Increase Coarse Flotation

Strategies for increasing coarse particle flotation in
conventional flotation cells

Erico Tabosaa,*, Kym Rungea,b,*, Kristy-Ann Duffya
a
Metso Process Technology & Innovation, Pullenvale, Queensland, Australia

Julius Kruttschnitt Mineral Research Centre, University of Queensland, Indooroopilly, Queensland, Australia
Abstract
If the particle size that could be effectively recovered in a flotation cell could be increased, the product
size from grinding could be significantly coarsened, resulting in a more eco-efficient flowsheet. A number
of strategies that could potentially increase coarse particle flotation recovery are investigated in this
work by performing tests using a pilot scale 3m3 Metso RCS flotation cell operated using a copper ore.
Turbulence was manipulated by changing the impeller speed, impeller size, feed pulp density and cell
aspect ratio. Tests were performed at different froth depth to enable the effect of the froth and the impact
of the turbulence on the froth phase to be evaluated independently of effects in the pulp. This work shows
that coarse particle recovery is extremely sensitive to froth phase effects with recovery optimal at shallow
froth depth and when turbulence at the pulp-froth interface is minimised.
Keywords: coarse particle flotation, froth recovery, turbulence
1. INTRODUCTION
Classically, flotation recovery is optimal for intermediate sized particles (10 to 150 m particles) with poor
recovery of the fine and coarse particles (Jowett, 1980; Trahar, 1981; King, 1982). The coarse particle size at
which recovery decreases varies significantly and is a function of the degree of liberation of the ore (Dunne,
2012), degree of oxidation of the particle surfaces, valuable mineral hydrophobicity and particle density
(Schulze, 1984).
Coarse particle recovery in flotation is low for a number of compounding reasons. Firstly, they exhibit low rates
of recovery in the pulp phase this is believed to be due to (1) poor suspension of the coarse particles in the
flotation cell which reduces their effective cell residence time and therefore their probability of particle capture
and (2) poor bubble/particle stability which results in coarse particles tending to detach from bubbles in the
highly turbulent environment of the stirred flotation tank (King, 1982; Schubert and Bischofberger, 1979). To
make matters worse, coarse particles have been measured to exhibit low froth recovery in comparison to finer
particles (Ata and Jameson, 2013; Rahman et al, 2012). This is thought to be due to coarse particles, which
detach from the bubbles due to bubble bursting within the froth phase, more readily draining from the froth back
into the pulp than finer particles.
Improving coarse particle recovery achieved during flotation would have many benefits. Not only would it
result in an increase in overall recovery and therefore revenue at a specific particle size but it could also enable
flotation at a coarser feed size reducing the amount of energy used in upstream comminution processes. For
example, if flotation could be performed at 0.3mm rather than 0.1mm, the potential energy savings in
comminution would be around 30 to 50%.
Coarse particle flotation potentially can be improved by either modifications to the design or operation of
conventional cells (Dunne, 2012), or by using alternative technologies, of which the most promising is the
fluidised bed type flotation cell (Kohmuench et al, 2010, 2013; Jameson, 2010).
Corresponding authors
e-mail: Kym.Runge@metso.com (Manager Flotation Process Technology) Tel.: +61 418 650 043, Fax: +61 3878 1717
Erico.Tabosa@metso.com (Process Engineer Flotation Technology) Tel.: +61 459 834 576
1
Strategies for increasing coarse particle flotation in conventional flotation cells

Flotation 13 - 18-21 November 2013
Conventional impeller driven flotation cells are currently the main technology employed in the mining industry
to perform separation by flotation. Modification in this technology through a change in operation or via a
retrofitted device to increase coarse particle recovery has the potential to be rapidly adopted by industry.
This paper will present the results from a series of experiments in Metsos 3m3 RCS flotation cell performed to
test strategies that have the potential to increase coarse particle recovery in a conventional flotation
machine. Strategies tested include:
-
Optimisation of froth depth (and therefore froth residence time);

