University OF Engineering and Technology, Lahore

Department of Chemical Engineering

Lab Report on Froth Flotation

Submitted by:
Hamna Abdullah
(2022-CH-55)
Submitted to:
Sir Shahzad
Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

Table of Contents:
1. Abstract............................................................................................................................

2. Related theory..................................................................................................................

2.1: Related Terminologies..................................................................................

2.2: Introduction...................................................................................................

2.3: Flotation Product...........................................................................................

a) Concentrate...................................................................................................

b) Tailings.........................................................................................................

2.4: Flotation Reagents........................................................................................

a) Collectors.....................................................................................................

b) Frothers........................................................................................................

c) Regulators/Modifiers....................................................................................

2.5: Types.............................................................................................................

2.6: Construction..................................................................................................

a) Froth Flotation tank......................................................................................

b) Launders.......................................................................................................

c) Air Supply....................................................................................................

d) Impeller........................................................................................................

e) Paddle mechanism........................................................................................

2.7: Working........................................................................................................

2.8: Performance indicators:..............................................................................

a) Separation Efficiency.................................................................................

b)Concentration Ratio....................................................................................

c)Recovery......................................................................................................

d)Enrichment Ratio........................................................................................

e)Ash Rejection..............................................................................................

2.9: Parameters Affecting Performance.............................................................

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

a) Design parameters:.....................................................................................

b)Operating Parameters..................................................................................

c)Feed Characteristics....................................................................................

2.10: Applications..............................................................................................

2.11: Features.....................................................................................................

2.12: Limitations................................................................................................

2.13: Specifications............................................................................................

3. Procedure.......................................................................................................................

3.1: Machine Study............................................................................................

3.2: Performance................................................................................................

3.3: Calculation Formula....................................................................................

4.Observation, Calculation and Results.............................................................................

5. Discussion......................................................................................................................

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

List of Figures:
Figure 1: Froth Flotation Equipment..............................................................................4
Figure 2: Concentrate Froth...........................................................................................6
Figure 3: Collector Dissolved in Aqueous Phase...........................................................7
Figure 4:Adsorption of Collector onto a Mineral Surface.............................................7
Figure 5: Construction of Froth Flotation Cell..............................................................9
Figure 6: Working of Flotation Equipment..................................................................10

List of Tables:
Table # 01: Specifications of Laboratory Flotation Tank……………………………15
Table # 02: Ash analysis on feed……………………………………………...…......16
Table # 03: Ash analysis on concentrate………………………………………....….17
Table # 04: Ash analysis on Tailings…………………………………………...…...17

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

Froth Flotation

1. Abstract

A surface-based separation method used for enrichment is called

foam flotation. It is a flexible and all-purpose method that works
with any type of material. Enriching particles of one composition
from another is its main goal. Increasing the hydrophobicity of
precious particles and their attraction for a specific reagent known
as collector is how flotation is accomplished. Feed is separated into
two product fractions as a result of flotation; the first fraction has a
higher concentration of the desirable particles, while the second
fraction is left with the unwanted particles. In the lab, we tested the
concentration of a coal sample. Conducting enrichment tests on a
laboratory flotation cell aims to examine the flotation cell's
functioning, examine its various components and their respective
roles, and percentage of ash free coal by mass was increased by
10%.

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

Figure 1: Froth Flotation Equipment

2. Related theory:
2.1: Related Terminologies:
Here are some important terms related to froth flotation:
 Hydrophobicity:
The characteristic of a material that makes it repel water is called
hydrophobicity. To put it simply, being hydrophobic implies not having much
attraction for water.
 Hydrophilicity:
The ability of a substance to be drawn by water is referred to as hydrophilicity.
It denotes a strong affection with water.
 Adsorption:
Adsorption is the process of adhering to the surface of a material and forming
a film or layer on the surface of the absorbent. The material to which the second
material adheres is referred to as absorbent.

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

2.2: Introduction:
Flotation has become a vital procedure, particularly in the mineral processing
industries. It is used in these industries to process low grade ores in order to remove
valuable materials from them. For example, if we extract a material from Earth and it
does not include the desired mineral particles in the required percentage, we must
enhance the amount of those particles. We use froth flotation for this. Flotation is
accomplished by injecting feed into a tank or cell filled with water. It works by
connecting the surface of valuable particles to a collector and then removing them
from the top of the flotation tank.
2.3: Flotation Product:
After the flotation, we get two fractions of product; one is called concentrate and
second is called tailings.

a) Concentrate
concentrate is a product distribution containing a higher percentage of valuable
material that we collect from the top of the flotation cell.

