Minerals Engineering 16 (2003) 11971203

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Froth recovery measurement in plant scale otation cells

a,* b,1 b,1
D.J. Alexander , J.P. Franzidis , E.V. Manlapig
a
JKTech, University of Queensland, Isles Road, Indooroopilly, Qld 4068, Australia
b
Julius Kruttschnitt Mineral Research Centre, University of Queensland, Isles Road, Indooroopilly, Qld 4068, Australia
Received 27 May 2003; accepted 14 July 2003

Abstract
Over recent years a number of techniques have been developed as part of the AMIRA 2 P9 project to represent mathematically or
measure directly sub-processes occurring in otation cells. These include the determination of:

a machine parameter (bubble surface area ux, Sb );

a froth parameter (froth recovery, Rf );
entrainment and drainage parameters (n and d); and
an ore oatability parameter (Pi ).

A methodology for estimating froth recovery in large scale plant otation cells is proposed. The primary aim of the technique is
to estimate the froth recovery in a way that is simple, inexpensive and non-intrusive. Plant engineers can use the estimate of froth
recovery in day to day trouble-shooting and circuit optimisation.
The current denition of froth recovery is given, along with a detailed description of the proposed methodology, equipment
required, assumptions and calculations. Advantages and limitations of the methodology are described and possible applications of
the froth recovery estimate in current otation circuit modeling are presented.

2003 Elsevier Ltd. All rights reserved.

Keywords: Flotation froths; Modelling; Process optimisation

1. Introduction Once validated, these sub-process models when com-

bined will provide the plant engineer with a tool for
Recent advances in the modelling of the otation optimising existing otation circuits.
process in industrial scale circuits have been based on A new method for measuring froth recovery in in-
the development of sub-process models of bubble sur- dustrial otation cells is proposed. The technique allows
face area ux (Gorain et al., 1997; Deglon et al., 1999), measurement of the froth performance in a otation cell
entrainment (Johnson, 1972; Savassi et al., 1998), ore directly, with minimum eect on cell operation. It is
oatability (Harris, 1997; Runge et al., 1997; Alexander based on a combination of two published methods to
and Morrison, 1998) and froth recovery (Vera et al., measure froth recovery; viz., Savassi et al. (1997) and
1999; Savassi et al., 1997; Mathe et al., 2000). However, Vera et al. (2000). This combination provides plant en-
all the above sub-process models are in their industrial gineers a method that will allow froth performance
scale infancy and extensive industrial trials are required measurements to be made easily in large scale otation
to collect data that will validate each sub-process model. cells. This paper outlines the previous work in this area
and describes the new experimental procedure to esti-
mate froth recovery.
*
Corresponding author. Tel.: +617-3365-5984; fax: +617-3365-
5900.
E-mail addresses: [email protected] (D.J. Alexander), 2. Background
[email protected] (J.P. Franzidis), e.manlapig@mail-
box.uq.edu.au (E.V. Manlapig).
1
Tel.: +617-3365-5888; fax: +617-3365-5999. Flotation is usually modelled as a single separation
2
Australian Mineral Industries Research Association. process with an overall rst order rate constant. In these
0892-6875/$ - see front matter
2003 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mineng.2003.07.016
1198 D.J. Alexander et al. / Minerals Engineering 16 (2003) 11971203

generalised approaches, it is often dicult to correlate y = -0.0019x + 0.113

First Order Rate Constant (min-1)

