University of Engineering and Technology, Lahore

LAB REPORT:

PARTICLE TECHNOLOGY

PRACTICAL NAME:

FROTH FLOTATION

SUBMITTED BY:

NAME:

MALIHA RAMZAN

REG.NO: 2021-CD-CH-01

SUBMITTED TO :

DR. MUHAMMAD SHAHZAD

DEPARTMENT:

MINING ENGINEERING
Table of Contents
8.1: Abstract:-..................................................................................................................................2
8.2: Related Theory:-.......................................................................................................................2
8.2.1: Introduction:-.....................................................................................................................2
8.2.2: Types:-...............................................................................................................................2
8.2.3: Working Principle:-...........................................................................................................3
8.2.4: Reagents:-..........................................................................................................................4
8.2.5: Parameters affecting the Performance:-............................................................................6
 Design Parameters................................................................................................................6
o Flotation tank size.................................................................................................................6
8.2.6: Applications and Limitations:-..........................................................................................7
8.2.7: Specification of industrial model:-....................................................................................7
8.3: Procedure:-................................................................................................................................8
8.4: OBSERVATION AND CALCULATION:..............................................................................8
8.4.1: Observations:-....................................................................................................................8
8.4.2: Calculations:-.....................................................................................................................9
8.5: Discussion:-............................................................................................................................10
8.5.1: Discussion on Efficiency:-...............................................................................................10
8.5.2: Discussion on experiment:-.............................................................................................10
8.6: Conclusion:-............................................................................................................................11

List of Figures
Figure 1 b Pneumatic Floatation Cell.............................................................................................3
Figure 2 a Mechanical Floatation Cell.............................................................................................3
Figure 3 Collector Types.................................................................................................................4
Figure 4 Frothers..............................................................................................................................5

List of Tables
Table 1 Specifications......................................................................................................................7
Table 2 Ash analysis of feed...........................................................................................................8
Table 3 Ash analysis of products.....................................................................................................9
Experiment # 08

Floatation

8.1: Abstract:-
The main objectives of the experiment are:

 To study various parts of laboratory floatation cell and their functions.

 Perform gravity separation test on the given sample.
 To determine the performance of the floatation cell.

Froth floatation process is highly specific technique to separate hydrophobic and hydrophilic
substances.
A brief introduction of the machine was given by the instructor. The main parts, their
construction, importance and function were described clearly. The experiment was performed to
accomplish the objectives. The different performance factors calculated were as follow:-
 Yield=43.48  Ash Rejection=9.696%,

 Concentration ratio=2.3  Enrichment Ratio=0.98,

 Separation Efficiency= 10.56%,  Recovery= 4.63%.

8.2: Related Theory:-

8.2.1: Introduction:-
Froth floatation is one of the widely used processes for the beneficiation of minerals. In
beneficiation by floatation, the valuable minerals are separated in a form of froth layer from the
invaluable minerals on the basis of the surface properties of the minerals (hydrophobic and
hydrophilic properties). The process is done in the floatation cell.

The purpose of the floatation cell is to attach hydrophobic minerals to the air bubbles so that they
can come to the top and then be removed as froth.

8.2.2: Types:-
 Pneumatic:-

In this type of the floatation cell, there is no mechanical part for the agitation and the agitation is
provided by inflow of air and the air bubbles are introduced by an injector. For the same size of
tank, the energy consumption is lower than the mechanical cell. The pneumatic cell provides
superior countercurrent flow. The energy consumption is low with high capacity.

 Types
 o Devcra Cell
o Flotation Column

Figure 1 a Mechanical Floatation Cell Figure 2 b Pneumatic Floatation Cell

 Mechanical:-

In these cells, there are impellers that rotate with baffles and air is pumped down through the
central shaft and is dispersed through impellers to form the bubbles. Although the design varies
from machine to machine. The energy consumption is high while its capacity is low due to the
impellers.

The selection of the machine is based on the performance, capacity and cost.