Figure 2: Concentrate Froth

b) Tailings:
The fraction of the product left after enrichment of desired particles that contains
a higher percentage of impurities and a very small amount of valuable material is
known as Flotation Tailings. Tailing can be treated again to recover more useful
particles.

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

concentrate

Feed

Flotation Tank

Tailings

Example:

We extracted an ore from Earth weighing 5 tons and containing 20% valuable
material, or 1 ton. After froth flotation, the total mass of 5 tons is divided into
concentrate and tailings. Furthermore, the valuable material has been distributed in
these two fractions. The concentrate will contain a higher percentage of valuable
grains. Assume the concentrate now contains 0.8 ton of useful particles out of a total
of 1 ton, and the tailings contain only 0.2 ton of pure particles.

2.4: Flotation Reagents:

The reagents that we use in flotation are of three types:
a) Collectors
b) Frothers
c) Regulators/Modifiers
Collectors:
Collectors are reagents that are added to the flotation tank to make the surface of
valuable grains hydrophobic so that they are repelled by water and stick to the collector,
where they can be separated during the process. For each material, a different collector is
chosen. It is determined by the type of grains to be collected. In the coal and other
industries, for example, kerosene oil and diesel are used as collectors. Collectors can be
ionized or non-ionic. Ionic collectors can be anionic or cationic.

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

Figure 3: Collector Dissolved in Aqueous Phase

Figure 4:Adsorption of Collector onto a Mineral Surface

b) Frothers:
The role of the flotation frother is to provide a stable froth at the top of the tank
containing the concentrate slurry. An ideal frother should not have a collecting
character so that the two functions can be controlled independently.
Common frothers are:
 Pine oil
 Cresylic acid
 Polyglycol ethers etc.
c) Regulators/Modifiers:
Such type of reagents neither serve the collecting purpose nor frothing. They are just
added for some additional functions. These are further divided into:

 Activators:
The collector is not always strongly attached to the surface of the particles. In this
case, a reagent is required to improve collector adsorption. This type of reagent is

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

known as an activator. It serves as a link between the collector and the grains to be
separated.
.
 Depressants:
It is a chemical that is required to prevent unwanted particles from being
absorbed by the collector.
. For Example:
 Starch
 sodium cyanide
 PH regulators: pH regulators are added to maintain the pH of froth. Common pH
regulators are:
 soda ash
 lime
 sulphuric acid
2.5: Types:
The flotation process requires the introduction of air to form froth at the top. Flotation
tanks are of different types depending upon the method by which air is introduced into
the cell. These are:
a) Mechanical flotation tank
b) Pneumatic flotation tank
c) Vacuum flotation tank
d) Electro flotation tank
e) Dissolved air flotation tank
2.6: Construction:
The construction of froth flotation equipment is very simple. Froth Flotation
equipment consists of following components:
a) Flotation tank
b) Launders
c) Impeller
d) Air supply
e) Peddle mechanism
Mechanical flotation tank is most commonly used.

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

a) Froth Flotation tank:

It is the tank or cell where the flotation process takes place. This tank is long,
cylindrical, or rectangular. It has a feed inlet at the top through which feed is fed into
the tank.
b) Launders:
There are two launders in commercial flotation cells to separate the concentrate foam
and remaining pulp. The obtained pulp is then introduced into the following flotation
cell for further particle recovery.
c) Air Supply:
Froth flotation process requires air supply so that the hydrophobic particles become
entrapped in air bubbles and are lifted up.
d)Impeller:
An impeller, rotating at high revolutions, is located in the center of the tank. When
we introduce feed material into the tank, it serves to keep the particles suspended.
Furthermore, when we add air, it disperses the air bubbles and distributes it
throughout the slurry, increasing particle-air contact.
e) Paddle mechanism:
To collect the foam of the concentrate, sometimes a paddle mechanism is also
available at the top of tank.

Figure 5: Construction of Froth Flotation Cell

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

2.7: Working:
The operation of a froth flotation cell is straightforward. It is determined by the
difference in wettability between the desired mineral and impurities. First, we
introduce the feed material into the water-filled tank. A constantly rotating impeller
will keep all of the particles suspended. Then a collector is injected, which attaches to
the useful grain, making it hydrophobic, while the impurities, which are hydrophilic,
are not attracted by the collector. We introduce a frothing agent after sufficient
conditioning time to provide a stable froth of the desired particles at the top. The
slurry is then aerated, encasing the valuable particles attached to the collector in air
bubbles and lifting them to the surface.