2
numerous commonly used operating parameters (ex- R = 0.9991
amples include air owrate, froth depth, etc.) with a 0.09
otation kinetic model. To overcome this problem, sev- 0.08
0.07
eral authors have suggested that the otation process 0.06
should be investigated by splitting the process into two 0.05
distinct phases; the pulp phase and the froth phase. Re- 0.04
cent studies into modelling the pulp phase in conven- 0.03
tional industrial otation cells have indicated that a 0.02
0.01
machine parameter (namely bubble surface area ux) and
0
distributed oatability components are a useful modeling 0 10 20 30 40 50
approach. A number of techniques have also been pro-
Froth Depth (cm)
posed to model the froth phase, including direct estima-
tion (Falutsu and Dobby, 1989; Savassi et al., 1997), mass Fig. 1. Linear relationship between overall rst order rate constant
balancing (Contini et al., 1988) and model tting (Moys, and froth depth.
1978; Yianatos et al., 1988). The majority of these tech-
niques were developed for batch otation cells or column
cells and are not applicable for continuously operated depth; i.e. y intercept. The collection zone rst order rate
industrial scale sub-aeration otation cells. constant can then be used to calculate the froth recovery
In a detailed critique of froth phase modelling, Mathe parameter at any froth depth using Eq. (1).
et al. (2000) concluded that the most practical approach The advantages of this technique are that it is simple
to modelling the froth phase in an industrial mechanical and applicable to various cell sizes, types and duties.
cell is to determine a froth recovery parameter. This However, the following factors have been found to limit
approach, developed for column cell otation, has been the applicability of this technique in most plant situa-
used by a number of authors (Feteris et al., 1987; Lap- tions:
lante et al., 1989; Finch and Dobby (1990); Mular and
Musara, 1991; Vera et al., 1999). Finch and Dobby the method is intrusive on the overall cell perfor-
(1990) dene the froth recovery parameter as mance;
k the method disturbs the performance of downstream
Rf 1 cells;
kc
the method generates a large number of samples;
where Rf is the froth recovery (%), k the overall rst the method assumes that entrainment has a minimal
order rate constant (min
1 ) and kc the collection zone impact on the general form of the relationship.
rst order rate constant (min
1 ).
In AMIRA P9 otation testwork, the froth recovery Savassi et al. (1997) proposed a method to estimate
parameter is currently estimated using the technique rst the froth recovery in large otation cells by collecting
developed by Feteris et al. (1987) and later used by samples of pulp just beneath the pulpfroth interface and
Laplante et al. (1989), Mular and Musara (1991) and the concentrate, and mass balancing the ow of attached
Vera et al. (1999). The technique involves varying the particles over the froth phase. The advantages of this
froth depth in a cell and taking samples of the feed, technique are that it is non-intrusive on the operation of
concentrate and tailings. These samples are assayed and the otation cell, removes the eect of entrainment, and
the information used to calculate the rst order rate downstream cells are not aected. However, Savassi et al.
constant for each froth depth, from the equation: (1997) noted that the main limitation of the method was
R that it was only applicable to rougher cells. This was
k 2 likely due to:
s  1
R
where R is the overall mineral recovery, and s the cell the diculty in estimating the attached particle grade;
residence time (min). the low mass of samples taken which may have high
Note that Eq. (2) assumes that the system behaves as sampling errors; and,
a perfect mixer. Previous authors have validated this the dierence between the attached and entrained
assumption in large industrial otation cells (Burgess, grade being typically too small in cells operated in
1997; Alexander et al., 2000). anything other than a rougher application, to allow
The overall rst order rate constant is then plotted use of the method with any degree of condence.
against froth depth to produce a linear relationship as
shown in Fig. 1. The collection zone rst order rate In this study, a new technique is proposed that im-
constant (kc ) is estimated by extrapolation to zero froth proves the estimate of froth recovery in a cell by com-
 D.J. Alexander et al. / Minerals Engineering 16 (2003) 11971203 1199

bining the methods of both Savassi et al. (1997) and

Vera et al. (1999).

