Physicochem. Probl. Miner. Process.
, 54(3), 2018, 732-740 Physicochemical Problems of Mineral Processing
ISSN 1643-1049
http://www.journalssystem.com/ppmp
© Wroclaw University of Science and Technology
Received October 25, 2017; reviewed; accepted January 21, 2018
Comparison of mechanical flotation cell and cyclonic microbubble
flotation column in terms of separation performance for fine graphite
Xiangning Bu 1,2, Tuantuan Zhang 2, Yuran Chen 2, Yaoli Peng 1, 2, Guangyuan Xie 1, 2,
Erdong Wu 3
1 Key Laboratory of Coal Processing and Efficient Utilization (Ministry of Education), China University of Mining &
Technology, Xuzhou 221116, China
2 School of Chemical Engineering and Technology, China University of Mining & Technology, Xuzhou 221116, China
3 Bakuang Coal Preparation Plant, Pingdingshan Shenma Group Coal Industry Co., Ltd, Pingdingshan 467000, China
Abstract: Comparison of flotation performance between the flotation column and mechanical flotation
was carried out to promote the grade and economic value of the graphite ore (15.40% ash content). The
ash content of the concentrate of the mechanical flotation was 10.77% at the yield of 79.34%. In contrast,
the yield of the concentrate of the column flotation was increased to 88.93% with 10.55% ash content.
Comparative study of the Fuerstenau upgrading curves indicated that the column flotation was more
efficient for cleaning the graphite ore in the presence of the centrifugal force field, nanobubbles
(generated by hydrodynamic cavitation), and the thicker froth layer in comparison with the mechanical
flotation.
Keywords: mechanical flotation, column flotation, Fuerstenau upgrading curve, graphite
1. Introduction
Natural graphite may occur in metamorphosed siliceous rocks (typically quartzite) as well as
metamorphosed carbonate rocks. Associated minerals with graphite occur as quartz, rock-forming
silicates such as amphiboles, kaolinite, mica, and feldspars, also calcite, sulphides, or magnetite
(Wakamatsu and Numata, 1991; Chelgani et al., 2015). Flotation is a main beneficiation method for
graphite ores (Wakamatsu and Numata, 1991; Lu and Forssberg, 2001; Shi et al., 2015; Jin et al., 2016).
Mechanical and column flotation technologies have been used to upgrade graphite ores by combining
a simple rougher flotation step with several stages of cleaning. Column flotation can give superior
performance compared to mechanical cell by either reducing the number of stages of operation or by
improving the grade and recovery (Acharya et al., 1996; Misra, 2003; Abd El-Rahiem, 2004; Vasumathi
et al., 2015).
Centrifugal force field flotation has been used to improve the separation efficiency of fine particles
since the 1980s (Miller and Camp, 1982). Air-sparged hydrocyclone (ASH), pioneered by Miller and
Camp (1982), diminishes the entrainment of gangue materials via an increase in the fine particle
flotation rate and froth drainage in the presence of a centrifugal force ( Tils and Tels, 1992; Yalamanchili
and Miller, 1995; Miller and Halbe, 2005). Basically, the flotation column consists of two distinct zones,
the collection zone (the bubbling zone and slurry or pulp zone) below the interface, and cleaning zone
(the froth zone) above the interface (Dobby and Finch, 1991). Cyclonic microbubble flotation column,
developed by China University of Mining and Technology, contains an additional zone named cyclonic
zone compared to the other flotation column (Bu et al., 2016b). The bubble generator used in the flotation
column, taking advantage of the Venturi principle, is the most widely used hydrodynamic cavitation
device (Fan, 2010). The occurrence of nanobubbles by hydrodynamic cavitation increases the probability
of collision and attachment and decreases the probability of detachment compared with conventional-
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Physicochem. Probl. Miner. Process., 54(3), 2018, 732-740 733
size bubbles (Tao et al., 2006). In other words, cyclonic microbubble flotation column can extend the
lower particle size limits for effective flotation due to the combination of nanobubbles and centrifugal
force separation (Miller and Camp, 1982; Rahman et al., 2014). In contrast to mechanical flotation cells
or dissolved air flotation column, the cyclonic microbubble flotation column was more efficient for the
beneficiation of coal fines (Li et al., 2003; Bu et al., 2017b), siliceous phosphate ore (Li et al., 2012),
magnetite ore (Zhang et al., 2013), and oil-in-water emulsion (Li et al., 2016).
