Operating & Maintenance Manual Mini Pilot Plant System - Compact Lab Column

OPERATING & MAINTENANCE MANUAL
Mini Pilot Plant System – Compact Lab Column
Prepared By:
ERIEZ FLOTATION DIVISION - CANADA INC.
January 2013 Rev. 02
7168 Venture Street, Delta B.C. Canada V4G 1H6 Phone:+1 604 952 2300 Fax:+1 604 952 2312
Email:emfg@eriez.com Web:www.eriez.com/flotation
Compact Test Cell Manual
The purpose of this manual is to provide instructions for assembly of the CPT Compact Test
Cell, plus an overall guide to column flotation technology and test column operation. This
manual has been divided into five sections, each dealing with a different aspect of the column
flotation process.
Section Heading Page
1 Equipment Description 1
2 Test Cell Assembly 5
3 Column Operation 23
4 Column Testing 30
5 Column Maintenance 37
For further information contact:
Eriez Flotation Division – Canada Inc.

7168 Honeyman Street
Delta, B.C. Canada V4G 1H6
Tel: +1 604 • 952 • 2300
Fax: +1 604 • 952 • 2312
Email: emfg@eriez.com
Compact Column Equipment Description Page 1
1.0 EQUIPMENT DESCRIPTION

A Flotation Column is a type of flotation machine that incorporates some unique design features
to enhance metallurgical performance. Some of these features include:
• Reduced surface area to cell volume ratio to promote froth stability
• Froth washing system to minimise the entrainment of impurities
• Quiescent flotation conditions to promote selectivity
Flotation Columns derive their name from the geometric shape of the vessel. Unlike
conventional flotation machines which tend to use
relatively shallow rectangular tanks, column cells
are very tall vessels with heights typically ranging
from 10 m to 15 m. The tank cross-section may be
either round, square or rectangular depending on
the specific application. For an equivalent
volumetric capacity, the surface area of the column
cell is much smaller than a conventional cell. This
reduced area is beneficial for promoting froth
stability and allowing very deep froth beds to be
formed.
An important feature of flotation columns is

the froth washing system. Froth washing
provides an additional means for removing
unwanted impurities from the flotation froth.
Wash water, added at the top of the column,
filters through the froth zone displacing
process water and entrained particles
trapped between the bubbles.
Figure 1 – Column Flows

Unlike conventional flotation machines, columns do not use mechanical agitation. The absence
of intense agitation promotes selectivity and aids in the recovery of very fine particles. The
basic flow streams in a column are illustrated in Figure 1. Feed slurry enters the column at one
or more feed points located in the upper third of the column body and descends against a rising
swarm of fine bubbles generated by the air sparging system. Particles which collide with, and
attach to the bubbles, rise to the top of the column, eventually reaching the interface between
the pulp (collection zone) and the froth (cleaning zone). The location of the interface, which can
be adjusted by the operator, is held constant by means of an automatic control loop which
regulates the speed of a variable speed pump on the column tailings line. Varying the location
of the interface will increase or decrease the height of the froth zone.
In commercial column cells, flotation air is introduced into an external manifold and is injected
through a series of parallel air lances (sparger tubes) located near the bottom of the column.
The air rate, used in the column is selected according to the feed rate and concentrates
production requirements and will determine, in part, the point on the grade/ recovery curve at
which the column operates.
For test columns, a porous HDPE tube is used for air sparging as this provides excellent air
dispersion. A recirculating pump sparging tube system is also used to increase bubble quality
and magnify bubble quantity. The column has been instrumented with an automatic level
control loop. Air flow is measured and controlled using a digital air mass flow controller, and
wash water flow is measured using a turbine flow meter. Both air and wash water flows are
controlled manually.
CAUTION: The power supply to the cabinet must be 220-240 Vac at 50/60 Hz. Damage to
the equipment may occur if incorrect voltage is used.
1.1 AIR CONTROL
1.2 Level Control The column control panel is equipped with an air pressure regulator,
pressure gauge and an air mass flow controller with digital display for measurement.
The air flow controller was calibrated at STP (Standard Temperature and Pressure) and will
display air flow measurements in sL/min (Standard Liters per Minute).
Note that reference conditions are as follows;
Standard Pressure: 101.325 kPa (760 mm Hg)
Standard Temperature: 21.1 °C (70 °F)
The test column uses a single pressure transducer to detect the interface level in the column.
The pressure transducer is calibrated at 0 to 50 inches Water (0 to 25 kPa).
The 4 to 20 mA analog output signal from the transducer reports to a single-loop digital PID
controller that automatically regulates the speed of the column underflow peristaltic pump to
maintain the level set-point.
The column is fed using another peristaltic pump, the speed of which is manually controlled.
1.3 WASH WATER DISTRIBUTION AND CONTROL
The control panel is fitted with a turbine flow meter for high precision measuring and a metering
valve for regulating the wash water flow. Wash water is used to control the grade of the column
concentrate. The normal range of wash water superficial velocity is 0.0 - 0.4 cm/s. The wash
water supply should be clean and free of reagents.
The CPT wash water distributor is designed to sit on top of the column. It is fitted with a movable
plate with “fingers” that extend through matching perforations in the fixed plate. Water introduced
into the wash water tank falls along the outside of the fingers, keeping them clean, and is injected
into the froth below the surface. Note that the fingers can be raised to provide a gentle rain of
wash water above the froth. This allows evaluation of both the overhead shower and submerged
header types of wash water distribution.
In commercial installations, the overhead shower type of wash water distributor is easier to keep
clean in plants where water quality is a problem. If overhead tanks are installed too high above the
froth and if high wash water flows are used, there is a potential for the higher velocity flow to
"beat" the froth, causing froth collapse. Overhead wash systems generally result in lower density
concentrates which may impact subsequent de-watering requirements. In addition, overhead
tanks are typically higher in capital cost and heavier to support above the column.
Submerged header designs typically produce a dryer froth, provide a clearer view of the froth for
operators, and are both lighter and lower in capital cost. On the negative side, submerged
headers can become plugged and the poor wash water distribution will not be readily visible to
operators. Without routine checking, plugged headers can lead to periods of reduced column
performance.
1.4 PLACEMENT OF VALVES