3. Experimental technique

The following procedure is used to estimate froth

recovery in industrial cells:

Measure supercial gas velocity (Jg ) and air hold-up

(eg ) at various locations across the cell;
Take samples of feed, concentrate, tail, air hold-up
and top of the froth using appropriate sampling
equipment (see below);
Measure slurry weight, solids weight and percent sol- Fig. 3. Plant demonstration of the air hold-up probe.
ids, and assay all samples (by size if required);
Conduct a mass balance over the entire cell with the demonstrates the use of the air hold-up probe in taking a
appropriate sample standard deviations; sample 10 cm below the pulpfroth interface.
Conduct a mass balance over the concentrate stream Vera et al. (2000) proposed that a sample taken at the
with the appropriate sample standard deviations; very top of the froth and well away from the lip of the
Conduct a mass balance over the air hold-up with the cell should represent the grade of attached particles in
appropriate sample standard deviations; the pulp. This top of froth sample has been incorporated
Calculate the ow of attached particles entering and into this method for measuring froth recovery.
leaving the froth (the ratio of these is dened as the Mass balances over the cell, concentrate and pulp (air
froth recovery). hold-up) are required to estimate the mass owrate of
attached particles entering the froth and the mass
Cell characterisation measurements (i.e. the super- owrate of attached particles in the concentrate. Each
cial gas velocity and air hold-up measurements) are mass balance uses a least squares minimization tech-
made at several locations across the otation cell. The nique to estimate balanced ows and assays.
experimental techniques required are well documented
in Power et al. (2000).
Feed, concentrate and tail samples of individual cells 4. Theory
are taken using appropriate sampling equipment. These
samples are assayed and percent solids noted. The air The technique is based on three key assumptions:
hold-up is dened as the ratio of the volumetric fraction
of air to the overall volumetric fraction of air and pulp. The grade of the froth sample represents the grade of
Fig. 2 illustrates the measuring equipment used (note particles attached to bubbles;
that the air hold-up equipment is operated vertically). The average grade of particles attached to bubbles
Briey, the device comprises a cylindrical tube with two does not change over the froth phase;
air operated pinch valves at each end. The device is The grade of the tail sample is equivalent to the grade
lowered to about 10 cm below the pulp/froth interface of particles that are entrained in the water.
with the pinch valves closed. The pinch valves are then
opened and air and pulp travels through the device for All three assumptions can be tested on a cell, bank or
approximately 30 s. After this period, the pinch valves circuit basis. Varying the froth level in a cell and de-
are closed and the volume of pulp is measured. This termining the maximum concentrate grade produced
sample is analysed for percent solids and assayed. Fig. 3 from the cell can test the rst assumption. This is illus-
trated in Fig. 4 where the maximum grade in this in-
dustrial rougher cell is approximately 9.2%. This gure
Rubber tube Rubber tube
compared very well to the grade of the top of froth
Plastic cylindrical tube sample of 9.3%. In other cases, this result may not be
valid and hence this should be tested on a regular basis.
Recently, several authors have suggested that the
Compressed air Three-way valve froth is non-selective in terms of attached particles, i.e.,
Air line
that particles do not break their bonds with air bubbles
in the froth phase due to their hydrophobicity but rather
The atmosphere Pinch valve 1 Pinch valve 2
that the dropback of particles to the pulp phase is
Fig. 2. Air hold-up sampling device. caused by bubble breakage and coalescence. A simple
1200 D.J. Alexander et al. / Minerals Engineering 16 (2003) 11971203

10 The three assumptions outlined above allow a set of

9 mass balance equations to be formed over the froth
8 phase. The air hold-up sample taken directly below the
7
Grade (%)

