FLOTATION KINETICS A flotation model is similar to chemical kinetics dN/dt =-k1 N1a- k2 N2b N - species (1 and 2) concentration t- time k - rate constant(s) a, b – process order -negative sign indicates that the concentration is diminishing due to the loss of particles being floated. -exponents a and b signify the order of the process Since flotation seems to depend only on particles concentration dN/dt =-k1 N1a 0 Flotation kinetics models Model Relation = [1 – exp (–k1t)] Classic first order Modified first order = {1 – 1/(k2t)[1 – exp (–k2t)]} = [1 – 1/(1 + t/k3)]* For reactor with ideal mixing = k4t/(1 + k4t)* Modified for gas–solid adsorption = ()2 k5t/(1 + k5t) Kinetics of second order = {1 – [ln (1 + k6t)]/(k6t)} Modified second order = [1– { exp (–k7t) + (1 – ) exp(–k8t)} Two rate constants Distributed rate constants * Equivalent models because k3 = 1/k4. – flotation recovery after time t, – maximum recovery, – fraction of particles having lower flotation rate constant, k7, k – flotation rate constant. = [1 – exp(–kt) f (k, 0) dk] Selected kinetic equations (ε – recovery of a component in separation product, εmax – maximum recovery of the same component in separation product, k – rate constant of separation, t – separation time Model Formula more ε k t Zeroth-order model ε ε max 1 e First-order model First-order with rectangular distribution of floatabilities Fully mixed reactor model -order model 2 Second-order model Second-order model with rectangular of floatabilites k t (2) 1 k t ε ε max 1 1 e k t ε ε max 1 1 t 1 k (3) (4) k t ε ε max 1 k t Improved gas/solid adsorption model 3 (1) ε ε max 1 1 1 1 k t 2 ε ε max 2 ε max (5) 2 k t 1 ε max k t 1 ln 1 k t ε ε max 1 k t (6) (7) (8) A. Bakalarz, J. Drzymala, 2013, Interrelation of the Fuerstenau upgrading curve parameters with kinetics of separation, Physicochemical Problem of Mineral Processing, 49(2), 443-451 Flotation kinetics of the whole mass and components 40 yield of concentrate, γ, % recovery of a component in concentrate, ε, % 100 80 component 1 60 40 20 remaining components 30 20 sum of kinetics of component 1 and remaining components 10 0 0 0 10 20 separation time, min components (recovery vs time) 30 0 10 20 separation time, min 30 product (yield vs time) Flotation results plotted as a relationship between recovery of each component in concentrate and separation time (a), yield of components forming concentrate vs. separation time (b) A. Bakalarz, J. Drzymala, 2013, Interrelation of the Fuerstenau upgrading curve parameters with kinetics of separation, Physicochemical Problem of Mineral Processing, 49(2), 443-451 relation between flotation kinetics and upgrading curves 80 60 component 1 0 10 20 separation time, min 30 100 80 80 60 ideal upgrading 20 0 recovery of component 2 in concentrate, ε2,c, % ideal upgrading 100 40 recovery of component 1 in concentrate, ε1,c, % recovery of component 1 in concentrate, ε1,c, % 100 Fuerstenau curve 40 20 0 0 60 20 40 60 80 100 recovery of component 2 in concentrate, ε2,c, % 40 component 2 20 0 0 10 20 separation time, min 30 b a The kinetics of separation of feed components (a) provide separation results in the form of the Fuerstenau upgrading curve (b). A. Bakalarz, J. Drzymala, 2013, Interrelation of the Fuerstenau upgrading curve parameters with kinetics of separation, Physicochemical Problem of Mineral Processing, 49(2), 443-451 ugrading curves (here Fuerstenau’s) equations based on kinetics of flotation 1, c 0 3 1 2 ,c ε 2 ,c ε k' ln 1 ,c 100 ε k ε 1 ,c 2 ,c 0 4 ε 1 1 ,c ε 2 ,c 100 k ln ε 1 ,c 1 ε 100 1 1 ,c 2 (1 5 k ε ) 2 ,c 100 ε 2 ,c 100 100 1 2 2 1 ε 100 1 1 ,c 100 ε 2 ,c 1 5 k ln 100 k k' ε ε 1 ,c 2 100 ε 1 ,c 2 ,c 100 (100 ε 2 2 ,c ) 100 ε 2 ,c 100 k ln 100 ε 2 ,c 100 100 k ln 1 7 3 2 1 ε 100 1 1 ,c 2 (1 5 k' ε ) 2 ,c 1 ε 100 1 1 ,c 100 ε 2 ,c 1 5 k' ln 100 2 ε 100 1 1 ,c 1 2 k (10 100 ε ) 2 ,c 1 100 ε 2 ,c ε 100 1 1 ,c 1 k' ε 2 ,c 1 20 (100 ε 2 ,c ) 2 9 ε 1 ,c 2 k ε 100 2 ,c 100 (100 ε ε 2 ,c ) 1 ,c 2 100 ε 2 ,c 100 k' ln 100 ε 100 k' ln 100 2 ,c 1 c,1 recovery of component 1 in concentrate ε 100 1 1 ,c 1 2 k ε 2 ,c 1 20 (100 ε ) 2 ,c ε 1 ,c 100 k ε ε 2 ,c 2 ,c ( k 1) 100 13 c,2 recovery of component 2 in concentrate Theoretical shape of the separation data in the Fuerstenau plot recovery of component 1 in concentrate, ε1,c, % 100 100 recovery of component 1 in concentrate, ε1,c, % recovery of component 1 in