The air and wash water streams should have an isolation valve (simple on/off) followed by a
measurement device (flow-meter) and a controllable valve (variable control). The control valve
should be between the measurement device and the column. Generally the control valves are an
integral part of the flow meters.
1.5 CONTROL PANEL

The control panel contains all of the electronic components required to operate the column cell.
Included are an electronic controller for level control and two variable speed peristaltic pumps.
The tailings pump is regulated automatically to maintain the level in the column. All control panel
inlet, outlet and control functions are appropriately tagged.
Compact Column Test Cell Assembly Page 5
2.0 TEST CELL ASSEMBLY
2.1 MAIN COMPONENTS
The compact test cell comprises of the following major components;
Figure 2 – Wheeled Table
Stainless steel bench with integral instrument and control panel. All
instruments, controls and pumps are pre-installed (except pressure
transducer & central support)
Figure 3 – Central Support
Adjustable height to allow for

column extension. Includes
hoses for column feed and
column wash water.
2.1.1 Column Cell Sections
Figure 4 – Top Section
with integral feed well and overflow
launder. Shown with inlet extension
and wash water distributor removed.
Figure 5 – Recirculating Sparging

Discharge Assembly
with sparger and fittings for Air Inlet

and Underflow Outlet
2.1.2 Instruments
Figure 6 – Left Side Panel

with Wash water digital LCD display and
flow control valve. Air mass flow controller,
sparger pressure gauge and air supply

regulator
Right Side Panel with
Transducer connection
Digital electronic PID level controller
Recirculating sparger pump speed controller (Optional)
Feed pump speed controller
Underflow pump speed controller
Figure 7 – Right Side Panel

Figure 8 - Level Sensor (pressure) Figure 9 - Pumps (peristaltic)
2.2 ASSEMBLY SEQUENCE
The correct sequence for assembly is as follows;
1) Install central support into wheeled table
2) Install upper, middle, lower and discharge column sections
3) Connect hoses for feed, underflow, sparger air and column wash water
4) Install level sensing pressure transducer
5) Connect incoming supply hoses for air and wash water, and connect to electrical power.
6) Power up column and check electrical and electronic components.
7) Perform leak test.
These operations are described in more detail in the following sub-sections.
The finished result is shown next, with column sections labelled for reference.
Figure 10 – Fully Assembled (mid-section not assembled)

Figure 11 – Assembly
2.2.1 Main Assembly
Insert the central support as indicated, then hand secure with the knob screw provided.
Install the middle and lower column sections, with one gasket above the table and one below.
INSTALLATION NOTE: Ensure that all gaskets for each section are properly located in the
flanges and that the bolts are tightened evenly to prevent leakage. Be careful to avoid excess
torque – bolts should NOT be over-tightened.
Attach the discharge section using a gasket and bolts.
Install the upper column section and secure to the central support using the bracket provided.
Screw in the feed pipe extension – hand-tighten only.

Position the wash water distributor above the column, with the four notches resting on the four
cross-members, and hand tighten the wing screws.
At this point, the wash water hose and column feed hose can both be threaded up through the
central support.
The hose barb fitting on the end of the wash water serves to locate the hose so that it will
discharge into the wash water distributor.
The feed hose then extends out through the hole provided and is inserted into the feed pipe
extension.
2.2.2 Hoses for Feed, Underflow, Air and Wash Water
Next, make the following connections;
Connect the air hose from the outlet side of the air control rotameter to the sparger inlet hose
barb at the bottom of the lower assembly.
Connect the hose from the lower assembly tailings outlet to the underflow pump.
Connect a length of hose to the lower assembly drain outlet.
Figure 12 – Recirculating Sparging Discharge Assembly

and Pump Connections
2.2.3 Peristaltic Pump Hoses
To insert the hose into the peristaltic pump, grasp the lever and rotate to the left, as shown in
Figure 13. This causes the pump head to open, as seen in Figure 14, allowing the hose to be
inserted.
Be sure, when inserting the hose, that it is centered in the small black clips on entering and
leaving the pump head.
Figure 13 – Closed Pump Head Figure 14 – Open Pump Head
2.2.4 Install Pressure Transducer
INSTALLATION NOTE: The metallic diaphragm end of the pressure sensor is very delicate
and must not be subjected to impact or abrasion.
To install the pressure transducer, first remove the protective cover from the threaded end,
wrap the threads with Teflon tape, then thread into the coupling on the side of the column,
being very careful not to cross-thread.
Next, unscrew the protective cover from the panel insertion fitting, plug the transducer fitting
into the opening and tighten the ring. Note that the protective cover is “captive” (retained by a
small chain to avoid loss).
2.2.5 Connect Air, Water and Power
External supplies of clean air, clean water and electrical power can now be connected to the
test column at the appropriate places. Supplies of air, water and power should be SHUT OFF.
2.3 COMMISSIONING
2.3.1 Set Up Controls for Initial Start
Before powering up the test column, the following settings should be made;
1 - Make sure that the pump speed controls are both set to zero and that the Reverse / Off /
Forward switch is set to Off.
The Auto / Manual switch select for Man (local) control, which allows the pump speed to be
controlled by rotating the speed control dial, or Auto (remote) control, which allows the PID
controller to regulate pump speed.
For operation, the underflow pump switch should be set to Auto.
2 – Make sure that the flow for air is set to zero on the flow controller, and the wash water flow
control knob is closed.
3 – Adjust the air pressure regulator to zero by turning counter-clockwise until no resistance to
turning is felt.
2.3.2 Power Up Column
Connect the test column to main power. Within a few seconds,