Optimisation of turbulence through manipulation of impeller speed, impeller size, feed pulp density
and cell aspect ratio.
2. EXPERIMENTAL
Test work presented in this paper was performed using Metsos 3 m3 RCS test rig. This rig consists of a 3 m3
flotation tank fitted with a RCS mechanism located on an upper platform with the products from the flotation
unit discharging via gravity to a pump sump located on the bottom platform (details of which are outlined in
Runge et al, 2012 and in Figure 1).
Feed sampling
box
Flotation cell
Concentrate and
tailings sampling
boxes
Sump tank
Figure 1. Metsos 3m3 transportable flotation rig operating at Rio Tintos Northparkes operation.
The rig was designed primarily for performing metallurgical testwork. It therefore incorporates easily accessible
full stream sampling points and is fully instrumented to facilitate stable operation. It has also been designed to
enable control and manipulation of the following flotation cell operating variables feed flowrate, air rate,
impeller speed and froth depth. The rig comes with three interchangeable froth launder configurations and two
sizes of RCS impeller (3 m3 and 5 m3 standard RCS impellers).
For this study the rig was operated in recycle mode where the concentrate and tailing stream are mixed in the
product sump and then recycled back as new feed. This mode enables operation of the rig with unchanging feed
properties. Feed flowrate in the rig is measured by an Endress Hauser nucleonic gauge and controlled by the
pumping rate to maintain a constant feed flow. A blower is fitted to the rig to supply the required air to the
flotation impeller via a draft tube. Air mass flowrate is measured using a calorimetric air flow transmitter and
controlled using a butterfly valve located in the air line. Froth depth is measured using an ultrasonic sensor that
determines the vertical position of a ball float. Rexroth dart valves in the cell tailing box are moved up and down
to control the tail flow to achieve the desired froth depth set point.

Testing Program
Testwork presented in this paper was performed at Rio Tintos Northparkes copper operation using flotation
feed. The test program involved running the test rig at its standard operating condition (RCS3 impeller operated
at 6.2m/s at 1.7cm/s superficial gas rate) as well as at (1) reduced impeller speed, (2) with an oversized RCS5
impeller, (3) reduced cell aspect ratio and at (4) reduced pulp density. At each condition, the cell was operated at
three froth depths. Table 1 summarises the set up of the rig on each of the six days of testing that will be
presented in this paper.
On each day of testing, the cell was filled with a sample from the plant and measurements were then performed
at an as received flotation feed at two or three froth depth conditions. In the case of the evaluation of the effect
of pulp density (Test 2), a measured amount of water was then added to the rig, frother was added to result in
the same frother concentration as in the plant and measurements were then performed at a lower than plant feed
density at three froth depth conditions.
Table 1. Tests used to investigate strategies for improving coarse particle flotation.
Test No. Condition
1
2
3
Date
Pulp density
17/10/2010
Normal
1
2
Normal
3*
2
20/10/2010
4
5
Low
6
1
3
2
23/10/2010
Normal
3
1
4
2
01/11/2010
Normal
3
1
5
2
09/11/2010
Normal
3
1
2
3
6
11/11/2010
Normal
4
5
*: Test 2 Condition 3 - standard operating condition
Cell Aspect ratio Impeller

(height:diameter)
size
0.85
RCS3
Impeller Tip
Speed (m/s)
3.5
Superficial gas Froth

velocity
depth
Jg (cm/s)
(cm)
1.7
0.85
RCS3
6.2
1.7
0.85
RCS5
6.2
1.7
0.65
RCS5
6.2
1.7
0.65
RCS3
3.5
1.7
3.5
1.7
0.65
RCS3
6.2
1.7
7.4
10.8
13.2
7.6
9.3
11.0
7.6
9.3
10.6
7.7
9.2
11
8.5
11.4
9.9
8.0
9.4
10.9
10.4
8.5
11.4
8.5
10.4
The feed was accessed from the flotation circuit feed in the Northparkes flotation circuit Module 1 and typically
assayed 0.4 per cent copper. Plant feed percent solids was usually 30 per cent and the flotation feed P80 was
around 75 to 100 m. There were some differences between the copper assay and percent solids of the plant
source stream and the measured feed characteristics during testing in the rig. This was a consequence of the
recycle mode of operation where a proportion of the copper and solids at steady state resides in the froth phase,
lowering the copper and solids content of the rigs feed stream.
Repeat testing (where the same test conditions were sampled repeatedly over a whole day of recycling
operation) resulted in similar copper recoveries but increasing copper concentrate grade. This increase in
concentrate grade was found to be a consequence of the water flow to concentrate (and thus entrained recovery)
dropping with time of operation of the rig. This paper will therefore predominantly analyse the copper recovery
change with a change in operational condition.