pulpfroth interface and the supercial gas velocity

6
measurement are used to estimate the mass owrate of
5
attached particles entering the froth phase, based on the
4
3
following equation:
2 Pulp
MATT 3:6  QAir  BPulp 3
1
Pulp
0 where MATT is the mass owrate of attached particles in
0 100 200 300 400 500 the pulp zone (t/h), QAir the volumetric owrate of air
Froth Depth (mm) (m3 /s) and BPulp the bubble load in the pulp phase
(grams of solids/litre of air).
Fig. 4. Typical industrial otation cell response of valuable mineral
grade to variation in froth depth.
The volumetric owrate of air can be measured di-
rectly in each cell or estimated using the supercial gas
velocity measurements across the cell cross sectional
test to determine the validity of this assumption is to area:
plot the froth recovery of one mineral against another QAir A  Jg 4
mineral under the same conditions. This is illustrated in
Fig. 5 from data collected using the change in froth where Jg is the supercial gas velocity (cm/s) and A the
depths method described previously. A 45 line through open area of cell (m2 ).
the origin and passing through the experimental results The bubble load is dened as the mass of attached
supports the hypothesis of non-selective drop-back in solids per volume of air. Numerous authors have at-
this case. Selectivity to mineral type in the froth phase tempted to measure bubble load in laboratory environ-
would be indicated by deviation of the data from the 45 ments with limited applicability to industrial scale
line. There is evidence in the literature that this as- performance. Savassi et al. (1997) proposed a method to
sumption may not always be valid for some mineral estimate the bubble load in industrial otation cells. In
systems. this method, samples are collected just below the pulp/
The third assumption can be tested using the en- froth interface using a funnel connected to a vacuum
trainment analyser developed by Savassi et al. (1998) or (see Fig. 6). This technique was shown by Savassi et al.
by determining the mixing characteristics (i.e. plug ow (1997) to be very good for obtaining reliable bubble load
of perfect mixing) of the cell using a soluble tracer. The
entrainment analyser sample is the preferred method
because it is simple, direct and requires one extra sam-
ple. The grade from the entrainment sample can be C
compared directly to the grade of the tail sample and if
there is a discrepancy the entrainment sample grade P V
should be used.

1.00 2 B
R = 0.9967
0.90
0.80 (a)
0.70
Rf Mineral 1

0.60
0.50
180
0.40
0.30
0.20
0.10
0.00
0.00 0.20 0.40 0.60 0.80 1.00
(b)
Rf Mineral 2
Fig. 6. (a) Sketch of the bubble load analysergeneral layout (after
Fig. 5. Typical plant data showing that the froth is non-selective Savassi et al., 1997). (b) Sketch of the bubble load analyserfunnel
within experimental error. layout (after Savassi et al., 1997).
 D.J. Alexander et al. / Minerals Engineering 16 (2003) 11971203 1201