It is observed that the literature regarding the cyclonic microbubble flotation column lacks emphasis
on the graphite flotation performance. So, in this article, the cyclonic microbubble flotation column was
employed to upgrade the graphite ore, and a comparison of the mechanical and column flotation was
also carried out in terms of flotation separation efficiency.
2. Materials and methods
2.1 Materials
Graphite sample from south China had 15.40% ash content. The size distribution was determined by a
Microtrac S3500 device using a laser diffraction method (Microtrac Inc., USA). The calculated d 95 of the
sample was 68.92 µm. The mineralogical phase was investigated by XRD analysis (Bruker D8 Advance,
Germany). The detailed operating process of the XRD measurements has been described in the literature
(Bu et al., 2017a). The major impurity mineral of this sample was quartz according to the X-ray
diffraction (XRD) measurement (Fig. 1).
Fig. 1. XRD patterns of the graphite ore
2.2 Mechanical flotation
Kerosene and sec-octyl alcohol (analytical reagent, Sinopharm Group) were used as collector and
frother, respectively. A standard laboratory RK/FD-II sub-aeration flotation cell (volume = 1.5 dm3)
(Fig. 2.). The sample was conditioned at 5-30% solids by weight with tap water. The required amount
of kerosene was added and conditioned for three more minutes. After that, the required amount of sec-
octyl alcohol was added, and the slurry was conditioned for 1 min. Then the air valve was opened at
4.17 dm3/ min air flow rate and 1900 rpm agitation speed, and the froth was collected for 3 min. In each
test, tap water was added to maintain a constant pulp level and a froth layer of 1 cm. The experiments
were carried out by varying different operating parameters such as collector concentration, frother
concentration and solids concentration. A detailed description of the working process of the mechanical
flotation cell is reported in the literature (Bu et al., 2016a).
734 Physicochem. Probl. Miner. Process., 54(3), 2018, 732-740
Fig. 2. Actual diagram of experimental system for mechanical flotation tests
2.3 Column flotation test
Column flotation tests were carried out using a laboratory-scale flotation column (diameter = 100 mm,
height = 1800 mm) in China University of Mining and Technology, Xuzhou, China. The effects of the
collector dosage, froth dosage, froth depth and circulation on the flotation performance of the column
flotation were investigated. The sample was prepared at 5.81% solids by weight with tap water for each
column flotation test. The procedure of the flotation column test is described in previous literature (Bu
et al., 2017b).
3. Results and discussion
3.1 Mechanical flotation
3.1.1 Effect of collector dosage
The effect of collector dosage in the mechanical flotation performance was investigated with 0.75 g/kg
frother dosage (mass of frother per unit mass of solids) and 5.81 wt. % solids concentration. As shown
in Fig. 3., the yield of the concentrate increased significantly from 50.01% to 91.25% with the increasing
collector dosage, while the ash content also witnessed an increase from 10.86% to 11.66%. High collector
dosage can enhance the flotation yield, which also leads to the low selectivity between graphite and
quartz (Shi et al., 2015).
Fig. 3. Effect of collector dosage on the mechanical flotation
Physicochem. Probl. Miner. Process., 54(3), 2018, 732-740 735
3.1.2 Effect of frother dosage
The variations of the yield and ash content of the concentrate at various frother dosages with the
collector dosage of 3 g/kg and solids concentration of 5.81 wt. % are shown in Fig. 4. With the increase
in frother dosage from 0.75 g/kg to 1 g/kg, the yield varied from 83.41% to 84.37%, while the ash content
revealed a decrease from 11.35% to 11.18%. The adsorption of frothers on the gas/liquid interface can
prevent bubble coalescence, which can lead to the high-grade product by stable froth (Harris, 2000).
With the further increase in the frother dosage, the serious entrainment of gangue materials results from
the exorbitantly stable froth, which leads to the increase of the ash content of the concentrate, which is
in agreement with previous observations by Nguyen and Schulze (2004).
