Mechanical

Flotation
 Presentation Outline

WEMCO Mechanical Flotation Products

SmartCell (Self Aspirating)
1+1 (Self Aspirating)

Operation
Components
SmartCell Performance
SmartCell & 1+1 Flotation Machines
SmartCell & 1+1
Flotation Machines

Similarities
Superior Metallurgical
Performance
Induced Air Mechanism
Elevated Rotor
Hood
Disperser
Draft Tube
False Bottom
Beveled Tank Bottom
SmartCell & 1+1
Flotation Machines

Differences
Tank Shape
Energy Consumption
Drive Mechanism
Radial Launders
Vertical Baffles
Improved Air Control
WEMCO Mechanism Operation

Characteristics
Self Aspirating
Primary Pulp Circulation
Secondary Pulp Circulation
Sanding Resistant
Superior Metallurgical
Performance
Components
Component Function

The V-Belt Drive transfers power from the motor to the rotor.
The V-belt drive has proven to be a dependable means of
power transfer, providing a high level of flotation machine
availability. In addition, the V-belt drive provides the most
efficient means of power transfer available
Component Function

The Mechanism Motor is a heavy

duty, high efficiency motor
designed to operate at elevation.
With proper maintenance, the
motor will provide years of
trouble free performance. The
motor is designed for vertical
operation in the Agitator
Mechanism as pictured.
Component Function

The Agitator Mechanism or

mechanism are terms
describing motor, rotor,
bearing housing assembly,
drive and driven sheaves,
standpipe, disperser,
disperser hood, froth
crowder, and the supporting
structure. The mechanism
is designed such that it can
be removed from the
flotation machine as a single
unit for service.
Component Function

The Froth Crowder and Standpipe

Assembly modifies the movement
of the froth and gives the froth a
velocity component in the direction
of the collection launders. The
crowder is provided to improve
metallurgical performance. The
standpipe is a rubber-lined
component of the mechanism that
is provided to control air intake and
stabilized the slurry vortex that
forms around an operating rotor.
Component Function

The Radial Launders and Vertical Baffles work together to improve

metallurgical performance.
SmartCell Flotation

Performance Benefits of Radial

Launders and Vertical Baffles
Increased Lip Length

Modified Froth Mobility Paths

Improved Surface Stability

Increased Recovery
Radial Launder Lip Length

WEMCO Cell Lip Length:Volume Comparison

0.55
WEMCO 1+1
Lip Length/Cell Vol., m/m3

0.45
SmartCell w/o
0.35 Radial
Launders
SmartCell with
0.25 8 Radial
Launders
0.15 SmartCell with
15 Radial
Launders
0.05
0 30 60 90 120 150 180 210
Cell Volume, m3
SmartCellFlotation

Froth-Mobility Paths
Cell # 1--CODELCO El Teniente

Cell 1--WEMCO 120 m3 SmartCells

16 Radial Launders
8 Vertical Baffles
1.0 % Cu Feed
13,000 MTPD
Component Function

The Rotor is the heart of the SmartCell flotation

machine and transfers mechanical energy into
pulp mixing, air draw, bubble formation, and
bubble/particle contact.
The Rotor Position, which is well above the tank
bottom, eliminates contact with abrasive, oversize
tramp material, thereby reducing wear on the rotor
and disperser surfaces. Induced airflow into the
pulp by the turning rotor provides efficient aeration
eliminating the need for blowers.
The Elevated Rotor also allows cells to restart
instantly after a shutdown, and it can be restarted
under full load. The rotor is designed to operate in
both the clockwise and counter-clockwise
positions and can be inverted, thus providing four
operating or wear positions. This feature provides
an exceptional wear-life.
The Connection/Discharge
Boxes each house dart valve
assemblies which control the
pulp level in the bank of
flotation cells immediately
upstream.
Circular Connection Box