concentrate, ε1,c, % 100 80 k=1.5 k=1 k=3 60 40 k=0.5 20 80 k=2 k=1 60 k=5 k=0.4 40 20 20 40 60 80 0 recovery of component 2 in concentrate, ε2,c, % k=0.5 60 40 k=0.02 20 k=0.005 0 0 100 80 0 0 0 k=1 20 40 60 80 recovery of component 2 in concentrate, ε2,c, % 4* 7 100 20 40 60 80 recovery of component 2 in concentrate, ε2,c, % 100 9 13 recovery of component 1 in concentrate, ε1,c, % 100 Remeber: for characterizing separation results we need either two parameter or a law governing separation and then you can use one parameter which can be called selectivity as in these plots selectivity k 80 k=1 k=3 60 k=0.5 40 k=0.2 20 0 0 20 40 60 80 recovery of component 2 in concentrate, ε2,c, % 100 *for a suitable equation see previous slide (more plots in A. Bakalarz, J. Drzymala, 2013, Interrelation of the Fuerstenau upgrading curve parameters with kinetics of separation, Physicochemical Problem of Mineral Processing, 49(2), 443-451 An example of separation results approximation using the Fuerstenau plot ideal upgrading 100 100 80 p la n t 3 , tria l 1 a = 1 0 2 .2 8 r 60 = a (1 0 0 - r )/(a - r ) 40 20 0 80 a=100 (c o m p o n e n t 1 in p ro d u c t 1 )% F = (89/89) 60 no upgrading 40 20 0 0 20 40 60 80 100 Polish copper ore – lab tests with xanthate 0 20 40 60 component 2 in product 2, 80 % 100 Homework Calculate the rate constant and order of a set of yield flotation data Microlaboratory cells Laboratory cells Laboratory machines Industrial machines Mechanical Pneumo-mechanical Pneumatic Pressurized (DAF) Other (sparged hydrocyclone, ASH) Laboratory cells water level magnetic stirrer porous glass gas deflector froth product water level x stirrer porous glass gas Other laboratory flotation devices a) cylindrical cell equipped with magnetic stirrer (Fuerstenau, 1964) b) laboratory flotation device of Partridge and Smith, 1971 flotaton product drive air Laboratory Mechanobr flotation machine Laboratory Denver flotation machine Industrial flotation EIMCO Product Leaflets, 2000 Flotation machines are used individually and as a group (bank) Flotation machines are rectangular and circular Svedala Product Handbook, 1996 Constructions and impellers of flotation machines are different Denver Mechanobr Fagergreen (WEMCO-EIMCO) DENVER Wemco-Fagergreen (V=0.085 ÷ 85m3) Kelly E.G., Spottiswood D.J., Introduction to mineral processing. J.Wiley& Sons, N.Jork 1985 Wemco-Fagergreen (WEMCO-EIMCO) mechanical flotation machines EIMCO Product Leaflets, 2000 Denver Agitair Metso RCS (Metso Minerals) Outotec (Outokumpu) X-Cell (FLSmidth Minerals) Humbolt-Wedag IMN Gliwice Fragment of mechano-pneumatic flotation machine (continueous, multi-impeller tankless Denver D-R Wills B.A., Mineral processing technology. Pergamon Press 1983 tailing Pneumo-mechanic multi-tank (15m3 each) (Aker FM – Humbold Wedag) Humbold-Wedag Product Leaflets, 1998 Pneumo-mechanical flotation machines IMN Maszyna przepływowa wielowirnikowa Maszyna jednowirnikowa New machines: large volume and output, saving energy Historyczny rozwój pojemności maszyn flotacyjnych Flotation technologies. Outotec Leaflets 2007 (Outokumpu OK-100, V= 100m3 TankCell 300 300m3 Outokumpu Oy Leaflets 2000 Flotation technologies, Outotec Oyj. Leaflets 2007 Outotec TankCell 500 (500m3) © 2012 Outotec Oyj. www.outotec.com RCS™ (Reactor Cell System) from 5 to 200 m3 (Metso Minerals/Svedala) 1-radial flow of slurry to tank wall 2-primary slurry stream to benith impeller 3-secondary recirculation towards upper part of tank Basics in mineral processing. Metso Minerals 2003 RCS™ (Reactor Cell System) from 5 to 200 m3 (Metso Minerals) Basics in mineral processing. Metso Minerals 2003 RCS™ (Reactor Cell System) from 260 m3 (Metso Minerals) pneumo-machanic XCELL (FLSmidth Minerals) XCELL™ Flotation Machines. FLSmidth Mineralss brochure 2008. FLOTATION COLUMNS Metso Outotec (Outokumpu) Jameson Cell Imhoflot Pneuflot (Humbolt-Wedag) Injection Jameson Cell Pneumatic PNEUFLOT Pneumatic flotation with PNEUFLOT® cells HUMBOLDT WEDAG leaflet 2009 Multi-injection Imhoflot 3 (centrifugal flotation) feed compressed air air plus suspension feed reagents concentrate tailing feed pump tailing pump Pneumatic cell Imhoflot. Maelgwyn Mineral Service leaflet 4/06 Chile 2006 Injection column Siemens SIMINE Hybrid Flot Metals and Mining, Siemens VAI, No. 1, 2011 Dissolved air flotation (DAF) Dissolved air flotation (DAF) Flotation, ZWR Polkowice