Fig. 4. Effect of frother dosage on the mechanical flotation
3.1.3 Effect of solids concentration
The influence of solids concentration on mechanical flotation at 3 g/kg collector dosage and 750 frother
dosage is presented in Fig. 5. The yield witnessed an increase from 79.34% to 94.97% with increasing
solids concentration. Meanwhile, the ash content of the concentrate increased apparently from 10.77%
to 14.21% with the decrease in solids concentration. This is attributed to the more serious entrainment
caused by the large amount of water transferred to the froth product due to the stable froth at a high
solids concentration and frother dosage (Akdemir, 2003; Li et al., 2015).
Fig. 5. Effect of solids concentration on the mechanical flotation
736 Physicochem. Probl. Miner. Process., 54(3), 2018, 732-740
3.2 Column Flotation
3.2.1 Effect of collector dosage and frother dosage
Fig. 6. presents the effect of collector dosage and frother dosage on the flotation performance of the
column flotation at 0.15 Mpa circulation pressures and 20 cm froth depth. The ash content of the
concentrate (10.86% - 12%) using the flotation column exhibited the same trend to that of the mechanical
flotation, under different collector dosages (or frother dosages). At a low collector dosage (<3000 g/Mg),
the yield of the concentrate the yields of the flotation column was much higher than that of the
mechanical flotation cell. This is due to the increase in the collision probability between fine particles
and bubbles in the presence of the centrifugal force field and nanobubbles (Miller and Camp, 1982;
Rahman et al., 2014).
With the increase in the frother dosage, the ash content of the flotation column various from 11.46%
to 11.98%. This high ash content of the concentrate can be explained by the severe entrainment resulting
from the stable forth. The froth is stabilized by fine hydrophobic graphite particles and becomes very
tenacious (Ata et al., 2004; Li et al., 2014). A more stable froth has fewer coalescence and bursting events,
which leads to the increase in the amount of material recovered by entrainment.
Fig. 6. Effect of collector dosage and frother dosage on the column flotation
(left: 0.75 g/kg frother dosage; right: 5 g/kg collector dosage)
3.2.2 Effect of circulation pressure
Column flotation tests carried out at various circulation pressures with 20 cm froth depth, 5 g/kg
collector dosage and 1.67 g/kg frother dosage are shown in Fig. 7. The yield and ash content of the
concentrate witnessed a stable increase in a relatively low circulation pressure (0.15 MPa - 0.20 MPa).
The lack of the enough strength of the negative pressure in the bubble generator causes the low
superficial air velocity and big bubbles under a relatively low circulation pressure (Li et al., 2003). With
the circulation pressure increasing from 0.15 MPa to 0.20 MPa, the increase in the gas dispersion
promotes the recovery of fine particles, while the entrainment of gangue materials also gets serious.
With the further increase in the circulation pressure, the ash content and the yield decreased
significantly, which relates to the increase in the centrifugal force strength of the flotation column. The
strong centrifugal force can improve the particle-bubble collision frequency, which leads to the
improvement in the concentrate grade (Zhou and Liu, 2007). Furthermore, the application of the Venturi
principle in the bubble generator can enhanced hydrophobic particle aggregation and bubble-particle
collision probability in the occurrence of nanobubbles generated by hydrodynamic cavitation
(Calgaroto et al., 2015; Zhou et al., 2016). With the increase in the separation efficiency, a large amount
of gangue materials reports to the tailings, resulting in the decrease of the yield.
3.2.3. Effect of froth depth
Fig. 8. presents the influence of froth depth on the column flotation performance at 0.15 MPa circulation
pressure, 5 g/kg collector dosage and 1.67 g/kg frother dosage. With the increasing froth depth, the
Physicochem. Probl. Miner. Process., 54(3), 2018, 732-740 737
yield of the concentrate decreased from 95.67% to 89.41%, while the ash content of the concentrate
decreased from 12.32% to 10.79 %. At higher froth depth, the froth residence time is longer, which results
in that more gangue materials detach from the froth zone. The mechanical entrainment and entrapment
of gangue materials decrease in column flotation in the presence of a thick froth layer (Yianatos et al.,
1988).