the controller LED display should light up, indicating that there
is power to the system.
On first lighting, the Process Variable (RED) display should

read “420A” (as shown at right) indicating that the controller is SV1
configured for 4 to 20 mA analog operation.
The small green “SV1” light indicates that the primary control
loop is active. The green “Set Variable” can be any value.
NOTE - If either pump begins to operate on system power-up, immediately adjust pump
controls to stop the pumps.
At this point, with no water in the column, the pressure

transducer will send it’s minimum signal to the controller, and
the controller PROCESS VARIABLE display should be some
low number – not necessarily zero.
SV1
The graphic above shows the LED displays for Process Variable (PV) and Set Variable (SV),
which is more commonly called Set Point.
PV represents the output of the pressure transducer on a scale of 0% to 100%.
SV is manually adjusted by the operator to maintain the desired interface level in the column.
This will be explained in more detail in a later section.
Figure 15 – Controller Display
The test column is now ready to be filled with water to check for leaks at the assembly flanges.
First – turn on the air flow controller and send a small amount of air flow to the sparger. Open
the slide valve at the air inlet line which is located on the underside of the cart table by sliding
the black aluminium sleeve up, then slowly turn the air regulator knob clockwise until a small air
flow is registered by the air mass flow controller. An initial reading of 5 to 10 will be sufficient. It
is important to have an air flow through the sparger whenever liquid (water or slurry) is in the
column, in order to minimise or eliminate liquid flowing into the sparger.
2.3.3 Leak Test
Next – begin filling the column with water. This can be done by hand filling or by using the wash
water system. If the wash water system is to be used, turn on the wash water external supply,
then apply a flow of water using the wash water flow valve adjustment knob.
NOTE - The wash water’s digital LCD display should automatically be on once the main power
of the column is activated.
As the column begins to fill with water, check all connections for leaks, and re-tighten if
necessary. If there are no leaks, then proceed with the electronic controls test.
2.3.4 Controls Test
Transducer Test
When the water level in the column moves above the transducer, the PID controller display
should begin to show increasing values. If the process variable LED display does NOT change
when the water level rises above the transducer, check for loose connections. If all connections
are correct and there is still no response, there may be a problem with the pressure transducer.
Feed Pump Test
Insert the suction (inlet) hose to the feed pump into a reservoir of clean water.
Select the Loc / Rem knob selector to Loc.
Select the Rev / Off / Fwd knob selector to Forward.
Turn the speed control knob slowly clockwise and observe the pump. The pump head rotor
should begin turning. If there is no response, check electrical connections.
Verify that Forward on the controller results in water flowing toward the column. It is possible
that the configuration and location of the pump will require selection of Reverse in order to feed
the column.
If the pump is rotating correctly and no water flows into the column, try replacing the pump head
hose with a thicker-walled hose.
Underflow Pump Test - Manual
Select the Loc / Rem knob selector to Loc.
Select the Rev / Off / Fwd knob selector to Forward.
Turn the speed control knob slowly clockwise and observe the pump. The pump head rotor
should begin turning. If there is no response, check electrical connections.
Verify that Forward on the controller results in water flowing away from the column. It is
possible that the configuration and location of the pump will require selection of Reverse in
order to remove tailings from the column.
If the pump is rotating correctly and no water flows into the column, try replacing the pump head
hose with a thicker-walled hose.
PID Controller Test
This test will be to insure that the controller set point can be adjusted, and that the controller will
then change the speed of the underflow pump in response to process changes.
It will first be necessary, therefore, to learn how to adjust the controller set point.
2.4 PID CONTROLLER
2.4.1 Controller Buttons
The control buttons are shown below. The MODE key is used to initiate a setpoint change and
also to select alternative menus used to make programming changes.
Increase Decrease
Mode
Pressing the MODE button once brings up the display shown at
left. The upper RED display indicates the variable that can be
changed, and the lower GREEN display indicates the current
value of the that variable.
SV1 In this case, the RED display indicates that the primary setpoint
can be changed. The GREEN value indicates that the current the
setpoint is 24.0.
The setpoint is changed by pressing the INCREASE or DECREASE buttons as necessary.

Note that a single push will change the display by 0.1 units. Holding the button will cause the
display to continue to change by 0.1 units at a time. If the button is held for a few seconds, the
values begin to change quickly.
Once the GREEN display shows the desired new setpoint,