Measurements Performed
At each froth depth condition, the cell was operated for 30 minutes in recycle before representative samples of
feed, concentrate and tailing streams were collected. Feed flowrate, as measured by the Endress Hauser
nucleonic gauge, was recorded and the flowrate of the concentrate was determined by diverting it into a drum
for a period of time and measuring the volume. Samples collected were weighed wet and dry to determine
percent solids and then analysed for copper content. Samples were also sized (to 38 m using wet and dry
screening methods) and size fractions analysed for copper content.
All experimental data was balanced using Solver in Excel to produce a consistent set of information to enable
calculation of solid, water and copper recoveries.
Additional measurements were also performed to assess how the different operational condition impacts on the
key parameters which affect flotation. Turbulence was characterized using a newly developed piezoelectric
sensor, details of which are outlined in Tabosa, Runge and Holtham (2012). This sensor deflects backwards and
forwards in the pulp as a consequence of velocity fluctuation in the turbulent flow. This produces a voltage
versus frequency signal, the average of which will be used to compare the degree of turbulence in the cell at the
different tests.
Analysis Methodology
A flotation cell consists of two distinct zones a mixed pulp zone in which bubbles collide with particles in a
liquid phase and a froth zone consisting largely of particle laden air bubbles rising and moving towards the
concentrate lip. A proportion of what is recovered in the pulp phase does not report to the final concentrate as it
is returned (or lost) from the froth phase.
Thus the overall recovery of a mineral in a flotation cell is a function of its recovery in both the pulp (R c) and
froth (Rf) phases (Dobby, 1984), as shown in Equation 1.
(1)
The drivers of recovery are very different in these two phases. In the pulp phase, recovery is largely driven by
the parameters which affect bubble particle collision, attachment and stability (e.g. bubble size, air rate,
residence time, turbulence and pulp viscosity) (Schulze, 1977; King, 1982). Whereas in the froth phase,
recovery is more a function of the time particles spend in the froth (a function of froth volume and froth
mobility), the bubble coalescence rate and the degree of liquid drainage from the froth phase (Mathe et al,
1998).
To ultimately be able to design a flotation regime which optimises coarse particle flotation recovery, one needs
to understand how the key variables of flotation impact on this recovery in both the pulp and froth phases. To
enable this type of investigation, it is important that one is able to measure the pulp and froth zone recovery
independently.
To enable this type of differentiation in this study, a changing froth depth methodology was used (Feteris et al,
1987; Vera et al, 1998). This involved performing testwork on a particular day at different froth depths. At each
condition, the overall recovery (Ro) in combination with the cell air holdup (
), cell volume (V) and feed
flowrate (Qfeed) was used to calculate the overall rate constant (Equations 2 and 3).
(2)
(3)

It is assumed that a linear relationship exists between froth depth and the overall rate constant, k, as illustrated in
Figure 2. The line is extrapolated to zero froth depth (since there should be no losses due to froth zone effects
under these conditions), giving the zero froth depth or pulp or collection zone rate constant referred to as kpulp or
kc. Equation 4 can then be used to calculate the recovery in the collection zone (R c) based on the estimated
collection zone rate constant.
Overall flotation rate - k
(4)
Collection zone rate constant (k c)

k = kc, Rf = 100%
Deep froth depth

k = 0, Rf = 0
Froth depth
Figure 2. Using the flotation rate versus froth depth relationship to estimate the collection zone rate constant.
It can be shown that the froth recovery is equal to the flotation rate constant divided by the pulp flotation rate
constant, i.e.:
(5)
Therefore by performing tests at different froth depths and measuring recovery, the flotation rate constant can be
determined at each froth depth, the collection zone rate constant and recovery can be determined by
extrapolation of the relationship depicted in Figure 2 and froth recovery can be calculated for every froth depth
as the ratio of the measured rate constant to the collection zone rate constant.
The higher the value at which the flotation rate versus froth depth line intercepts the y-axis, the higher the
recovery rate in the pulp phase. The steeper the flotation rate versus froth depth relationship, the greater the
losses in the froth phase (froth recovery) at a particular froth depth.
RESULTS
Standard Flotation Condition
The RCS 3m3 flotation cell in an industrial application would usually be fitted with the standard 3m 3 impeller
and have a height to diameter ratio of 0.85. It would be operated at a standard impeller tip speed of 6.4 m/sec
and at a superficial gas rate in the order of 1.0 and a froth depth of 10 to 30 cm.
For purposes of comparison in this paper, Test 2 Condition 3 Froth Depth = 11cm will be considered to reflect
standard flotation operating conditions. In this experiment the cell is fitted with the standard 3m 3 impeller and
has an aspect ratio of 0.85. Impeller tip speed is 6.2m/sec (close to the standard of 6.4), pulp density was as
received from the plant and froth depth is in the usual range. The superficial gas rate was 1.7 cm/sec which is
higher than normal but not outside the range usually observed in operating plants. Feed rate was 80m 3/h.
At this test condition, the flotation cell residence time was 1.7 minutes and the copper flotation recovery
achieved was 64.6% at a concentrate grade of 14.6%.
The recovery versus size relationship at this condition is shown in Figure 3. Recovery is optimal for particles
smaller than 53 micron and decreases as particle size increases. A large proportion of the copper in the feed to