Fig. 7. Effect of circulation pressure on the column flotation
Fig. 8. Effect of froth depth on the column flotation
3.3 Comparison of separation efficiency
The Fuerstenau upgrading curves have been used in the characterization, comparison and analysis of
the beneficiation for coal fines (Drzymala, 2005; Fuerstenau, 1978; Jia et al., 2002; Li et al., 2013), Polish
copper ore (Drzymala et al., 2003; Drzymala et al., 2013; Drzymala et al., 2010; Zarudzka, 2009). Those
curves can be approximated by various mathematical equations with simple multi-parameter
polynomials and ending with more sophisticated formulas (Drzymala and Ahmed, 2005). An equation
containing only one adjustable parameter, which is used as a measure of selectivity of separation is used
to compare the flotation separation efficiency between the mechanical and column flotation. This
equation can be represented as follows:
100 R2, T
R1,C (1)
100 1
738 Physicochem. Probl. Miner. Process., 54(3), 2018, 732-740
where R1, C stands for the recovery of valuable matter (also known as non-ash matter) in the concentrate
and R2, T denotes the recovery of ash matter in the tailings, respectively. α is the separation selectivity
factor. If α = 1, there is no upgrading between graphite and gangue minerals; when α > 1, the upgrading
process exists in the concentrate. The bigger the value of α is, the higher the separation efficiency is; the
upgrading process occurs in the tailings with the value of α between 0 and 1; idea separation presents
when α is equal to 0 or ∞.
Fig. 9. The Fuerstenau upgrading curve of the mechanical and column flotation
The upgrading curves of the mechanical and column flotation are presented in Fig. 9. The lines
represent the Fuerstenau upgrading curves for the mechanical and column flotation obtained by fitting
their experimental results, respectively. The calculated separation efficiency factor (α) results by MatLab
software are shown in Table 1. The lowest ash content was obtained at 5.81 wt. % solids concentration,
20 cm froth depth and 0.30 MPa circulation pressure. The amount of the collector and frother were 5
g/kg and 1.67 g/kg, respectively. The optimum flotation performance of the mechanical flotation cell
was obtained at 5.81 wt. % solids concentration, 3 g/kg collector dosage and 0.75 g/kg frother dosage.
Table 1. Comparison of the efficiency factor and optimum flotation performance between the mechanical and
column cells
Concentrate Model Parameter
Flotation device
Yield, % Ash content, % α R2
Mechanical 79.34 10.77 2.13 0.98
Column 88.93 10.55 2.70 0.99
Joglekar and May (1987) suggest that for a good fit of a model, the coefficient of determination (R2)
should be at least 0.80. The R2 values were above 0.80, which indicated that Equation (1) could be used
for the approximation of separation results. The separation efficiency factor of the column flotation was
higher that of the mechanical flotation, which indicated that the separation between graphite and
gangue particles using the flotation column was closer to the ideal separation. However, there is still
big difference of the separation performance between the flotation column and the ideal separation. In
the column flotation, the thick froth layer and long residence time can diminish the entrainment of ash
materials compared to the mechanical flotation. Furthermore, the yield of the concentrate of the column
flotation was increased from 79.34% to 88.93% at the similar level of the ash content in comparison with
the mechanical flotation. This can be attributed to the scavenging process in the use of the centrifugal
force and nanbubbles.
4. Conclusions
The ash content of the graphite was reduced from 15.40% to about 10%-11%. The cyclonic microbubble
flotation column technology can significantly increase the yield from 79.34% to 88.93% in the use of
Physicochem. Probl. Miner. Process., 54(3), 2018, 732-740 739
centrifugal force and nanobubbles in comparison with the mechanical flotation. Comparison of the
Fuerstenau upgrading curves indicated that the upgrading process of the column flotation was closer
to the ideal separation than that of the mechanical flotation.
Acknowledgements
This work was supported by the National Nature Science Foundation of China (Grants No. 51474213
and 51374205) and Postgraduate Research & Practice Innovation Program of Jiangsu Province (Grants
No. KYCX17_1511).
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