Benefits
Shortens Row Length

Can Be Changed Quickly

Down Flow Design

Circular Box Layout
Internal Dart Valves

Hinged Darts
Reduce Space
Minimum Moving Parts
Low Maintenance
Component Function

The Draft Tube/False Bottom

promotes the circulation and
suspension of solids in the flotation
cell by drawing the pulp from the
tank bottom up the draft tube into
the rotor, where the pulp is mixed
with air and pumped back out into
the cell. Draft tubes are noted for
their efficiency of mixing. The false
bottom extends the effect of the
draft tube over the entire bottom of
the flotation cell.
Component Function

The Tank Bevel is provided to effectively reduce the area of the flotation cell
tank bottom. This reduced area allows for a false bottom of reduced
diameter. The net result is increased pumping velocities in the bottom of
the flotation machine and the ability to better transport oversize material.
This feature is particularly important in SAG mill plants where the supply
of oversize material to the flotation cells can be quite common.
Component Function

The SmartCell Tank has a cylindrical

shape that improves mixing and
air distribution because all points
on the tank periphery are
equidistant from the rotor. The
symmetry that is inherent in the
SmartCell tank provides a
significant improvement in
metallurgical performance over
rectangular flotation machines.
Component Function

The Disperser and Disperser Hood function to reduce the energy in the pulp
as it leaves the rotor and to modify the direction the pulp and air move
through the flotation cell. Both contribute to improving the surface
properties of the flotation cell.
Component Function

The Feed Box is located

at the head of each
flotation row providing
a means to uniformly
distribute feed into the
first cell of the row.
Component Function

The Ambient Air Intake is the point where ambient air is

drawn into the flotation air control assembly.
 Findings
from the
Chuquicamata
Competitive
Test
Chuquicamata

CODELCO Test Site

Presentation Objectives

Review Chuquicamata Test Findings:

Residence Time
Metallurgical Recovery
Hydrodynamics (RTD)

Why are we Concerned about

Flotation Cell Residence Time?

Metallurgical Performance (Recovery)

Recovery = F(K,T)
Flotation Kinetics
Plug Flow: R = Ro [1 - e-KT]

Well Mixed: R = Ro [KT / 1 + KT]

Klimpel: R = Ro [ 1 - (1-e-KT)/KT ]

120%

100%
Recovery, %

80%

60%

40%
Plug Flow

Well Mixed
20%
Klimpel

0%
0 5 10 15 20 25
KT
Hydrodynamics (RTD)

Tests were Conducted by Department of Nuclear

Applications, Chilean Commission of Nuclear
Energy to Determine the Residence Time
Distribution in Each Flotation Cell

RTDs were Determined for Both Liquid and Solids

Liquid RTD Tests--Tracer Br82

Solid Tracer Tests--Tracer Activated Na24
Solid Sample (Composite)
Solid Sample (+100 Mesh)
Solid Sample (- 100 +325 Mesh)
Solid Sample (- 325 Mesh)
 Hydrodynamics (RTD)

Tracer Added to Feed Box

Qf

Tracer Measured at
Discharge Box

Theoretical Mean Residence Time = Vn/Qf

Observed Mean Residence Time (50% of Area)
Hydrodynamics (RTD Liquid)

Chilean Commission of Nuclear Energy Report--Page 38

Hydrodynamics (RTD Solids)

Chilean Commission of Nuclear Energy Report--Page 34

Hydrodynamics (RTD)

Observed Mean Retension Time

7

6 Dorr Oliver
Minutes

5 Outokumpu
WEMCO
4

2
Liquid Solids Solids Solids Solids
(All) (325) (100-325) (100)
Hydrodynamics (RTD)

Observed Mean Retension Time

7

6 Dorr Oliver
Minutes

5 Outokumpu
WEMCO
4

2
Liquid Solids Solids Solids Solids
(All) (325) (100-325) (100)
Hydrodynamics

Data Analysis by Dr. Octave Levenspiel

Dr. Levenspiel is Widely Considered the Worlds

Foremost Authority on Reactor Design
and Mixing Kinetics

Dr. Octave Levenspiel

Distinguished Professor of Chemical Engineering
Oregon State University
Corvallis, Oregon USA
 Hydrodynamics (RTD)