Figure 6: Working of Flotation Equipment

2.8: Performance indicators:

The performance of the froth flotation process is indicated by the following factors:
a) Separation Efficiency
b) Concentration Ratio
c) Recovery
d) Enrichment ratio
e) Ash Rejection

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

The performance of the flotation process is entirely determined by capacity,

energy consumption, recovery, and one of the other factors. Because we
performed flotation on coal samples in the laboratory, these indicators have
formulas based on ash analysis.
2.8(a) Separation Efficiency:
Separation efficiency is defined as the ratio of amount of material separated to the
amount of material that has to be separated.
In case of flotation, it is given by following formula:
Y (F A−C A )
Separation Efficiency= … … Eq .(i)
F A (100−F A )
where,
FA = Ash % in Feed
CA = Ash % in Concentrate
Y = Yield which is found by:
Mass of Concentrate
Y= … … Eq .(ii)
Mass of Feed

2.8(b): Concentration Ratio:

Concentration Ratio is given by the ratio of total mass of the feed to the total mass of
the concentrate. It is reciprocal of Yield. At industrial level, we require high
concentration ratio which means the total mass of the concentrate should be small but
the amount of valuable particles in concentrate should be large.
Mass of feed
Concentration ratio= … … Eq .(iii )
Mass of Concentrate

2.8(c): Recovery:
The amount of valuable material that is reported in concentrate is called Recovery.
Mass of Valuable material∈concentrate
Recovery =
Total mass of valuable material ∈feed
Which is equal to:
Y (100−C A )
Recovery = ∗100 … … Eq .(iv)
100−F A
Industrially, we want higher recovery near to 100%. Usually, we get recovery near to
90%. Moreover, recovery is inversely proportional to concentration ratio.

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

2.8(d): Enrichment Ratio:

Enrichment Ratio is defined as the ratio of grade of concentrate to the grade of feed
material. Thus, we write Enrichment Ratio as:
Grade of Concentrate
Enrichment Ratio = … … Eq .(v )
Grade of Feed
Grade of Concentrate = Valuable material percentage in concentrate
Grade of Feed = Valuable material percentage in feed
Enrichment ratio is inversely proportional to both Concentration Ratio and Recovery.
Higher the concentration ratio smaller will be the enrichment ratio. Moreover, greater
the recovery lesser is the enrichment ratio.
2.8(e): Ash Rejection:
Only when dealing with coal is Ash Rejection calculated. In the case of coal, the
gangue material will be ash, and the valuable material will be the ash rejection, which
is reported as a higher percentage in the concentrate. Because coal is used for
combustion, a higher ash percentage indicates that the coal is less flammable. Thus,
we use froth flotation to enrich coal with combustible matter. The ash rejection is
calculated using

(F ¿ ¿ A−C A )∗100
Ash Rejection = … … Eq .(vi)¿
FA

2.9: Parameters Affecting Performance:

There are 3 types of parameters that may affect the efficiency or performance of
flotation tank.
a) Design parameters
b) Operation parameters
c) Feed characteristics
These parameters affect the concentrate grade and concentrate recovery which as a
result affect the process performance.
2.9(a): Design parameters:
These are the parameters that are selected during the design of equipment according
to requirements and cannot be changed afterwards. There are 5 different types of

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

flotation machines and each type has its own design based on impeller size and the air
jet.
2.9(b): Operating Parameters:
Operating parameters are variable and can be changed during the operation of the
machine. These are:
a) Impeller Speed
b) Collector type and dosage
c) Frother type and dosage
d) Other reagents types and dosages
e) Conditioning time
f) Process time
a) Impeller Speed:
Impeller speed has a large impact on the flotation efficiency.
 If the impeller speed is very slow then particles will not remain in suspension
form and will settle down at the base of tank thus reducing the recovery.
 Similarly, Higher impeller speed creates more agitation in the cell. As a result,
bubbles are distracted and only pure and stable bubbles are reported in concentrate
thus dropping the recovery and increasing the grade. (1)
b) Collector type and dosage:
The choice of a collector depends upon the material to be collected in concentrate.
Hence, there are different types of collectors having different effects and should be
used in a specific amount. Each type of collector has an optimum value of dosage
with respect to amount of feed material:
Quantity of Collector
Optimum Dosage =
Quantity of Feed
c) Frother type and dosage:
Frother type and frother dosage both affect the quality of froth and determine the
effectiveness of flotation process. The type of frother is also very specific to the feed
material. Moreover, frother amount should also be selected carefully.
d) Other reagents types and dosages:
When collector and frother are not sufficient in flotation process, we have to inject
some other reagents i.e., Depressants, Activators and Modifiers of certain type and in
specific amount.
e) Conditioning time:

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

It is the time given to the collector to adhere to the valuable grains. Larger
conditioning time defines higher recovery but reduced grade.
f) Process time:
The time given to the flotation process to take place is called Process Time. It is
related to capacity. Larger the process time, smaller will be the capacity but both
recovery and grade will be increased.
2.9(c): Feed Characteristics:
The Characteristics of feed which determine the performance of flotation process are
as follows:
a) Feed particle size
b) Feed percent solids
c) Dry feed rate
a) Feed particle size:
If feed particle size increases only those particles which are extremely hydrophobic
are reported in concentrate enhancing the grade but the quantity of such very pure
particles is very small thus the recovery will be decreased.
b) Feed percent solids:
Greater the percentage of solid particles in the feed, froth concentration will be large
which means higher will be the recovery but grade will be less.
c) Dry feed rate:
The effect of dry feed rate is same as that of feed percent solids on recovery and grade
of concentrate. Greater quantity of solid particles in the feed defines larger recovery
and lesser grade.
2.10: Applications:
Froth flotation is a selective universal technique which can be used to enrich almost
every kind of material. It has found wide applications in mineral and ore industries.
Throughout the world, this technique is used to enrich sulphide, oxide, iron, nickel,
copper, zinc and lead ores. Sometimes, gold is also concentrated using froth flotation.
2.11: Features:
Advantages/Features of froth flotation are:
 Simple structure
 Easy handling and usage
 Reliable work

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

 Simple operation
 Very less maintenance requirement
 Universal applications
2.12: Limitations:
Besides its wide range of applications, froth flotation has some limitations as well:
 Due to its relatively small size, large capacities cannot be achieved using single
flotation tank. For this purpose, we have to install multiple flotation tanks.
 Very large sized particles cannot be separated using it. The particles must have
size smaller than 150µm.
2.13: Specifications:
Table # 01: Specifications of Laboratory Flotation tank

Name of Machine
Denver Flotation tank
Motor Power 0.5hp

Impeller RPM 2000

Motor RPM 1800

Feed Size Range 15+325mesh

3. Procedure:
3.1: Machine Study:
 Investigated in depth the mechanism and applications of froth flotation, as
well as its working principle, features and advantages, and limitations.
 We also investigated all of the flotation tank's key components and their
functions.
 We learned about froth flotation terminology such as hydrophobicity,
hydrophilicity, adsorption, concentrate and tailings, and so on.
 Investigated in depth the various indicators that influence flotation
performance, including separation efficiency, recovery, enrichment ratio,
concentration ratio, and ash rejection.
 The various design, operating, and feed factors that affect flotation
performance were discussed.

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

3.2: Performance:
 Took 50g of feed and performed ash analysis on it.
 Switched to machine and carefully analyzed its different parts.
 Started operating the machine, entered feed in it, and after the flotation operation,
collected the froth. The froth is then allowed to settle.
 Both tailings and froth are collected separately and dried.
 After this performed ash analysis on both concentrate and tailings and the results
were noted.
3.3: Calculation Formula:
 Separation is calculated by Eq.(i):
Y (F A−C A )
Separation Efficiency=
F A (100−F A )
 Concentration ratio is found by following Formula written in Eq(ii):
Mass of feed
Concentration ratio=
Mass of Concentrate
 Recovery is found by using:
Y (100−C A )
Recovery = ∗100
100−F A
 Formula to find enrichment ratio is:
Grade of Concentrate
Enrichment Ratio =
Grade of Feed
 Ash Rejection is calculated from Eq(vi):
( F ¿ ¿ A−C A )100
Ash Rejection = ¿
FA

4.Observation, Calculation and Results:

4.1: Observation and Calculation:
Feed Analysis:
Feed Sample = Dirty Coal
Feed Size = less than 0.2mm
Feed weight = 50g
Collector= Kerosene Oil
Frother = MIVC
Conditioning time = 2 to 3 min

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

Table # 02:Ash analysis on feed:

Weight of
Weight of
crucible and
Weight of crucible and Ash
sample Average
Sr. # crucible ‘A’ sample after content
before Ash %
(g) combustion ‘C’ %
combustion
(g)
‘B’(g)

1 25.05 26.04 25.82 45

39.5
2. 20.66 21.65 21.44 34

Product Analysis:
a) Concentrate:
Weight of Concentrate = 22g

Table # 03:Ash analysis on concentrate:

Weight
Weight of crucible Weight of crucible Ash
Sr. of Average
and sample before and sample after content
# crucible Ash %
combustion 'B'(g) combustion ‘C’(g) %
‘A’(g)

