Flotation Equipment

and
Processes

By
Dr. Corby G. Anderson
Kroll Institute for Extractive Metallurgy
Colorado School of Mines
 Flotation
Flotation is the primary concentration process based upon
the interfacial chemistry of mineral particles in solution,
other processes based on surface properties include:
selective flocculation, selective agglomeration, and
various modifications of the flotation processes.
North American Tungsten Sulfide Flotation
 Flotation
Flotation is the dominant mineral concentration method,
used for sulfide minerals, non-sulfide minerals, industrial
minerals and coal.

It can be applied to some low grade ores and to minerals

that require fine grinding for liberation.

It can be a relatively selective process.

It is important to the treatment of complex ores, for

example sulfide ores containing copper, lead and zinc.
 Flotation Equipment
There are two groups of variables in
concentration by flotation:

chemical conditions :(the interaction of

chemical reagents with the mineral particle
surface to make one selectively hydrophobic)

physical-mechanical conditions : (which are

determined by the flotation machine
characteristics).
 Flotation Equipment
Although there are equipment different designs, they
all have the primary function of:

 making the particles (that have to be rendered

hydrophobic) contact and adhere to air bubbles, thus
allowing those particles to rise to the surface and
form a froth.
 Flotation Equipment
To achieve this, a flotation machine must:

Maintain all the particles in suspension. This

requires that upward pulp velocities exceed the
settling velocity of all the particles present (including
the largest and heaviest).

Ensure that all the particles entering the machine

have the opportunity to be floated. Bypassing and
short circuiting through the machine should be
minimized.
 Flotation Equipment
To achieve this, a flotation machine must:

Avoid dead space as this is undesirable.It

reduces the effective volume of the machine

Disperse fine air bubbles throughout the pulp.

The extent of aeration required depends on the

particular mineral system and the mass to be
floated.
 Flotation Equipment
To achieve this, a flotation machine must:

Provide a quiescent pulp region immediately

below the froth to minimize pulp entrainment in
the froth and turbulent disruption of the froth
layer.

Provide sufficient depth of froth to permit

drainage of entrained particles to occur.
 Flotation Equipment
The selection of a particular type of flotation
machine for an application is not
straightforward. The main factors are:

Metallurgical performance, as represented by a

grade and recovery curve.

Capacity (tons per hour per unit volume).

 Flotation Equipment
The selection of a particular type of flotation
machine for an application is not
straightforward. The main factors are:

Operating costs per ton of feed, power

consumption, maintenance, direct labor, etc.

Ease of operation (which may be subjective and

based on past experience)
 Flotation Equipment
Many designs of flotation machines have been
developed.

They are based on two categories:

mechanical flotation machines

and
pneumatic flotation machines

(both as single cells or in banks of cells).

 Mechanical Flotation Machines
The most commonly used in the flotation of metallic
minerals.

Each individual machine has an impeller that rotates

within baffles.

Air is introduced through the impeller to provide

good dispersion and sufficient mixing to cause the
particle-bubble collisions that are essential to
particle-bubble attachment.
 Mechanical Flotation Machines
The air can be drawn through the impeller shaft or
through a stand pipe surrounding the shaft by the
suction created at the impeller (in which case the
aeration rate is limited by impeller design).

Air can be introduced under pressure.

These parameters (air flow and pressure) may be

used as a variable in the automatic control of
flotation operations.
 Mechanical Flotation Machines
The design of the impeller and dispersion baffles
varies widely.

All require a highly turbulent region to provide

particle bubble contact and a quiescent zone adjacent
to the froth layer in which the mineral laden bubbles
can rise to the surface.

The size of flotation cells have increased substantially

over the years. These large cells have been designed
using hydrodynamic scale up criteria.
 Mechanical Flotation Machines
Froth product discharge may be by direct overflow,
with or without the aid of paddles.

Pulp flow is from one cell to the next, with an overflow

weir between the cells, a partial baffle or no baffle.

The goal should be to obtain as close to perfect mixing

as possible.
 Pneumatic Flotation Machines
In both cell and tank types, mixing or air and
pulp occurs in injection nozzles.

In the flotation column, countercurrent flow is

established in the lower section of the column.

If water sprays are used at the top of the froth

column, enhanced drainage of entrained
particles from the froth can be obtained.
Mechanical Flotation Machines
Pneumatic Flotation Machines
Flotation Machine Summary
North American Tungsten Sulfide Flotation
Early Flotation Equipment
EARLY FLOTATION EQUIPMENT
Microflotation Testing
New Microflotation Column

Jordens, A. et al. 2014

Bench Scale Lab Flotation Machine
Maxwell Flotation Machine
Denver Flotation Machines
Denver D-R Flotation Machine
Outokumpu Flotation Cell Agitator
Wemco – Fagregren Flotation Cell
Cyclo-cell
Dissolved Air Flotation Machine
Dissolved Air Flotation Machine
Agitair Flotation Machine
 Cell Step Height
Each cell or bank of cells needs a certain drop to the next cell or bank
for driving head.

