured under different air flowrates and
Although more data points would be warranted to confirm this compared with the fraction of air overflowing the cell, , which
observation, it appears that the grade-recovery plot is divided was measured using image analysis. The industrial experiments
into different stability regions, suggesting that the process allowed quantification of the influence of air flowrate on froth
performance and the froth stability factor are related. The stability and matched the results given by video image analysis.
conditions corresponding to high froth stability ( >5 per cent) In particular, the froth stability factor was found to be linearly
result in an overall higher performance, notably in terms of PGM related to the actual fraction of air overflowing the cell. The
recovery. On the other hand, the conditions corresponding to low results presented in this study indicate that the air recovery at a
froth stability ( <5 per cent), result in a lower PGM recoveries. specific froth depth in a single flotation cell can be accurately
estimated from the froth stability column results.
The metallurgical results indicated that changes in air flowrate
result in variations in flotation performance that can be attributed
to changes in froth stability. The study showed that high froth
0.015%
stability conditions occur at medium air flowrates, and result in
0.010% improved flotation performance.
These findings indicate that the froth stability factor can be
0.005% > 5% used to assess the stability of flotation froths at industrial scale
and appears to be an essential parameter in linking froth stability
PGM Grade

0.000%
beta > 5% and flotation performance. The results suggest that further work
-0.005% is required to build a complete model that incorporates the froth
beta < 5%
stability factor. Once such a descriptive model is developed, it
-0.010% will be possible to manipulate the flotation variables to produce
< 5% the optimal froth stability and flotation performance.
-0.015%

-0.020% REFERENCES
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-0.025%
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froth stability column: linking froth stability and flotation
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Barbian, N, Ventura-Medina, E and Cilliers, J J, 2003. Dynamic froth
FIG 8 - Grade-recovery plot showing different stability regions. stability in froth flotation, Minerals Engineering, 16:1111-1116.

318 Brisbane, QLD, 6 - 9 June 2005 Centenary of Flotation Symposium

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