pressing the MODE button once will “set” that value and return
the display to normal operating mode. For example, as shown at
right, the new setpoint is 24.0 and the actual operating value is
SV1
24.6. At this point, in normal operation, the controller would
immediately initiate a slight increase in the underflow pump
speed to bring the operating level back down to the setpoint value.
With no pumps operating, this procedure should be repeated several times until the operator is
completely familiar and comfortable with the process of changing the controller set point.
It should be noted that the controller PV values DO NOT represent level. The PV values
displayed represent the mA output of the pressure transducer, on a 0% to 100% scale.
Since the column is fabricated of transparent material, it is possible to physically observe the
actual interface level, and therefore it is not necessary for the controller to display actual
interface level. When the column is operating with the desired froth depth, the operator must
simply observe the PV (process variable) value at this time, and use that value as the SV (set
point).
Once the set point is keyed in, the controller will then modulate the speed of the underflow
peristaltic pump so as to maintain the PV value at or very close to the SV.
At this time, with a reasonable air flow applied (5 to 10 sL/min) and with the system powered
up, add water to the column until the interface level rises to approximately 20 cm below the
overflow lip. Observe and record the PV (transducer output) value.
Input this value as the SV (setpoint).
The system is now ready for a full operational test on water.
2.4.2 Underflow Pump Test – Automatic
Drain the column until the water level in the column is BELOW the transducer.
Select Forward or Reverse, as determined in the previous test, on the Underflow Pump panel.
Select Auto (remote) control on the Underflow Pump panel.
With no signal from the transducer, the controller should be trying to raise the interface level,
and will therefore be calling for ZERO underflow pump speed.
Select Forward or Reverse, as determined in the previous test, on the Feed Pump panel.
Apply a speed setting to the feed pump – maximum 50%.
As the interface level rises above the transducer, the controller should begin to show increasing
PV values.
As soon as the PV value gets close to the SV value, the controller should begin to activate the
underflow pump.
NOTE – if the fill rate is fairly fast, the level (PV) may slightly overshoot the set point (SV). This
is normal. Under these conditions, the controller will increase the underflow pump speed to
compensate. Within a few minutes, however, the level (PV) reading should match the set point
(SV) reading
2.5 ADDITIONAL PROGRAMMING
There are three additional programming modes available, allowing varying degrees of
refinement and configuration of the controller functions.
To access the Sub-Setting mode, press and hold the button then press and hold the MODE
button for about 3 seconds. This area allows changes to the controller PID functions.
To access the Auxiliary Setting mode, press and hold the button while pressing the MODE
button. This area allows changes to the controller communication functions.
Pressing both the UP and DOWN buttons then the Mode button brings up the second Auxiliary
Mode setting function which allows very detailed changes to be made to controller operation.
Note that the display only approximates correct characters, due to the limitations of the
segmented LED display. The upper RED characters display the programming function, and the
lower green characters show the values set for each programming function.
At this point, it is possible to step through the various programming functions by repeatedly
pressing the MODE key.
Note – the controller will automatically return to normal PID control mode if no changes are
made for several minutes.
The most important uses of the alternate functions will be to initiate an “Auto-Tune” cycle and to
change the maximum and minimum controller outputs.
2.5.1 Output Limits
In order to prevent damage to the peristaltic pump hose, it is recommended to set the maximum
pump speed to 90%. If the column interface level rises above the set point, the controller will
call for an increase in underflow pump speed. If, for example, the underflow line is plugged, or if
the feed rate has increased significantly, the controller will keep increasing the underflow pump
speed to “catch up”. This can lead to the underflow pump running at full speed, and this leads
to premature hose failure. Therefore, it is prudent to limit the maximum pump speed to 50%. If
a pump speed of 50% does not restore the level, there is likely some other problem that must
be attended to.
Similarly, in order to prevent sanding of the underflow lines, it is recommended to set the
minimum pump speed to about 5%. Whenever the interface falls below the set point, the
controller will call for a reduction in underflow pump speed. If the level is not restored, the
controller will continue to reduce the pump speed, all the way to zero. This can lead to sanding
at the bottom of the column. Therefore, it is prudent to set a minimum underflow pump speed
that will prevent sanding.
To change the maximum speed (Output Limit High), press and hold the UP and DOWN
buttons, then press and hold the MODE button for 3 seconds to access Auxiliary Mode 2.
Next, press the MODE button repeatedly until the upper RED
display looks like this.
Then press the UP or DOWN buttons to change the setting to

90%.
SV1
Press the MODE button again to access Output Limit Low, and
change the value to 5.0.
NOTE – the CPT Test Unit is shipped with Output Limit High set to 90.0 and Output Limit Low
set to 5.0. By observing the operation of the column, it can be determined if these settings
should be changed to new values.
2.5.2 Auto-Tune
PID Controllers incorporate values for Proportional, Integral and Derivative plus filters,
hysteresis, dead band, overlap, anti-reset wind-up, etc. Factory setting for these elements of
PID control may not be optimized for the test column.
The digital controller supplied has an “Auto-Tune” function that can automatically determine and
set the best values for the many PID elements.
With the column operating in stable state, with normal feed, air and wash water flows, the Auto-
Tune function temporarily takes control of the output. The controller will increase output to the
high limit and then reduce it to the low limit, and observe the reaction of the whole “system”.
After a few cycles of this, the controller will then determine optimum settings, and will set these
values in place, then return control to the normal mode.
Implementing the auto-tune function will result is smoother control with little or no “overshoot” or
“hunting”.
To access Sub-Setting mode to initiate Auto-Tune, press the UP button and the MODE button
and hold for 3 seconds. The RED display will then display for either Auto-Tune or Reset.
Press the UP button until the display looks like this.
Not this
Then press the MODE button and wait until the controller is finished auto-tuning itself.
2.6 AIR FLOW CONTROLLER
The digital membrane display of the air flow controller displays the value of the variable, and is
used to set and adjust the controller. Buttons on the display are used to change the set point of
the variable.
Figure 16 – Air Flow Controller Display Module
2.6.1 Mode Button
The digital display has several modes which can be set via the Mode button. Pushing the button
once will set the display menu cycle into operation. Pushing the button while the desired
parameter is on the display will select that parameter. If the selected parameter has a sub
menu, the sub menu will cycle until a menu item is selected by pushing the button while the sub
menu item is on the display. Cycle rate is approximately 1 per second.
Compact Column Column Operation Page 23
3.0 COLUMN OPERATION
3.1 PRE-START CHECK
Prepare feed sample or sample line.
Turn on air and adjust to the desired flow rate.
Place underflow line in the feed well to establish a recycle.
Place the level control loop on automatic.
Check for minimum underflow flow rate. If the underflow pump is stopped, check alternate
programming on PID controller.
Start feed pump and adjust speed to desired rate.
When the underflow flow increases, indicating that the level has passed the level set-point,
remove the underflow line from the feed well and turn on the wash water to the desired flow.
Sample around the column to make sure that all flows are at the desired rate.
Make any changes that are required.
Allow column to achieve steady state – wait at least two residence times.
3.2 COLUMN SHUTDOWN

