Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Flotation
Flotation is the most widely used concentration process in the world. Flotation made it possible to treat ores that were previously not economical. Flotation i the i i l Fl t ti is th principle means of concentrating copper, f t ti lead, zinc, molybdenum, phosphate and many others. Flotation is usually used to separate one solid from another.
Particle Liberation
Flotation Model
dN1 = kN1 dt
1 k = Sb P 4
1 D b3
Model Derivation
dN1 = kN1 dt = Z12 P
k = Z 12 P N1
32 12 2 2 12
Probability Functions
3 d1 3 Re Pc = 1 + 2 d 2 16 1 + 0.249 Re 0.56 E1 Pa = exp E k
2
Z12 = 2 N1 N d
P = Pc Pa (1 Pd ) P f
(U
2 1
+U
2 2
(Wa + E1 ) Pd = exp Ek
Pf = Pmax exp( f ) + Pe
k =
Z 12 Pc Pa (1 Pd )P f N1
Bubble Generation
Schulze (1982)
Collision probability
S th l d 1948; R Sutherland, 1948 Reay and Ratcliff, 1973; Flint and Howarth, d R t liff 1973 Fli t dH th 1971; Weber and Paddock, 1983; Ahmed and Jameson, 1989; Luttrell and Yoon, 1989
Pd = (Dp/Dm)z
Gaudin, 1931
Pc = A(Dp/Db)2
0.68 0 68 mm iron particle hydrophobized with i ti l h d h bi d ith thiol (=70o) at 8,000 fps
INDUSTRIAL MINERALS
POTASH PHOSPHATE CLAYS CLAYS
PRECIOUS METALS
GOLD PLATINUM AND PALLADIUM SILVER
Industrial Operation p
Industrial Operation p
10
12
Equipment
FLS Minerals Conventional flotation cells consist of a series of tanks (rectangular or cylindrical) that are individually agitated using an impeller. The impeller provides the energy needed to: keep particles in suspension suck in air (a blower may also be used) disperse air into small air bubbles contact mineral particles with air bubbles
Feed Tails
Froth
Types of cells
Forced Ai F d Air
August 26, 2010
Self Aspirating S lf A i ti
Flotation
SmartCell Flotation
Wemco cells
WEMCO SMARTCELLTM
Short froth travel distance Sh f h l di Up flow pumping for suspension and flotation of heavy fines Increased retention time High energy dispersion for fine particle flotation g g
Power Consumption
Optimize Pc p
Increase Internal in pumping rate increases the number of cycles a floatable particles makes through the rotor.
Average Retention Time: The average length of time that g g a particle remains in the flotation cell.
Power Consumption
Average Circulation Time: The average length of time q p required to circulate a particle through the rotor.
Power Consumption
Qp/Qf
Dorr Oliver
DO600UT
Simple design Few components Dynamically balanced Easy to operate and maintain
DO Standard Rotor
Non-plugging design Low power L Long wear life Reduced core to give maximized pumping volume
XCell
TM
External Launder
Velocity Cone
35% Power Savings over WEMCO 10% Power Savings Over Outotec Statistically Similar Metallurgical y g Performance
Second Test Series Statistics
Valid Tests Global Recovery Mean, % Cu Global Recovery SD Global Conc. Grade, % Cu
FFEM
45 89.87 1.68 9.18
Outotec
43 89.95 2.00 8.29
Bench-Scale Testing
DO-Std DO Std DO-Mod1 DO Mod1 DO-Mod2 DO Mod2 OK-Old OK Old OK-New OK New
Xcell
VT-FJ
VT-SB
VT-TF
VT-USD
Bench-Scale Testing
Power(Watts)
Bench-Scale Testing
1800
Bench-Scale Testing
Bench-Scale Testing
Sanding Assessment S di A t
(Iron Ore, 95% passing 106 m, SG=4)
Stopped
Running
Quiescent Zone
Settled Solids
Settled Solids
Bench-Scale Testing
QuiescentZone(mm)
Bench-Scale Testing
SandBedDepth(mm)
Merge Point P i t
Bench-Scale Testing
2.6 2.4 2.2 2.0 1.8 1.6 1.4 1.2 1.0 2 2.5 3 3.5 4 4.5 5
DO Std (Vg=1 cm/s) DO Std (Vg=2 cm/s) OK New (Vg=1 cm/s) OK New (Vg=2 cm/s) ( g )
Power (Watts) ( )
8.6x106 nodes
Pilot-Scale Testing
XCell 0.8m3 Pilot-Cell DO 0.8m3 Pilot-Cell
Pilot-Scale Testing
Construction/Installation C t ti /I t ll ti Metal test cell fabricated/constructed with interchangeable components components. Evaluate three existing mechanisms as well as new designs.