the cell is predominantly less than 38 micron with very little material above 150 micron. It should therefore be
noted that errors in the +150 micron data are considered reasonably high. Copper recovery versus size under
these standard conditions is similar in shape to that observed in the first cell in the plant.
100
100
Standard Condition
90
80
80
Copper in Feed
70
70
Copper Recovery
60
60
50
50
40
40
30
30
20
20
10
10
Copper in Feed, %
Overall copper recovery, %
90
0
-38
38
53
75
Particle size, um
106
+150
Figure 3. Copper recovery versus size and copper distribution in the feed under standard operating conditions in the Northparkes test work
(Test 2 Condition 3, Froth depth = 11 cm, Residence Time = 1.7 min)
Using the changing froth depth method outlined above, the copper recovery in the pulp phase and the froth
recovery as a function of size was estimated at the standard condition in the test cell. Results are shown
graphically in Figure 4.
100
80
70
60
50
40
30
FD=0cm
20
FD=11cm
10
Standard Condition
90
100
Standard Condition
90
80
70
60
50
40
30
20
FD=11cm
10
0
-38
38
53
75
Particle size, um
106
+150
-38
38
53
75
Particle size, um
106
+150
Figure 4. (a) Copper recovery estimated at zero froth depth compared to actual recovery versus size and (b) Copper froth recovery versus
size estimated at the standard operating condition (Test 2 Condition 1, Froth depth = 11 cm, Residence Time = 1.7 min).
Recovery in the pulp phase (Figure 4a) does exhibit a decrease as particle size increases probably due to the
fact that in this ore these particles are not full liberated. However, the decrease is much less severe than
observed in the overall data. Froth recovery, on the other hand, is very strongly correlated with particle size
(Figure 4b) with finer particles (<75 micron) exhibiting a froth recovery in the order of 80% and coarser
particles exhibiting a froth recovery less than 30%. This drop in froth recovery with size has been observed by
Savassi et al (1997) at plant scale and by Jameson et al (2012) in the laboratory. It is believed that coarse
particles when detached in the froth phase during bubble coalescence more readily drain and return to the pulp
than fines which remain in the froth and report to concentrate.
It is therefore concluded that poor froth recovery is the main reason why coarse particles exhibit much lower
recovery than fines at the standard operating condition.
Effect of Froth Depth
Most test conditions outlined in Table 1 were performed at a range of froth depths. A reduction in froth depth
reduces the residence time of bubbles and particles in the froth phase and is known to increase overall recovery.
Coarse particles under the standard operating condition exhibit poor froth recovery and therefore poor overall

recovery. In this section the sized data from the different tests will be analysed to determine the extent to which
coarse particle recovery can be increased by operating a flotation cell at a shallower froth depth.
Figure 5 shows the recovery and concentrate grade achieved when using the standard flotation conditions as a
function of froth depth. Note that the recoveries in this section (and in comparisons in later sections) have been
standardised to a residence time of 1.8 minutes to allow direct comparison. This was performed by calculating
the overall rate constant using the measured recovery and cell residence time (Equation 2 and 3) and then
calculating a recovery at 1.8 minutes using Equation 6. Most tests were performed at close to this residence time
so it does not result in a large change from the experimentally measured recovery.
(6)
20
Copper Concentrate Grade (%)
100
90
80
70
60
50
40
30
20
10
0
18
16
14
12
10
8
6
4
2
0
10
12
Froth depth, cm
10
12
Froth depth, cm
Figure 5. (a) Copper recovery and (b) Copper concentrate grade achieved in the Metso RCS3 cell operated using the standard conditions
(Test 2 Residence Time = 1.8 min).
Overall recovery in the cell increases only marginally as the froth depth becomes shallower. This is because the
froth recovery in the first cell of a process is reasonably high. In this case froth recovery is estimated to be 60%
at the deepest froth depth and increases to 70% at the shallowest froth depth. In contrast, copper concentrate
grade decreases significantly at shallower froth depth and this is because the water recovery (and therefore the
entrainment recovery) increases significantly.
Figure 6a shows the recovery achieved at each froth depth as a function of size. It also includes an estimate of
the recovery that would be achieved if the froth depth was zero.
100
100
Test 2 - Standard Condition
80
70
60
50
40
FD=0 cm
30
FD=7.6 cm
20
FD=9.3 cm
10
Test 2 - Standard Condition
90
Copper froth recovery, %
90
80
70
60
50
40
FD=7.6 cm
30
FD=9.3 cm
20
FD=11 cm
10
FD=11 cm
-38
38
53
75
Particle size, um
106
+150
-38
38
53
75
106
+150
Particle size, um
Figure 6. (a) Copper overall recovery and (b) Copper froth recovery as a function of size at different froth depths for the standard cell
operating conditions (Test 2 Residence Time = 1.8 min)