Shut off feed supply and stop feed pump.
Maintain wash water until column is clean then turn off wash water.
Turn off underflow pump.
Unscrew column drain plug.
Turn off air.
Close air and water isolation valves and disconnect power supply.
OPERATING NOTE: To avoid sparger plugging, make sure to turn on the air before feeding
slurry, and shut down the air after draining and flushing the column.
3.3 OPERATING GUIDES

This section suggests approximate settings for some of the more common variables which should
be optimised during operation. Also given here are the general effects that changing one variable
will have on a column at steady state. Compensation for variations can be made for non-transient
changes, however, quick swings in flow rates, or pulses of high or low grade material may cause
poorer performance than would otherwise be expected. Therefore the feed volumetric slurry rate
and total flux of floatable material, should be as constant as possible.
3.3.1 Air
Recovery increases with air flow. However, at a critical superficial air rate, the bubble
characteristics change resulting in decreased recovery. The exact value will vary from this
depending on bubble size, bubble loading, and slurry velocities. Increased air flow will:
 decrease the grade of the concentrate
 increase to an optimum then decrease recovery to the concentrate.
 decrease the percent solids in the concentrate
These effects are only valid within a specific region of flow. The type of bubble will eventually
change producing a different flow regime that may be detrimental to performance. One sign of
this is the loss of the interface. Increases in air will lead to increases in concentrate production,
and increased wash water rates will be needed to maintain a positive bias. Very low air volumetric
flows may cause froth bed collapse. In this case the froth zone depth will have to be decreased.
3.3.2 Level
The interface level between the froth and pulp zones can, in part, determine the concentrate
grade. A deeper froth will promote grade at the expense of recovery. However, little benefit is
expected at depths greater than 1.5m. The lower limit is the point at which the froth becomes so
heavy that it collapses on itself. The collapse is seen as a highly turbulent froth zone that often
suffers from a "volcano" like appearance. (Recovery under these conditions may be very low.) At
start-up a froth depth of 0.5m is suggested. Much shallower froths are possible and upgrading
from feed to concentrate may occur even without a froth zone. Tests can be performed to predict
performance at various interface levels. Increased froth depth will:
 increase the displacement wash

 increase the percent solids in the concentrate
 increase the grade of the concentrate
 decrease the recovery
3.3.3 Bias
Non-selective entrainment can be reduced by preventing feed water from entering the
concentrate. This is done by operating with a positive bias (+Jb). Jb should be operated within the
extreme of zero and 0.3 cm/s1, (0 < Jb < 0.3 cm/s). Positive bias operation is critical in the
production of high-grade concentrate. A Jb of 0.10 is suggested at start-up. Increased bias flow
will:
 increase the displacement wash and tail/feed ratio (quickly)2
 increase the concentrate percent solids to an optimum before reducing concentrate
percent solids
 increase the grade of the concentrate
 decrease tail percent solids
These effects do not continue indefinitely with increased amounts of bias. Eventually channelling
of the water and breaking of the froth occurs that negates all the benefits of extra wash water. To
ensure a positive bias maintain an underflow liquid flow greater than feed liquid flow by altering
the wash water rate.
1
Jb is calculated by the difference between tail and feed liquid flows, as described in the glossary
(Introduction section).
2
Displacement wash, differential wash, bias ratio and superficial bias rates are all different ways of
describing the liquid flux through the column froth zone.
3.3.4 Wash Water
Wash water is increased to control the bias (see bias section). Wash water rates as low as 6
L/min. or higher may cause froth collapse depending on distribution and delivery pressures. The
movable distribution system allows some investigation into this phenomenon and allow easy
inspection of the froth.
3.3.5 Frother Dosage
The use of a frother is common in a column and it may be added directly to wash water and/or
feed to control bubble size. Increased frother to the feed will:
 decrease the bias rate (can cause a negative bias)
 decrease the percent solids in the concentrate.
 increase the gas hold-up of the collection zone
 decrease froth zone gas hold-up
 decrease the grade (slowly)
 increase the recovery (slowly) (at constant air rate)
 decrease the maximum air rate
 decrease bubble size
Frother acts to stabilise the froth zone. An unstable froth floats poorly. As froth stability increases
recovery increases but the less selective flotation decreases grade. Increased frother produces
smaller bubbles which may or may not improve collection of particles.
3.3.6 Feed Rate
An increase in feed rate will have the direct physical effect of reducing column residence time
which will result in decreased recovery. In addition, the increased downward flow of slurry will
partially overcome the rise rate of the bubbles, thus increasing gas hold-up. In the extreme case,
when downward slurry velocity approaches the rise rate of the bubbles, the column will froth up
and recovery will drop very quickly. The optimum feed rate for good recovery is a function of the
density and grade of the feed, as well as the flotation characteristics of the ore.
In general, increased feed rate will:3
3
Assuming maximum float capacity has yet to be reached.
 decrease the bias or displacement wash

 increase concentrate percent solids
 increase the gas hold-up
 increase the grade
Initial tests should be conducted with a residence time of approximately 10 - 15 minutes.
3.4 PERFORMANCE TROUBLE SHOOTING

This section gives possible causes of poor performance and suggests improvements. Two
conditions are dealt with: poor concentrate grades, and poor recovery. Each is then subdivided
into two categories: problems originating with the column and those that originate in the rest of the
circuit. Possible solutions are given in order from most to least likely.
3.4.1 Is Concentrate Grade Low?
Column
High air rates may cause an increase of entrained gangue particles in the concentrate by
increasing the amount of feed water that is carried by the bubbles. To improve concentrate grade,
try one at a time:
1. Reduce the air rate.