Total step height for bank

Courtesy of Outotec
Cell Step Height ????
Mechanical Cell Components: Tank

Courtesy of Outotec
Mechanical Cell Components: Conventional

Courtesy of Outotec
 Flotation Tanks
Made of steel plate. The beams on
top of the tank serve as support for
the drive unit

The tank inside can be lined with

rubber or painted with epoxy.

Access hatches – important

consideration

Courtesy of Outotec
 Tank Types: Conventional (OK-R)
Also known as rectangular cell,
OK-XX-R, 2R,4R(M)
Usually 2 cells together
Volumes 0.5 … 3 m3
Rotors 310 … 500 mm
Motors 2.75 … 15 kW
Double drives.
Level and air control per bank

Courtesy of Outotec
 Tank Types: Conventional (U-Cell)
OK-XX-U, 2U, 3U, 4U
One to four cells together
Volumes 8, 16, 28, 38 m3
Rotors 650 … 900 mm
Motors 15 … 75 kW
Single drives
Level and air control per bank
Sold from 1973 

Courtesy of Outotec
 Tank Types: Cylindrical (TankCell)
 Outotec’s range from 5 to 630 m3 !
 Have in built froth crowding
 Single drives
 Individual air and level control
 Even mixing profile and even air
distribution

Courtesy of Outotec
 Feed Boxes
Collects the feed streams
coming into the cells

It provides an opportunity for

air to escape the pulp before
entering the cell.

Reagents are often added to

these.

Bottom feed port directs feed at

mixing mechanism

Courtesy of Outotec
 Launders and Crowding
• Changing tank top configuration changes
performance.

• More froth
 More area
 More lip length
 Little or no crowding

• Less froth
 Less area
 Less lip length
 More crowding

Courtesy of Outotec
 Example Launder: Donut

• Froth flows into both sides of the

launder

• Tank walls taper in at top to

create outer froth crowder

• Inner & Outer areas

interconnected through an
“Equalisation Duct”

Courtesy of Outotec
 Example: External Peripheral
• More surface area
• More expensive
• Bigger footprint
• Does not consume tank volume

Courtesy of Outotec
 Drive Train
Belt drive
Low speed (6 .. 12 pole) foot
mounted motors
V-belt transmission

Direct Gear Drive

High speed (4 pole)
flange motors
No belts

Courtesy of Outotec
 FloatForce™ Mechanism
Pumping channel from the centre to
outer radius

Separate air dispersion slot

Sustained pumping under high aeration rates

Enhanced suspension of coarse solids

Decreased sanding

Minimised friction losses and impact angles

 lower wear

Courtesy of Outotec
Upflow Discharge Dart – Save Head

Downflow Upflow

Courtesy of Outotec
 Dart Valve Location
1. Conventional
• Dart valves in a box between the cells

2. Internal Darts
• Dart valves inside the tank,
on the floor

2.
1.
Internal
Classic Darts
Darts

Courtesy of Outotec
Internal Darts – Save Footprint Space

Courtesy of Outotec
 Flotation Cell Support Types
 Steel – grillage
 Concrete floor
 Concrete Mushroom

Courtesy of Outotec
Flotation Cell Construction

Courtesy of Outotec
Maintenance Frame

Courtesy of Outotec
 Tricky Layouts Can be Mastered
• Codelco Andina, 1997
• 32x TankCell®-100
• Concentrator built inside the
mountain!

Courtesy of Outotec
 Tricky Layouts Can be Mastered
• LKAB Kiruna, Sweden – 2001
• 6 x TankCell-100
• Existing plant with strict
space limitations

Courtesy of Outotec
TankCell e500 Development and Scale-up
 Same scale-up methodology and
rules used than for other proven and
successful large TankCells

• TankCell-100 (1995)
• TankCell-160 (1997)
• TankCell-200 (2002)
• TankCell-300 (2007)
• TankCell-500 (2013)
Now designing for 630 m3
Courtesy of Outotec
 Outotec e500 Flotation Cell Status
 Design complete

 Fabrication
complete

 First installation is
currently
underway!

Courtesy of Outotec
Photos: Introducing the e500 (500m3 tank)
> small one is 300m3 tank

Courtesy of Outotec
Energy Usage in Mechanical Cells
Theoretical Power = Np.ρ.N3.D5
Np = power number for mechanism
ρ = pulp density
N = rotational speed
D = impeller diameter

Actual Power = Efficiency x Theoretical Power

Air typically reduces power drawn by 10-20%

Courtesy of Outotec
 Flotation Cells

Courtesy of Outotec

6
 Flash Flotation Cell

Outotec SkimAir™

Courtesy of Outotec
Flotation Cell Bank

Courtesy of Outotec
 Flotation Cell Bank

Courtesy of Outotec

6 7/12/201 2012
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Flotation Equipment
Flotation Equipment
Flotation Equipment
 Flotation Equipment
and
Processes

By
Dr. Corby G. Anderson
Kroll Institute for Extractive Metallurgy
Colorado School of Mines