The finer particle classes exhibit similar recovery at all three froth depths. Coarse particles, on the other hand,
show a significant improvement in recovery as the froth depth decreases. For example, for a froth depth change
of 11 to 7.5 cm, the recovery of the +106 micron fraction doubles and is estimated to triple if the cell was
operated with no froth. This is a consequence of an improvement in froth recovery (Figure 6b).
Improvement in coarse copper recovery was observed when running at shallower froth depths at all test
conditions (Figure 7).
100
Test 1
80
70
60
50
40
FD=0 cm
30
FD=7.4 cm
20
FD=10.8 cm
10
80
80
70
60
50
40
30
FD=0 cm
20
FD=7.7 cm
-38
38
100
53
75
Particle size, um
106
-38
+150
100
Test 5
90
70
60
50
FD=0 cm
30
FD=8.0 cm
20
FD=9.4 cm
10
FD=10.9 cm
FD=0 cm
FD=8.5 cm
38
53
75
Particle size, um
106
+150
40
30
20
-38
38
53
75
Particle size, um
106
+150
Test 6 - High impeller speed
80
70
60
50
40
30
FD=0 cm
20
FD=8.5 cm
FD=10.4 cm
10
FD=10.4 cm
FD=11.4 cm
0
0
-38
50
90
50
20
60
100
60
30
70
+150
70
10
106
80
40
FD=0 cm
FD=8.5 cm
FD=9.9 cm
FD=11.4 cm
53
75
Particle size, um
Test 6 - Low impeller speed
90
80
40
38
Test 4
10
FD=11 cm
90
10
FD=13.2 cm
100
Test 3
90
90
100
-38
38
53
75
Particle size, um
106
+150
-38
38
53
75
Particle size, um
106
+150
Figure 7. Copper recovery as a function of size at different froth depths for different test conditions (Residence Time = 1.8 min).
These results are in agreement with the literature, where it has been shown that froth recovery of coarse particles
can be significantly increased at shallow froth and be similar to that of the fines Figure 8 (Rahman
et al., 2012).
Figure 8. Froth recovery as a function of particle size for three different froth depths (Jg=1cm/s, 70% 60G silica in feed, feed rate =
280g/min, collector dose = 100g/t, frother dose = 20ppm). (After: Rahman et al., 2012).
It is therefore concluded that operating a cell at shallower froth depth selectively improves the recovery of
coarse particles by improving coarse particle froth recovery. This type of operation, however, results in much
higher water recoveries and entrained recoveries and therefore lower concentrate grade.
Shallow or no froth operation therefore has the potential to be used to increase coarse particle recovery in a
flotation cell. It would require a change in the way cleaning circuits are designed so that they could cope with
the higher feed flows, reject the higher amounts of entrained recovery as well as regrinding to achieve final
concentrate grade targets.

Turbulence in the Pulp phase

Anecdotally it is believed that coarse particle flotation recovery is negatively affected by turbulence
(Schulze, 1977). Under highly turbulent conditions, the probability of coarse particle detachment from bubbles
is increased in the pulp phase. In the testing program performed, a number of different methods of changing
turbulence were employed:
Tests were performed at an impeller speed half the standard speed which was expected to reduce
turbulence;
Tests were performed with an impeller with a larger diameter which was expected to increase
turbulence;
Tests were performed at a lower cell aspect ratio. A flotation cell consists of a highly turbulent region
at the bottom of the cell and a quiescent less turbulent region in the top half of the cell. By reducing
the cell aspect ratio, the proportion of the cell which is highly turbulent is increased.
At the various test cell conditions, there was a measurable significant change in both the power imparted to the
impeller per m3 of slurry (Figure 9) and the localised distribution of this turbulence in the machine (Figure 10).
8
High cell aspect ratio
Low cell aspect ratio
Specific Power, kW.m-3
6
5
4
3
2
1
0
RCS3, IS = 3.5m/s
RCS5, IS = 3.5m/s
RCS3, IS = 6.2m/s
RCS5, IS = 6.2m/s
Figure 9. Specific power drawn by the impeller measured.
Figure 10 shows the magnitude of the turbulence as a function of height in the RCS flotation machine when
operating at low versus high impeller speed, with a 3m3 impeller versus a 5m3 impeller and with a low versus
high cell aspect ratio. In all cases, there is a noticeable transition from a quiescent low turbulent zone at the top
of the cell to a highly turbulent zone in the bottom third of the cell. It is interesting to note that when operating
at higher impeller speeds, with the 5m3 impeller or at low aspect ratio, the high turbulent region increases in
height and gets closer to the pulp froth interface.