2. Excessive wash water addition rates may cause channelling of the froth which reduces the
froth's cleaning ability. This is seen as an unstable froth. Reduce wash water flow.
3. If Jb < 0.3 cm/s increase QW. A negative Jb may cause excessive entrainment.
4. The interface level may be too high causing a decrease in the froth zone cleaning action.
Increase interface depth.
Circuit
High frother dosages will cause excessive amounts of feed water to report to the concentrate
causing reduced grade and increasing the wash water rate. The froth will be very stable. Reduce
frother consumption.
Collector or activator dosage may be too high causing non-selective flotation. Decrease reagent
addition rates.
Grind size may be too large creating middling particles that are removed as concentrate. If this is
a problem reduce the D80 of the feed. This may either be done using the primary grind, or a
regrind.
3.4.2 Is Column Recovery Low?
Column
Low recoveries are primarily caused by low air rates or insufficient residence time. Increase the
air rate, but watch for loss of interface. As an alternative the feed rate may be decreased in order
to increase residence time.
High air rates may cause turbulent flow in the column which is not conducive to flotation. The
interface may also be lost4. This will appear as volcanoes or geysers in the froth. The volcanoes
can also be caused by very low gas rates. Decrease the air rate.
A wash water rate greater than 6 L/min. may be causing "beating" of the froth that reduces the
production capacity. This will be seen as an unstable froth. Lower the wash water rate.
The interface level may be low causing a shorter collection zone residence time, and increased
"drop-back" in the froth zone. Decrease froth depth. Under extreme condition "drop-back" may
be so severe that the froth actually collapses.
Poor air distribution causes eddies within the collection and froth zones that decrease the effective
column residence time. This may be seen as an unstable froth. Check sparger for possible
damage.
Circuit
Low frother dosages will cause excessively large bubbles to be produced by the spargers. This
4
When no interface level exists between pulp and froth zones the column is flooded. Under these
conditions flotation is usually poor. If a high percent solids is used in the column, or if the material being
floated is light in density, dark in colour, or very fine (-20µm) an existing interface level may be very
difficult to detect.
causes limitation in collection zone capacity that limits production rates and can be seen as low
gas holdup and possibly as an unstable froth. Increase frother additions. Grind size may be too
large creating middling particles that are removed from the concentrate in the froth zone. This
can be determined by microscopic examination for locked particles. Either reduce the D80 of the
primary grind, or of the regrind.
Recirculation may have to be established.

Compact Column Column Testing Page 30
4.0 COLUMN TESTING
4.1 INTRODUCTION
The purpose of these tests is to determine parameters for column sizing and proving column
performance. All data should be collected when the column is at steady-state conditions,
therefore, the fewer disturbances in the system the better. Any changes in interface level, wash
water, air or other parameters should be made slowly. A minimum number of variables should
be adjusted at one time (ideally only one) so that the fewest number of effects interact.
Small test columns are more difficult to run than the industrial units. Their small volume makes
them very sensitive to changes in feed solids and reagent content. If a stream is being sampled
directly from the plant it should be steady stream not subject to fluctuations due to operator
changes or sump activity. An agitated surge tank may help reduce the variations.
It is important to remember that a column has the ability to build up floatable solids through
recycle. If solids are building-up due to insufficient air rate or other concentrate transport
problems, excellent grades can be achieved without immediately sacrificing recovery.
However, these solids will eventually report to the underflow and lower the recovery.
For cleaner applications a bias range of 0.1cm/s to 0.2 cm/s superficial velocity, in relation to
the column, should be maintained. For rougher and scavenger applications the bias should be
negative to zero.
In each application the bias should be maintained at a constant level for all tests. Bias changes
with concentrate production and column level when a specific wash water rate is maintained,
therefore, the bias flow (wash water minus concentrate water or feed minus tail water flow)
should be checked periodically.
All optimal reagent additions should be determined prior to column testing. Changes in reagents
can affect column performance and introduce uncertainty into the test program. All tests should
be conducted at the optimal reagent dosages.
Air loading, level and bias tests are described.

4.2 BEFORE STARTING COLUMN TESTING
(1) Run bench scale time-recovery tests to determine the approximate residence times
needed.
(2) Estimate the air carrying capacity of the column using Table I.
(3) Perform a mass balance using the expected feed and recoveries, based on the column
residence time (1) limited by the maximums imposed by (2). This will indicate
approximately what liquid, slurry, and gas flows to expect.
4.3 COLUMN TESTS
(1) Proceed with the air loading tests to refine the estimates found in Table I.
(2) Perform the level tests to get an indication of the froth stability.
(3) Perform the bias tests to determine the entrainment characteristic of the system.
All of the tests results can be used to generate a grade recovery curve, however, additional
data may have to be generated using column parameters similar to grade/recovery points of
interest which have already been determined.
TABLE 1: APPROXIMATE AIR CARRYING CAPACITY

(all rates in kg of solids per m3 of air)
d80 High Low
(um) (silica) (lead)
160 400 160

80 200 80
40 100 40
20 50 20
4.4 SAMPLING
All the streams from the column should be sampled. The following guidelines are suggested as a
standard:
 Sampling should commence at t = 3 x T (residence time) after the last
parameter change.
 The entire stream should be cut.
Obtain wet and dry weights for all the streams. Assay, then calculate the mass balances. All
samples should be large enough to allow future screen analysis. An example test report sheet is
shown in Table II .
TABLE 2: SAMPLE RESULTS SHEET
Date: Title:
Time:
Column Level: Air Line Pressure:
Air Rate (STP): Local Pressure:
Feed Rate: Tail Rate:
Wash Water Flow:
Sampling Volume Net Weight Dry Weight ____ ____ ____
Stream Time - Sec. ml g g % % %
Tail
Conc.
Feed
Comments: Reagents:
4.5 TESTS
4.5.1 Air Loading
OPERATING NOTE: If residence time in the column is too short, target recovery may not be
achieved. One option is to save the tailings and re-float in a second pass through the column.
The purpose of this test is to determine the amount of solids that can be floated per unit of air
(Gas Carrying Capacity, Cg). This will vary with the volume of air introduced into the column, the
froth depth, and the particle size being floated.
4.6 TEST PARAMETERS