measurements in industrial cells. However, Savassi et al. grade of entrained particles (Gent ) is taken to be equiv-
(1997) also showed that the technique was not accurate alent to the grade of the tailings. This is in accordance
in low bubble load environments (scavengers) or in high with the assumptions made at the beginning of this
grade pulp environments (cleaners and recleaners). This section.
limited the application of the technique to the rougher The estimate of the mass of attached particles in the
sections of otation circuits. In addition, the method- air hold-up sample obtained from Eq. (6) can then be
ology was dicult to use in most plant applications used to calculate the mass owrate of attached particles
since it was time consuming and the equipment was not into the froth phase (Eqs. (3) and (5)).
particularly robust. The mass owrate of attached particles in the con-
A new method of obtaining bubble load is proposed centrate can be calculated using a similar mass balance
which is based on the Savassi technique, but uses more equation to Eq. (6) applied to the concentrate sample:
robust equipment and a more accurate method. It in- mConc
total  Gtotal
Gent
volves obtaining a sample using the air hold-up probe mconc
att 7
Gatt
Gent
and using the assumptions outlined above. Fig. 7 illus-
trates that air bubbles (with particles attached) and pulp where mConc
att is the mass owrate of attached particles in
(with particles entrained) pass through the air hold-up the concentrate stream (t/h), mConc
total the mass owrate of
sample in the open position. When the air hold-up probe all particles in the concentrate stream (t/h), Gent the
is closed, the attached particles become detached from grade of entrained particles in the concentrate, Gtotal the
the air bubbles and are included with the pulp con- concentrate grade and Gatt the grade of attached parti-
taining entrained particles and water. The volume of air cles in the concentrate.
and the mass and grade of the pulp sample are noted. The froth recovery of attached particles can then be
The bubble load can then be calculated using: calculated using the following equation:
matt  1000 mConc
att
BPulp 5 Rf 8
V mPulp
att
where matt is the mass of attached particles in the air where Rf is the froth recovery of attached particles, mConc
att
hold-up probe (g), V the volume of air measured in the the mass owrate of attached particles in the concen-
air hold-up probe (ml). trate stream (t/h) and mPulp
att the mass owrate of attached
The mass of attached particles in the air hold-up particles in the pulp (t/h).
probe is estimated using the following mass balance
equation: 4.1. Case studycentury zinc concentrator, Australia
mtotal  Gtotal
Gent
matt 6
Gatt
Gent The new froth recovery technique was used to mea-
sure froth recovery in a rougher and scavenger appli-
where mtotal is the total mass of particles in the air hold-
cation. In both cases, the otation cells were
up probe (g), Gent the grade of entrained particles in the
Outokumpu 100 m3 tank cells in the zinc circuit. Sam-
air hold-up probe, Gtotal the grade of all particles in the
ples of feed, concentrate, tail, air hold-up and top of
air hold-up probe and Gatt the grade of attached parti-
froth were taken from each of the cells and analysed for
cles in the air hold-up probe.
percent solids, lead, zinc, iron and silica. The supercial
In order to calculate the mass of attached particles
gas velocity was measured at several locations across the
(matt ), the grade of attached particles (Gatt ) is taken as
cell with the average supercial gas velocity calculated at
that of the grade of the top of froth sample, while the
1.43 and 1.30 cm/s in the rougher and scavenger, re-
spectively. Measurements of the average air hold-up
were estimated at 12% and 15% in the rougher and
scavenger, respectively. Froth depths of 50 cm in the
rougher and 20 cm in the scavenger were also recorded.
The bubble load was calculated using Eqs. (5) and (6).
Bubble load estimates of 46.8 and 29.2 g/l were calcu-
lated in the rougher and scavenger, respectively. The
rst point to note from these results is that the magni-
tude of the bubble loads are in a similar range to that
reported by Savassi et al. (1997). Secondly, the bubble
load attained in the rougher was signicantly higher
Fig. 7. Simple illustration of the use of the air hold-up probes in ob-
than the scavenger. This follows the logical argument
taining fast, robust and reliable bubble load estimates in large scale that more attached particles would be present in the
otation cells. rougher section of the circuit than the scavenger. Finally,
1202 D.J. Alexander et al. / Minerals Engineering 16 (2003) 11971203

the measurement was easily attained and time required to validate the proposed method at numerous sites and
for calculation was dependent only on the assay turn applications. Included in these studies will be a statisti-
around time. cal analysis to estimate the statistical reliability of these
The bubble load was used to calculate the mass measurements.
owrate of attached particles in the pulp phase (rougher
68.1 t/h; scavenger 38.7 t/h). In addition, a mass balance 4.2. Proposed areas of froth recovery technique use
of the concentrate sample was conducted to estimate the
mass owrate of attached particles in the concentrate The proposed froth recovery technique can be used in
(rougher 27.8 t/h; scavenger 35.5 t/h). The froth recovery the following areas:
was then calculated using Eq. (8). The estimate of the
froth recovery in the rougher cell was 40.8% and 91.6% For plant engineers to estimate froth recovery in op-
in the scavenger cell. The large dierence in the froth erating plant cells, to assist with operational trouble
recovery values measured was due to the dierence in shooting;
the froth depths in each of the cells (rougher 50 cm; For project engineers to estimate froth recovery in
scavenger 20 cm). Gorain et al. (1997) showed that operating plant cells, to assist with plant diagnosis
strong relationships between froth recovery and the and future project areas;
froth residence time of air and slurry existed. Examples For engineering consultants to measure froth recov-
of these relationships in a 100 m3 plant operating cell are ery in plant cells, to provide better models and simu-
shown in Figs. 8 and 9 from work previously conducted lators of otation circuits.
by the authors at another site. These relationships show
that small dierences in froth depth can have a large 4.3. Future work
impact on the froth recovery and is the likely reason for
the dierence in froth recovery between the two cells. The following work is proposed by the authors to
The study at Pasminco Century shows that the new improve the reliability of the froth recovery technique:
technique provides froth recovery and bubble load val-
ues which are similar to reported values in similar ap- Collect froth recovery measurements in dierent ap-
plications in the literature. Extensive testwork is planned plications to better dene the main areas of use.
These applications should include various cell types
and sizes, duties (i.e. rougher, cleaner scavenger,
etc.) and ore types (zinc, copper, nickel, etc.);
Measured Froth Recovery (%)