8.2.3: Working Principle:-

The minerals are first grinded finely and the slurry is made. The slurry of the minerals is
introduced in the floatation cell which agitates the mixture and provide air. The ability of mineral
to float depends upon the surface properties. Through the chemical modifications ( adding the
frothers, collectors and regulators ) the valuable mineral attach to the air bubble and rise up in the
tank as froth. It is noted that the chemical modifications reactants should only react with the
valuable minerals and be inert for the invaluable minerals. The froth is removed which contain
the valuable mineral in excess.
The remaining solution containing the invaluable minerals and some value of the valuable
minerals is termed as tailings which is removed from the bottom.
8.2.4: Reagents:-
 Collectors:-

A collector is a chemical that selectively binds to the surface of the targeted minerals on the
slurry and impacts hydrophilicity to those minerals. This enhances the necessary conditions to
bind to the air bubble to come in the froth. The collector only binds to the valuable minerals in
the slurry. It adsorbs on the mineral surface enhancing its surface properties. The time it takes to
bind on the mineral is called the conditioning time.

Collectors can generally be classified into three categories –

o Nonionic
o Anionic
o Cationic

Nonionic collectors are simple hydrocarbon oils. Anionic and cationic collectors consist of a
polar component that selectively attaches to mineral surfaces, and a non-polar component that
projects out into the solution making the surface hydrophobic. Collectors can either chemically
bond to the mineral surface with high selectivity (chemisorption), or be held on the surface by
physical forces (physical absorption). Collector selection is critical for effective mineral
separation via froth flotation.

Figure 3 Collector Types

  Frothers:-

The reagents that helps in the formation of froth and keep it stable.

The functions of frothers are:-

o Reduce surface tension of the liquid-gas interface to enable froth formation

o Hinder coalescence in order to stabilize bubble size
o Facilitate hydrophobic particle adhesion to air bubbles.

During floatation, frothers help to produce the hydrodynamic conditions within the pulp. It
makes the froth stable and enough to held the collected particles, and mobile enough to flow and
it decays quickly to assist the process in the downstream.

Frother chemicals are usually heteropolar surface-active organic surfactants with properly
balanced hydrophile-lipophile properties, having branched hydrocarbon radicals and forming
loosely packed gaseous films at the liquid/gas interface.

Figure 4 Frothers

 Regulators:-

These reagents are used to control the floatation process by either activating or depressing the
mineral attachment to the air bubbles and are so used to control the pH of the system.

The main purpose of these reagents is to modify the action of the collectors and govern the
selectively of the floatation process.

o Activators:-

These will attach to the minerals allowing other reagents to act on the minerals.

This helps them to attach to the collectors.

Example : Copper Sulphate

o Depressor:-
These reagents attach to the minerals to avoid the floating with the collectors. They are added to
slurry to prevent the unwanted material from floating.

Example : Potassium Cyanide

o pH controller:-

These reagents help to strengthen the bond between the collector and the mineral. And hence
help in the selectivity of the floatation process.

8.2.5: Parameters affecting the Performance:-

 Design Parameters

o Flotation tank size

Greater the size of the tank greater is the capacity and hence the energy consumption is
increased.

o Flotation machine design

The machine type has its own ups and downs described above.

o Operating Parameters
o Feed particle size

The particle size has to be very fine for the efficient separation.

o Feed percent solids

The slurry should be dilute so the particles are suspended freely.

o Dry feed rate

The feed rate in the tank affects the capacity. The rate should be such that as the froth separates
the valuable mineral to the highest possible concentration.

o Impellor speed

Impellor speed affects the agitation and the speed should be such that the mixing of the reagents
should be optimum.

8.2.6: Applications and Limitations:-

 Applications:-
The applications of the froth flotation are as follow:-
o Enrichment of ores such as copper and nickel
o In Paper and Pulp industry
o In water waste treatment plant
 o For purifying the desired component from the mixture
o For removal of impurities from the mixture

 Limitations:-
The limitations of the froth flotation are discussed as follow:-
o The size of the particles should be very small and fine
o The process is costly because of using high amount of reagents
o High maintenance cost