1.0
1.0
Test 1 (3.5 m/s)
0.4
0.2
0.0
0.6
0.4
0.2
0.0
0.0
1.0
2.0
3.0
4.0
5.0
1.0
(a)
2.0
3.0
0.2
4.0
0.0
1.0
(b)
0.2
0.0
0.6
0.4
0.2
4.0
5.0
0.0
Vibration signal, mV
5.0
Test 3 (High cell aspect ratio)
0.8
0.6
0.4
0.2
0.0
0.0
3.0
4.0
Test 4 (Low cell aspect ratio)
0.8
Relative cell height (h/H)
0.4
3.0
(c)
Test 4 (RCS5)
0.6
2.0
1.0
Test 6 (RCS3)
Test 6 (6.2m/s)
0.8
2.0
0.4
1.0
Test 6 (3.5m/s)
1.0
0.6
1.0
0.0
0.8
0.0
0.0
Test 5 (Low cell aspect ratio)
0.8
0.6
Test 1 (High cell aspect ratio)
Test 3 (RCS5)
0.8
1.0
Test 2 (RCS3)
Test 2 (6.2m/s)
1.0
2.0
3.0
4.0
0.0
1.0
2.0
3.0
4.0
5.0
Figure 10. Magnitude of vibration signal from piezoelectric vibration sensor as a function of height in the flotation tank and impeller speed
for (a) Comparative tests performed at different impeller speed, (b) Comparative tests performed with the 3m3 and 5m3 impeller mechanism
and (c) Comparative Tests performed at high and low cell aspect ratio.
Data from these tests were sized to determine how turbulence specifically affects coarse particles (in comparison
to the fines). Figure 11 shows the overall recovery achieved as a function of size at what is being considered in
this paper as the standard froth depth of 11cm.
Froth depth ~ 11 cm
Copper recovery, %
100
80
Test 1 (HAR, RCS3, LIS)

Test 2 (Standard)
60
Test 3 (HAR, RCS5, HIS)

Test 4 (LAR, RCS5, HIS)
40
Test 5 (LAR, RCS3, LIS)

20
0
-38
38
53
75
Particle size, um
106
+150
Figure 11. Copper recovery versus size achieved in tests in which the turbulence imparted to the flotation cell has been changed using low
(LIS) and high (HIS) impeller speeds; impeller size (RCS 3 or RCS 5); or low (LAR) and high (HAR) cell aspect ratio (residence
time = 1.8 minutes).
The change in turbulence is having a significant impact on the copper recovery achievable in the cell. Higher
recoveries are generally correlated with test conditions which result in low turbulence (low impeller speed,
smaller impeller, high aspect ratio). Very low recoveries are observed across all size fractions for Test 4 which
exhibits the opposite set of conditions (i.e. high impeller speed, large impeller, low aspect ratio).
Coarse particles, in particular, exhibit a negative correlation with the specific power imparted to the slurry
(Figure 12). Coarse particle recovery more than doubles between the lowest power condition and the highest
power condition.

100
90
80
70
60
50
40
30
20
10
0
+106um
+75um
Overall energy dissipation rate, kW.m -3
Figure 12. Copper recovery in the coarse size fractions as a function of specific power imparted to the slurry (residence time = 1.8 minutes).
In contrast to the general rule of thumb, turbulence is not resulting in an improvement in the fines particle
recovery either, with the highest recoveries being for the lowest turbulent conditions.
The changing froth depth method was used to estimate the pulp zone recovery (froth depth = zero) and froth
recovery at each of the test conditions to determine the extent to which these losses occur in the pulp and froth
phases. It should be noted that the results, especially in terms of froth recovery have a high degree of error. The
results are an interpolation of three size fraction recoveries and error in sized information is higher than for the
overall data and error can cause large deviations in the interpolated results. Because of these problems, this
information will only be viewed with the objective of determining general trends.
Figure 13 shows the copper recovery estimated if froth depth were zero in the different tests. Most tests exhibit
very similar size versus recovery curves.
Froth depth = 0 cm
Copper recovery, %
100
Test 1 (HAR, RCS3, LIS)
80
Test 2 (Standard)
Test 3 (HAR, RCS5, HIS)
60

40

20
0
-38
38
53
75
Particle size, um
106
+150
Figure 13. Copper recovery versus size estimated at zero froth depth in tests in which the turbulence imparted to the flotation cell has been
changed using impeller speed, impeller size or cell aspect ratio (residence time = 1.8 minutes).
The trend in the overall results must therefore be largely a consequence of froth phase effects. Figure 14 shows
the copper overall recovery as a function of copper froth recovery and particle size estimated at 11 cm froth
depth. Large variations from size to size class are not expected and are a consequence of the high error
associated with the analysis methodology.
Copper Overall Recovery, %

100
90
80
70
60
50
40
30
20
10
0
Test 1 - 0.82 kw/m

+38m
-38m
+38m
+53m
+53m
+75m
+75m
+106m
+106m
Test 4 - 7.12 kw/m
20
40
60
80
100
Copper Froth Recovery, %