100.0%
90.0% Test the three main assumptions to determine the sit-
80.0%
70.0% y = 0.6862e-0.0046x uations where they do not apply;
60.0%
2
R = 0.6843 Conduct an error and statistical analysis on the froth
50.0% recovery technique by
40.0%
30.0%  Multiple measurements at similar conditions;
20.0%  Using a Monte Carlo simulation.
10.0%
0.0% Investigate the usefulness of the entrainment and
0.00 50.00 100.00 150.00 200.00 250.00 300.00 350.00 bubble load estimates in determining the impact
Froth Residence Time of Slurry (s) of various operating variables including reagent ef-
fects.
Fig. 8. Typical relationship between measured froth recovery and the
froth residence time of slurry in a 100 m3 Outukumpu tank cell.

5. Conclusion
Measured Froth Recovery (%)

100.0% A practical methodology for measuring the froth

90.0%
80.0% y = 1.4357e
-0.0519x
performance in plant scale otation cells has been pro-
2
70.0% R = 0.9079 posed. The technique was developed to improve the
60.0%
50.0%
practicality of two previous methods of measuring froth
40.0% recovery, namely, Savassi et al. (1997) and Vera et al.
30.0% (1999). The improvements were based on:
20.0%
10.0%
0.0% Measuring the froth performance in a sub-aerated
0.00 10.00 20.00 30.00 40.00 50.00
plant scale otation cell directly, with minimum eect
Froth Residence Time of Air (s)
on cell, bank or plant performance;
Fig. 9. Typical relationship between measured froth recovery and the Reducing sample numbers and time required to take
froth residence time of air in a 100 m3 Outukumpu tank cell. measurement.
 D.J. Alexander et al. / Minerals Engineering 16 (2003) 11971203 1203

The technique requires three assumptions which can be Finch, J.A., Dobby, G.S., 1990. Column Flotation. Pergamon Press,
easily tested in each application of the technique. Future Oxford. Chapter 3.
Gorain, B.K., Franzidis, J.P., Manlapig, E.V., 1997. Studies on
work will be conducted to conrm the validity of these impeller type, impeller speed and air ow rate in an industrial
assumptions under various conditions and cell duties. otation cellPart 4. Eect of bubble surface area ux on otation
The froth recovery technique was used to measure the performance. Minerals Engineering 10, 367379.
froth recovery in a 100 m3 rougher and scavenger cell at Harris, M.C., 1997. A practical framework for otation circuit
Pasminco Century lead/zinc mine in North Queensland. modelling and simulation, paper presented at SAIChE 97, the
Eighth National Meeting of the South African Institute of
The results of this application show that the technique Chemical Engineers, Cape Town, 1618 April, 1997.
can be applied to both a zinc rougher and zinc scavenger Johnson, N.W., 1972. The otation behaviour of some chalcopyrite
duty. Both the bubble load and froth recovery estimates ores, PhD Thesis, University of Queensland.
were in a similar range to previous results reported by Laplante, A.R., Kaya, M., Smith, H.W., 1989. The eect of froth on
other authors. Further studies at various sites are plan- otation kineticsa mass transfer approach. In: Frothing in
Flotation. Gordon and Breach Science Publishers, New York,
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Mathe, Z.T., Harris, M.C., OConnor, C.T., 2000. A review of
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