1 22.58 23.58 22.88 30

29.5
2 26.96 27.96 27.25 29

b) Tailings:
Weight of tailings = 27g

Table # 04:Ash analysis on Tailings:

Weight
Weight of crucible Weight of crucible Ash
Sr. of Average
and sample before and sample after content
# crucible Ash %
combustion ‘B’(g) combustion ‘C’(g) %
‘A’(g)

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

1 24.97 25.97 25.56 59

58.5
2. 21.10 22.10 21.68 58

4.2: Calculations of Performance Indicators:

Mass of Concentrate
 Yield = Y= Mass of Feed
Y = 22/50
Yield = 0.44
Y (F A−C A )
 Separation Efficiency=
F A (100−F A )
0.44(39.5−29.5)
= ∗100
39.5(100−39.5)
Separation Efficiency = 18.4 %

Mass of feed
 Concentration ratio= Mass of Concentrate

Concentration Ratio = 50/22

Concentration Ratio = 2.27

Y (100−C A )
 Recovery = ∗100
100−F A
44 ( 100−29.5 )
Recovery = ∗100
100−39.5
Recovery = 51.27%

Grade of Concentrate
 Enrichment Ratio =
Grade of Feed
Grade of Concentrate = 100-29.5=70.5
Grade of Feed = 100-39.5=60.5
Enrichment ratio=70.5/60.5
Enrichment Ratio=1.16

( F ¿ ¿ A−C A )100
 Ash Rejection = FA
¿

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Particle Technology Lab Lab Report: Froth Flotation 2021-CH-38

( 39.5−29.5 )∗100
Ash Rejection =
39.5
Ash Rejection =25.32%

5. Discussion:
5.1: Discussion on performance indicators:
a) Separation Efficiency:
Conditioning time may not be sufficient for collector adhesion. The efficiency of
separation increases the effectiveness of flotation equipment. In small tanks, the
separation efficiency of a laboratory flotation tank was found to be around 18.4%.
Furthermore, at the industrial level, this value is much higher. We get this
separation efficiency value because useful grains are floated in a laboratory.
b) Concentration Ratio:
A higher concentration ratio indicates better flotation equipment performance.
The concentration ratio of the laboratory flotation cell is nearly equal to 2.27,
which is lower than the concentration ratio of industrial flotation models. This
could be due to a difference in the design of the laboratory model or to collector
inefficiency.
c) Recovery:
The flotation process's recovery should be as high as possible. In the industrial
sector, it is usually greater than 90%. If the recovery rate is less than 90%, the
cell's performance is subpar. When we ran a concentration test on a laboratory
flotation machine, we discovered that the recovery was about 51%, indicating that
the quantity or mass of desired material in concentrate was lower than expected.
The reason for this could be due to tank size, collector inefficiency, shorter
process time provided, and so on.
d) Enrichment Ratio:
The enrichment ratio is the proportion of valuable grains in concentrate to the
proportion of valuable grains in feed. As a result, a higher enrichment ratio equates to
better flotation. The laboratory tank's enrichment ratio was calculated to be 1.16. This
value is low in comparison to industrial models, indicating lower operational
efficiency.
e) Ash rejection:

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As discussed earlier, smaller the ash content larger will be the ash rejection and better
will be the quality of coal. Thus, we want to achieve larger ash rejection. The
laboratory flotation tank has ash rejection percentage equal to 25.32%. In industries,
the desired ash rejection % depends upon the next process where the coal is to be used
after enrichment. To achieve higher ash rejection value, we have to perform flotation
in a series of multiple tanks.
5.2: Discussion on Experiment:
In this experiment, we used 50g of feed which was dirty coal having ash percentage
equal to 39.5%. 0.2ml of kerosene oil was used as a collector. Collector was provided
with conditioning time of 3 minutes to attach the ash free mass with itself. After this
conditioning time, we injected MIVC which acts as a frother. Air was supplied to lift
the froth up. When the process was completed, we collected the froth from the top
allowed to settle completely and the ash analysis was performed on both concentrate
and tailings, results were noted and the performance of operation was calculated using
different formulas.
5.3: Conclusion:
We concluded from this flotation experiment that because the size of the flotation
tank used in the laboratory is smaller than that of industrial models, its performance is
less efficient. Other factors that can reduce performance efficiency include
insufficient conditioning and process time, a collector that is ineffective or has a low
dosage.
5.4: References:
 Mineral Processing Technology by B. A. Wills ,7th Edition-2005.
 Construction working and maintenance of crusher for crushing bulk material by
k.P. shah.

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