Figure 14. Copper overall recovery as a function of copper froth recovery and particle size estimated at 11 cm froth depth in tests in which
the turbulence imparted to the flotation cell has been changed using impeller speed, impeller size or cell aspect ratio.
The general trend, however, is for the froth recovery to decrease as the turbulence imparted to the pulp
increases. Test 1 presented the highest froth recoveries and is correlated with the lowest turbulent conditions
(0.82 kw/m3). Test 4, however, exhibits very low froth recoveries and is correlated with conditions which result
in the highest turbulent conditions (7.12 kw/m3). Turbulences detrimental effect on froth recovery occurs across
all size fractions not just specifically the coarse particle.
In summary, it is concluded that running the 3m3 test cell under highly turbulent conditions results in poorer
coarse particle recovery predominantly due to turbulence adversely affecting the froth phase and resulting in
poorer froth recovery. Turbulence does not affect coarse particle recovery in the pulp phase to a significant
degree. It should be noted that the top size in this work is not overly coarse and it cannot be discounted that
turbulence could have a significant detrimental effect in the pulp phase for coarser feeds.
These results, in combination with the changing froth depth results, highlight that coarse particles are selectively
lost in the froth phase and therefore froth recoveries need to be maximised if one is to achieve high coarser
particle flotation recoveries.
Effect of pulp density
Runge et al (2012) studied the effect of pulp density using the Metso 3m3 test cell at Northparkes. In this study
pulp density was found to affect recovery in both the pulp and froth phases.
In the pulp phase, recovery increased as the pulp density decreased. At lower pulp density, the bubble size
increased and there was an observable increase in the size of the high turbulent zone presumably due to the
change in pulp density affecting pulp viscosity. The net result of these changes is more effective bubble particle
collection the mechanism of which is yet to be determined. Froth recovery at a particular froth depth, on the
other hand, was adversely affected by a decrease in pulp density. Presumably this is because there are less
particles in the froth and it becomes less stable.
Potentially high pulp density is therefore a variable which could be used to increase coarse particle flotation
recovery. High density could dampen turbulence and increase recovery of coarse in the pulp phase whilst also
increasing stability in the froth phase and therefore increase coarse particle froth recovery.
Test 2 in Table 1 involved operation of the test rig at different float feed densities. In this test, the cell was
operated at standard operating conditions at three different froth depths and sampled and then water was added
to dilute the feed and samples again collected at three different froth depths.
Figure 15 shows the copper recovery achieved as a function of size at (a) the standard froth depth of 11 cm and
(b) shallower froth depth of 7.6 cm. There is very little difference in the results across all size fractions which
may indicate that under the standard operating conditions there would be no advantage in terms of coarser
particle recovery to operating at a different pulp density.

80
80
low density, FD=10.6
low density, FD=7.6

70
high density, FD=11
70
60
50
40
30
20
10
high density, FD=7.6
60
50
40
30
20
10
-38
38
53
75
Particle size, m
106
+150
-38
38
53
75
Particle size, um
106
+150
Figure 15. Overall copper recovery as a function of particle size at (a) Standard froth depth of 11cm and (b) 7.6 cm froth depth (Test 2).
Figure 16 shows the pulp and froth recoveries estimated at high and low pulp density as a function of size in
Test 2. The high error in these results means that no conclusions can be confidently drawn from this data. Low
density tends to improve pulp recoveries and results in deterioration in froth recovery of all particle sizes.
Potentially the counteracting effects of these two zones result in very little change in the overall particle size
recovery.
Froth Depth = 0 cm
Froth Depth = 11 cm
100
100
25% Solids
90
Copper froth recovery, %
Copper Recovery, %
80
70
60
50
40
30
20
10
25% Solids
90
31% Solids
31% Solids
80
70
60
50
40
30
20
10
0
-38
38
53
75
Particle size, um
106
+150
-38
38
53
75
106
+150
Particle size, um
Figure 16. (a) Estimated copper recovery versus size when operating at zero froth depth and (b) estimated froth recovery as a function of
size at 11 cm froth depth for the two density feeds in Test 2
In summary, results do not show any significant difference in coarse particle recovery at different pulp densities.
Whether this would still be the case for much coarser particles (which potentially would be adversely affected
by the observed increase in turbulence at low density) or when froth stability is much poorer (e.g. coarse only
float where there are no fines to provide stabilisation or scavenger application), is unknown.
CONCLUDING REMARKS
Samples from a test program were sized to enable an assessment of the effect of different operational and design
variables on the coarse particle recovery achieved in a flotation cell. A flotation cell consists of two distinctly
different zones a pulp zone where bubbles and particles collide and attach and a froth zone where bubbles
burst, returning a proportion of the attached particles as well as entrained material back to the pulp phase.
Overall recovery is a combination of pulp and froth zone recoveries. The overall coarse particle recovery was
found to be about half that of the finer particles in all of the RCS testwork.
In the pulp zone, coarse particle recovery was marginally lower than for the fines and this is probably due to
these particles being less liberated. A change in turbulence in the flotation cell (either through a change in
impeller speed, impeller size, cell aspect ratio or pulp viscosity) did not have a significant effect on this coarse
particle pulp phase recovery. This was unexpected as the literature suggests that coarse particles should become