Pilot-Scale Testing
0.8 m3 Cell
Instrument Pack
Pilot-Scale Testing
Bubble Size A l i B bbl Si Analysis External Camera - Bubbles viewed through inclined glass surface of chamber placed above the tank tank. w/o pumping: bubbles rise as a result of their natural buoyancy w/ p / pumping: Gas-pulp flow to p g p p chamber promoted by pumping Submersible Camera - Bubbles recorded as they pass gap between camera and l h source. d light Compact high-speed camera and LED design enabled building a system with low flow interference Pulsed strobe light maximizes light intensity and image quality y g q y
External
Submersible
Pilot-Scale Testing
12 mm
Pilot-Scale Testing
100
90 80 70 60 50 40 30 20 10 0 100 0.1
P = 100
90 80 70 60 50 40 30 20 10 0
10
0.1 01
10
Kennecott SuperCell
Row 4-6
TM
2 5d
PP20,21 PP24,25
From Grind
4c 5b
4b
Scav Regr
Row 1-3
2 5c 4a 10
10
10
PP18,19
5a 20 9
1st Scavenger Cleaners
300
22 21 10
2nd Scavenger Cleaners
6 7
Rougher Cleaners
19
To Tails
11
12
23 8
PP16,17
Tower Mill
PP6,7
18
13
14
Note: Water is added t all dd d to ll launders 17 Legend Water addition To Cu/Moly Thickener
PP10,11 Mech Scavs
15
PP12,13
16
Design Parameters
Cell Diameter 8.25 m Weir Height -- 5.72 m Cell Height 6.03 m Volume-300 m3 Rotor Diameter 1.51m Gear Reducer
Flender / SEW
Installation at Kennecott
300 SuperCell
TM
Flotation Machine
300 S SuperCell fl t ti C ll flotation machine Safety Record 33,320 man hours to date hi S f t R d 33 320 h t d t without a recordable incident which has added to a record at KUCC
TM
Construction involved a civil/concrete crew of 12 to 14 personnel working 6 days a week for 7300 man hours There were days on site where we had 75 personnel working in one capacity or another
Mechanical involved a crew of 25 to 30 personnel working 7 days a week for a total of 15,840 man hours Electrically we had a crew of 14 to 17 personnel working 7 days a week for a total of 6,850 Support personnel logged another 3,330 plus manhours
300 SuperCell
TM
Feed Tank designed by FLS/Centry and supplied by FLS Minerals All pumps supplied by KREBS All the valves supplied by KREBS/TECHNEQUIP Plant engineering supplied by FLS/CEntry
Civil construction included excavation of 1,996 cu yards of old concrete and dirt Installation included 975 cu yards of new concrete and 28 750 lbs of rebar 28,750
300 SuperCell
TM
Flotation Machine
Installation
Hydrodynamic Testing
Machine Parameters
Submergence Rotor Speed Rotor Engagement
Measured Response p
Machine Power Aeration Rate Pulp Circulation
Cone-350 lbs
Gearbox-9900 lbs
Motor-Approx. 6000lbs
14 13 12
pH
60 50 40 30 20 10 0 1 3 5 7 Run# 9 11 13
1stCampaign 2ndCampaign p g 3rdCampaign 4thCampaign 5thCampaign
Fe
FirstCampaign Wemco SecondCampaign Wemco ThirdCampaign Wemco FourthCampaign Wemco FifthCampign Wemco
11 10 9 8 7 1 3 5 7 Run# 9 11 13
Cu
120 100
CuCollector,cm3/min Frother,cm3/min
Mo
200 180 160 140 120 100 80 60 40 20 0
1stCampaign 2ndCampaign 3rdCampaign 4thCampaign 5thCampaign 5th Campaign
6000 5000
PlantTonnage, tph
80 60 40 20 0 1 3 5 7 Run# 9 11 13
1stCampaign 2ndCampaign 3rdCampaign 4thCampaign 5thCampaign 5th Campaign
7 Run#
11
13
7 Run#
11
13
SuperCell
PilotCell
FeedFlow OreType O T
CuFeedGrade
SuperCell
PilotCell
FeedFlow OreType O T
CuFeedGrade
SuperCells HowtooperateSuperCellstomaximizeCuandMorecoveryat20%Cucongrade???
Factor Agitator Speed rpm (m/s) Froth Depth cm Air Flow m3/min Agitator Power kW Blower Power kW Specific P S ifi Power kW/m3 Xcell-350 62 (6.1) Dorr-Oliver-330/350 79 (6.9) Wemco-300 97 (7.6)
50
37
43
39.6
42.9
23.6
114
123
258
55
61
N/A
0.48
0.56/0.53
0.86