Evaluating Residence Time Distributions

Levenspiels Diagnosis
Short Circuiting Lack of Mixing

Octave Levenspiel, Chemical Reactor Omnibook, Page 62-6, 1996

 Hydrodynamics (RTD)

Comparison of Observed and Theoretical Mean Residence Times, Min.

Tracer Test
Dorr Oliver Outokumpu WEMCO

Obs. Theory Obs./Theory, % Obs. Theory Obs./Theory, % Obs. Theory Obs./Theory, %

Liquid 5.3 5.2 101.9 3.2 5.6 57.1 6.2 5.6 110.7
All Solids 3.2 5.0 64.0 3.1 5.6 55.4 5.1 5.7 89.5
Fine Solids 3.4 5.2 65.4 2.6 5.5 47.3 5.5 5.5 100
Interm. Solids 2.9 5.3 54.7 3.0 5.6 53.6 5.0 5.5 90.9
Coarse Solids 3.9 5.1 76.5 3.1 5.2 59.6 5.2 5.8 89.6
Average Solids 65.1 54.0 92.5

Early Curve (Early Observed Mean Residence Time with

Respect to Theoretical) Means Stagnant Fluid.
Octave Levenspiel, Chemical Reactor Omnibook, Page 62-6, 1989
Hydrodynamics (RTD)

Analysis by Octave Levenspiel

No Evidence of Short Circuiting
No Evidence of Stagnant Areas in the
WEMCO SmartCell
Significant Stagnant Areas in Blown Cells

Stagnant Vessel Fraction, %

Tracer Material Dorr-Oliver Outokumpu WEMCO
Liquid 15 48 0
All Solids 37 39 0
Fine Solids 38 53 0
Intermediate 42 40 0
Coarse Solids 45 40 0
Average Solids 41 43 0
Hydrodynamics--CODELCO

Measured Flotation Cell Active Volume

Dorr Oliver
148.0 Outokumpu

160 WEMCO
3
Active Volume, M

96.3 86.4
120

80

40

0
Hydrodynamics

Residence Time is Important. It is the Criteria From

Which Flotation Circuits are Often Sized.

Average Residence Time for Solids:

Dorr Oliver 3.4 minutes
Outokumpu 3.0 minutes
WEMCO 5.2 minutes

Recovery = F(K,T)
Metallurgical Performance

Average Copper Recovery

73.4
75
71.3
73
Percent

71
68.2
69
67
65
Dorr OK WEMCO
 Metallurgical Performance

Normalized Test Results Dorr Oliver

80 Outokumpu
78 WEMCO
76
Cu Recovery

74
72
70
68
66
64
5 10 15 20 25
Concentrate Cu Grade
WEMCO Flotation

The Chuquicamata Test Results Provide an Indication of

How the First Two Cells in a Rougher Row will Perform
at the Test Conditions.
Feed

100

80

60 Recovery
% Cu

40 Grade
20

0
1 2 3 4 5 6 7 8 9
Flotation Cell
 Metallurgical Performance

Normalized Test Results Dorr Oliver

80 Outokumpu
WEMCO
78
76
Cu Recovery

74
72
70
68
66
64
5 10 15 20 25
Concentrate Cu Grade
 Why Competitive Tests

Value of 1% Copper Recovery

Assumptions: 5.0

350 Operating 4.0

US $1,000,000
Days/Year 3.0

2.0
0.6 % Feed
Copper Grade 1.0

0.0
$0.80/Lb. 0 40,000 80,000 120,000
Copper Tonnage, MTPD

A Small Recovery Advantage can have Significant

Financial Consequences