unstable in a highly turbulent environment and recovery should decrease. This may be because the coarsest
particles in the feed used were -212 +150 m, which may not be coarse enough to suffer from this effect.
In the froth zone, however, coarse particle recovery was significantly lower than that of the finer particles.
Presumably coarse particles either detach more easily than the fines in the froth or they detach at an equal rate
and the coarse particles drain more readily through the froth. Froth depth was found to have a large impact on
the froth recovery of coarse particles and much less of an effect on the froth recovery of fines. Tests performed
at shallower froth depth had significantly higher coarse particle recovery and it is estimated that coarse particle
recovery would be about double that achieved under standard froth depth conditions if the cell was run with no
froth. Use of a low aspect ratio or a larger sized impeller or a higher impeller speed resulted in significantly
more losses in the froth phase and lower coarser particle froth recoveries.
It is therefore concluded from this work that the best means of increasing coarse particle recovery rates is to
operate a flotation cell under conditions which maximise froth recovery shallow or no froth depth and
conditions where turbulence at the interface is minimised (smaller impellers, high cell aspect ratio).
ACKNOWLEDGEMENTS
The authors would like to acknowledge the assistance of Metso Process Technology and Innovation
personnel involved in the testing campaign and during sample preparation and data analysis: Jaclyn
McMaster, Robert Crosbie, Kevin Cummins, Rae de Rusett, Diana Li and Shaun Baker. Rio Tintos
Northparkes operation is also gratefully acknowledged for assisting during the research work and
assay analysis.
REFERENCES
Ata, S., Jameson, G.J., 2013. Recovery of coarse particles in the froth phase A case study, Minerals Engineering,
Volume 45, pp 121-127
Dobby, G.S., 1984. A fundamental flotation model and flotation column scale-up. Department of Mining and
Metallurgical Engineering. PhD thesis, McGill University, Montreal, p. 259
Dunne, R.C., 2012. The journey of the coarse particle through the pulp and froth in flotation. In: Proceedings of the XXVI
International Mineral Processing Congress, New Delhi, India, pp 1259-1268
Feteris, S.M., Frew, J.A. and Jowett, A., 1987. Modelling the effect of froth depth in flotation, International Journal of
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Somasundaran (Ed.). AIME, New York, N.Y, pp. 720-754
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Metallurgy
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AusIMM, 2012 Publication series 10/2012, pp171-178
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Increase Coarse Flotation

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Strategies for increasing coarse particle flotation in

conventional flotation cells

Metso Process Technology & Innovation, Pullenvale, Queensland, Australia

Strategies for increasing coarse particle flotation in conventional flotation cells

Optimisation of froth depth (and therefore froth residence time);

Strategies for increasing coarse particle flotation in conventional flotation cells

Cell Aspect ratio Impeller

Superficial gas Froth

Strategies for increasing coarse particle flotation in conventional flotation cells

Strategies for increasing coarse particle flotation in conventional flotation cells

Overall flotation rate - k

Collection zone rate constant (k c)

Deep froth depth

Strategies for increasing coarse particle flotation in conventional flotation cells

Overall copper recovery, %

Overall copper recovery, %

Overall copper recovery, %

Strategies for increasing coarse particle flotation in conventional flotation cells

Copper Concentrate Grade (%)

Overall copper recovery, %

Test 2 - Standard Condition

Test 2 - Standard Condition

Copper froth recovery, %

Overall copper recovery, %

Strategies for increasing coarse particle flotation in conventional flotation cells

Overall copper recovery, %

Overall copper recovery, %

Test 6 - High impeller speed

Test 6 - Low impeller speed

Overall copper recovery, %

Overall copper recovery, %

Overall copper recovery, %

Overall copper recovery, %

Strategies for increasing coarse particle flotation in conventional flotation cells

Turbulence in the Pulp phase

Low cell aspect ratio

Specific Power, kW.m-3

Figure 9. Specific power drawn by the impeller measured.

Strategies for increasing coarse particle flotation in conventional flotation cells

Test 1 (3.5 m/s)

Test 3 (High cell aspect ratio)

Test 4 (Low cell aspect ratio)

Relative cell height (h/H)

Relative cell height (h/H)

Relative cell height (h/H)

Test 5 (Low cell aspect ratio)

Relative cell height (h/H)

Test 1 (High cell aspect ratio)

Relative cell height (h/H)

Relative cell height (h/H)

Test 1 (HAR, RCS3, LIS)

Test 3 (HAR, RCS5, HIS)

Test 5 (LAR, RCS3, LIS)

Test 6 (LAR, RCS3, HIS)

Overall copper recovery, %

Strategies for increasing coarse particle flotation in conventional flotation cells

Overall energy dissipation rate, kW.m -3

Test 1 (HAR, RCS3, LIS)

Test 4 (LAR, RCS5, HIS)

Test 6 (LAR, RCS3, LIS)

Copper Overall Recovery, %

Strategies for increasing coarse particle flotation in conventional flotation cells

Test 1 - 0.82 kw/m

Copper Froth Recovery, %