8.2.7: Specification of industrial model:-

Table 1 Specifications

Machine Capacity Cell Size Cell Motor Dimensions

Size no. (Tons/day) Volume (H.P)
(cubic ft) Length Width Hieght
Motor Belt
25 5-15 16’’x16’’ 2.75 1 1’9’’ 2’1’’ 1’8’’ 3’0’’
50 10-35 22’’’x22’’ 10 1.5 2’6’’ 2’7’’ 2’2’’ 4’8’’
100 25-60 24’’x24’’ 12 2 3’0’’ 2’10’’ 2’6’’ 4’8’’
250 50-125 32’’x32’’ 24 5 3’6’’ 3’6’’ 3’0’’ 5’5’’
500 100-250 38’’x38’’ 40 7.5 4’0’’ 3’11’ 3’6’’ 6’6’’
750 200-500 43’’x43’’ 50 10 4’5’’ 4’3’’ - 6’6’’
1500 450-1200 56’’x56’’ 100 15 5’8’’ 5’6’’ - 7’7’’

8.3: Procedure:-
 The sample was added to the tank making it a slurry.
 The slurry was mixed for 5 minutes.
 The collector was added and mixed for the 3 minutes.
 The frother was added and mixed for the 30 seconds and then the air was introduced.
 The froth started forming containing the valuable minerals.
 The invaluable minerals were remained in the tank regarded as tailings.

The efficiency of the machine is calculated by the following equations:-

Y ( F A −C A )
Separation Efficiency= ×100
F A ( 100−F A )
 Weight of Feed
Concentation Ratio=
Weight of Concentrate

Y ( 100−C A )
Recovery= ×100
100−F A

Grade of Concentrate
Enrichment Ratio=
Grade of Feed

F A −C A
Ash Rejection= × 100
FA

8.4: OBSERVATION AND CALCULATION:

8.4.1: Observations:-
Feed weight=92g

Product of weight:-

 Concentrate weight=40g
 Tailing weight=52g

Table 2 Ash analysis of feed

Weight of Weight of Weight of sample

Crucible Percentage of Ash
Crucible with after Combustion
Sr. No. Contents
(gm) coal sample (gm) (gm)

1 23.932 24.9318 24.3308 39.83

Table 3 Ash analysis of products

Sr No Weight of Weight of crucible Weight of coal sample + Percentage of ash

crucible with coal sample crucible content

1. 23.1837 24.1840 23.5236 33.98

2. 23.2014 24.2039 23.6035 40.11

8.4.2: Calculations:-
 Yield:-
 WEIGHT OF CONCENTRATE
Yield= ∗100
WEIGHT OF FEED

40
Yield= ∗100
92

Yield=43.48

 Concentration Ratio:-

Weight Of Feed
Concentration Ratio=
Weight Of Concentrate

92
Concentration ratio=
40

Concentration ratio=2.3

 Separation Efficiency:-

Y ( F A −C A )
Separation Efficiency= ×100
F A ( 100−F A )

43.48 ( 39.8−33.98 )
Separation Efficiency= ×100
39.8 (100−39.8 )

Separation Efficiency=10.56%

 Ash Rejection:-

F A −C A
Ash Rejection= × 100
FA

(39.8−33.98)
Ash Rejection= ×100
100−39.8

Ash Rejection=9.696 %

 Enrichment Ratio:-

Grade of Concentrate
Enrichment Ratio=
Grade of Feed

100−39.8
Enrichment Ratio=
100−33.8

Enrichment Ratio=0.98
  RECOVERY:-

Y ( f A−C A )
Recovery= ×100
100−F A

0.4348 ( 39.8−33.98 )
Recovery= × 100
100−39.8

Recovery=4.63 %

8.5: Discussion:-
8.5.1: Discussion on Efficiency:-

The efficiency of the separation is the product of the yield fraction to the percentage ash content
in the feed, and the concentrate to the percentage of precious minerals in the feed. The separation
efficiency was found out to be 10.56%. The efficiency can be increased by performing the
experiment with great care and using the equipment in good state.

8.5.2: Discussion on experiment:-

While performing the experiment following precautions must be taken:-

 The slurry should be dilute and particles should be suspended.

 The time of the mixing should be taken critically.
 The sequence and amount of reagents added should be taken with care.

The experiment was performed with care and the sequence and amounts of reagents were
taken precisely.

8.6: Conclusion:-
The theory about the flotation process including types, working principles, parameters and
applications were discussed. The experiment was performed with care and the observations were
noted and the result was calculated. The results calculated were found out to be, yield=43.48,
Concentration ratio=2.3, Separation Efficiency= 10.56%, Ash Rejection=9.696%, Enrichment
Ratio=0.98, Recovery= 4.63%.