Initial scope tests should be conducted at a Jg of about 0.5, 1.0, 1.5 and 2.0 cm/s to determine the
approximate air rate required. Once the correct range has been established further tests should
be conducted to optimise the air rate. If frother is to be used, frother concentrations between 10
and 20 ppm are recommended as a starting point. This should produce bubbles on the order of
1.1mm to 1.5 mm in diameter which will appear as distinct spheres.
The values found in Table 1 approximate the air loading in a column. For each particle size two
values are given which correspond to different combinations of angularity, hydrophobicity and
density.
The solids feed rate, Qf, must be greater than Qg multiplied by the proper high Cg estimate of
Table I according to particle size. When silica is floated 20 to 30% extra feed solids should be
used because it has a high Cg value.
Tests should be conducted at various increasing feed rates until the resulting Cg value does not
increase.
The column level should be maintained at one point. If the column to be designed is a cleaner this
level should be between 0.5 m and 1.0 m. A rougher column should be between 0.2 m and 0.5 m
and a scavenger between 0.05 m and 0.10 m. If the suggested level results in an unstable froth,
raise the interface level.
Bias in the column should be maintained in the positive region. For best results the range of
0.1cm/s to 0.2 cm/s should be used.
Screen analysis of concentrates must be performed.
These results can be used to plot a grade - recovery curve. More air rates can be tested to further
define this curve. Changes in bias or level will effect the shape of this curve.
4.7 TEST RESULTS

The data generated by this test are sufficient to obtain Cg and CPT should be advised of its value
for column sizing. If Cg varies with air rate CPT will require either the raw data, or a function
relating solids carried to air rate. This number can be used to predict the recovery of solids to the
column overflow at varying gas rates. When combined with the minimum and maximum gas rates
that the column will support it allows a determination of the columns production range.
The Qg value can be used to estimate the amount of air needed to float a specific amount of
solids.
Level (2)
Both the upper and lower column levels should be determined.
The lower level is the point at which the froth collapses. This will depend on the gas rate, frother
concentration, and the amount of solids being floated.
The upper level is the lip of the column, however, significant entrainment will occur when
operating without a froth. Therefore, the upper level should be chosen at the point where the
grade is no longer acceptable.
The column should be able to maintain grade at interface levels as high as 400 mm below the lip,
possibly higher, and also retain a stable froth while operating as low as 1500 mm.
While operating under steady conditions, slowly alter the level and note any changes in grade and
recovery. Use this information to construct a grade/recovery curve vs interface level response plot
at varied air rates.
At least one test should be conducted with only a 1-2 cm froth bed and no wash water. This will
allow characterisation of the column's collection zone.
Froth Bias (3)

Absolute Jb values should be determined for each test in order to optimise the wash water addition
rate. While keeping all parameters and tonnage constant, alter the wash water rate.
As water addition is lowered from the optimum, a slight, possibly unnoticeable, decrease in grade
should occur. In sulphide flotation the lower grade is usually associated with a lower percent solids
in the concentrate. This relationship between the froth bias flow and grade/percent solids
continues until a critical point at which water flow in the froth zone becomes positive upward
(negative bias). At this point grade should drop rapidly as entrainment into the concentrate
becomes an important factor.

As the water addition is raised from the optimum the grade should slightly improve, with a higher
percent solids, without much change in recovery. This will continue until channelling of the wash
water occurs in the froth, or the wash water beats the froth too severely causing collapse. These
could cause a rapid drop-off in recovery.
Circulating Load
Like mechanical cells, a single column will only rarely achieve high stage recoveries because of
short-circuiting. However, the recovery can be obtained by establishing a circulating load or
recycle with either another column or mechanical cells. Two factors influence the performance of
a recycling system:
 The increased circulation enables solids to have more than one chance of being floated to
concentrate, thereby increasing recovery.
 In opposition to this is the increased flow that accompanies the circulation. This reduces
column residence time, thereby reducing particle collection probability.
The circulating load should be varied to determine performance. Make sure that the results are
compiled after equilibrium has been established. Recoveries at any one short time span may not
be accurate because the system may either be loading (lowering calculated recovery) or dumping
(rising calculated recovery) the circulating load. Higher re-circulations need longer test duration to
give accurate results.
The effect of re-circulation can be accurately estimated using a column simulator. Additional data
can be collected by saving the column tail and concentrates and re-floating them separately in the
column to determine scavenger and re-cleaner characteristics.
Bubble Size
Bubble size is a column parameter that is not usually monitored. It will affect the carrying
capacities of the column and possibly the selectivity of different size fractions.
Maintain as many column parameters constant as possible then add small amounts of frother to
the feed.
Rate Constants
Rate constants can be determined by using the results of previously described tests in a
simulator.
Grade Recovery Curves

Results of all of the previous described tests can be plotted to give a grade recovery curve. The
column will give a band rather than a single line depending on the level and bias conditions.
4.7.1 Density Estimation
Collection Zone
The collection zone density can be determined by overflowing the column with slurry and
reading the pressure transducer signal. This estimation will only be good at one point on a
density contour which is a function of air rate, slurry velocity, and bubble size.
Collection zone gas hold-up (average) can be determined by comparing the calculated
collection zone (3 phase) density to the tail density. This value will only be an estimation since
the slurry density does not remain constant with height.
Froth Zone
Density can be estimated by lowering the level of the interface from one point to another while
noting the pressure readings of both levels. The pressure difference will be a function of the
difference between the densities and level. This represents only one point on a continual plane
which is a function of feed grade, feed rate, frother concentration, air rate, and wash water rate.
Compact Column Column Maintenance Page 37
5.0 COLUMN MAINTENANCE
5.1 INTRODUCTION
All maintenance should be done on a scheduled basis. Operators should regularly inspect all
parts of the circuit: column, lines, pumps, and sparger.
5.2 COLUMN
The column is simple to maintain. The fundamental concern should be that of keeping the flow
channels clear of scale. This will ensure that the flow of concentrate is not hindered. Scale
could slowly build-up on the column lip, however, this is easily spotted and removed by
operators.
The wash water system must be maintained so that a non-pressurised shower of water is
applied to the top of the concentrate bed. Periodically inspect the distributor for trap material.
Periodic inspections should be made of the pressure transducer and any scaling should be
carefully removed according to manufacture's maintenance procedures.
Be careful to avoid excess frother (MIBC in particular) additions as this can cloud the surface of
the plastic.
5.3 PUMPS
From time to time the pump hoses may wear-out causing an unexpected shut-down. When
prompt action is taken the test being conducted may continue after the interruption.
If the feed pump stops, recycle the underflow line to the column feed and turn off the wash
water and level control until feed is again available. Keep the underflow pump operating.
.
5.4 PLUGGED LINES
The feed, underflow, or froth lines may plug if the slurry flow through them is interrupted or
slowed. If prompt action is taken to replace or clear these lines the tests may continue. A
plugged underflow line is usually detected by a rising level despite actions of the control
system. Interruption in the feed will cause the level within the column to drop.
OPERATING NOTE: After any interruption, the column must be returned to proper and stable
flow conditions and at least two (2) residence times must be allowed to pass before resuming
sampling.
5.5 HIGH DENSITY POLYETHYLENE POROUS SPARGER

The bubbles are generated by forcing air through an internal of porous sparger. Under normal
conditions at low gas rates the uppermost regions of the sparger should produce bubbles while
the bottom remains unused. As the air rate is increased a larger area of the sparger will be used.
If the sparger becomes plugged or broken, the HDPE porous tube should be replaced.
A sparger with poor air distribution is recognized when some portions of the sparger discharge
a disproportional amount of the air, or when a lower section of the sparger produces bubbles
well before the upper part.
The sparger can be removed from the column by detaching the bottom plate from the column.
5.6 POOR AIR DISTRIBUTION

A sparger with poor air distribution is recognised when some portions of the sparger discharge
a disproportional amount of the air, or when a lower section of the sparger produces bubbles
well before the upper part.
OPERATING NOTE: To avoid sparger plugging, make sure to turn on the air before feeding
slurry, and shut down the air after draining and flushing the column.
Specification:
Column Diameter: 76mm (3”)
Column Height (Body): 2000mm (Max.)
Weight: 185 Kg
Requirement for air:
Min. Pressure: 207 kPa (30 psi)
Min. Capacity: 10 L/min (1 CFM)
Requirement for water:
Min. Pressure: 207 kPa (30 psi)
Min. Capacity: 2 L/min (0.5 GPM)
Operational air flow:
Column Size Minimum Nominal Maximum
2” 0.6 LPM 1.2 LPM 1.8 LPM
3” 1.4 LPM 2.7 LPM 4.1 LPM
Communication: Modbus-TCP (Optional)
Voltage: 220-240 VAC, 1PH, 50/60 Hz
Amperage: 11 A

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OPERATING & MAINTENANCE MANUAL

Mini Pilot Plant System – Compact Lab Column

January 2013 Rev. 02

Section Heading Page

2 Test Cell Assembly 5

For further information contact:

Eriez Flotation Division – Canada Inc.

1.0 EQUIPMENT DESCRIPTION

• Reduced surface area to cell volume ratio to promote froth stability

• Froth washing system to minimise the entrainment of impurities

• Quiescent flotation conditions to promote selectivity

An important feature of flotation columns is

Figure 1 – Column Flows

1.1 AIR CONTROL

Note that reference conditions are as follows;

Standard Pressure: 101.325 kPa (760 mm Hg)

Standard Temperature: 21.1 °C (70 °F)

The pressure transducer is calibrated at 0 to 50 inches Water (0 to 25 kPa).

1.3 WASH WATER DISTRIBUTION AND CONTROL

1.4 PLACEMENT OF VALVES

1.5 CONTROL PANEL

2.0 TEST CELL ASSEMBLY

2.1 MAIN COMPONENTS

The compact test cell comprises of the following major components;

Figure 2 – Wheeled Table

Figure 3 – Central Support

Adjustable height to allow for

2.1.1 Column Cell Sections

Figure 4 – Top Section

with integral feed well and overflow

launder. Shown with inlet extension

and wash water distributor removed.

Figure 5 – Recirculating Sparging

with sparger and fittings for Air Inlet

Figure 6 – Left Side Panel

flow control valve. Air mass flow controller,

sparger pressure gauge and air supply

Right Side Panel with

Digital electronic PID level controller

Recirculating sparger pump speed controller (Optional)

Feed pump speed controller

Underflow pump speed controller

Figure 7 – Right Side Panel

Figure 8 - Level Sensor (pressure) Figure 9 - Pumps (peristaltic)

2.2 ASSEMBLY SEQUENCE

The correct sequence for assembly is as follows;

1) Install central support into wheeled table

2) Install upper, middle, lower and discharge column sections

4) Install level sensing pressure transducer

6) Power up column and check electrical and electronic components.

7) Perform leak test.

These operations are described in more detail in the following sub-sections.

Figure 10 – Fully Assembled (mid-section not assembled)

2.2.1 Main Assembly

Attach the discharge section using a gasket and bolts.

Screw in the feed pipe extension – hand-tighten only.

2.2.2 Hoses for Feed, Underflow, Air and Wash Water

Next, make the following connections;

Connect a length of hose to the lower assembly drain outlet.

Figure 12 – Recirculating Sparging Discharge Assembly

2.2.3 Peristaltic Pump Hoses

Figure 13 – Closed Pump Head Figure 14 – Open Pump Head

2.2.4 Install Pressure Transducer