Minerals Engineering 16 (2003) 11971203

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Froth recovery measurement in plant scale otation cells

a,* b,1 b,1
D.J. Alexander , J.P. Franzidis , E.V. Manlapig
a
JKTech, University of Queensland, Isles Road, Indooroopilly, Qld 4068, Australia
b
Julius Kruttschnitt Mineral Research Centre, University of Queensland, Isles Road, Indooroopilly, Qld 4068, Australia
Received 27 May 2003; accepted 14 July 2003

Abstract
Over recent years a number of techniques have been developed as part of the AMIRA 2 P9 project to represent mathematically or
measure directly sub-processes occurring in otation cells. These include the determination of:

a machine parameter (bubble surface area ux, Sb );

a froth parameter (froth recovery, Rf );
entrainment and drainage parameters (n and d); and
an ore oatability parameter (Pi ).

A methodology for estimating froth recovery in large scale plant otation cells is proposed. The primary aim of the technique is
to estimate the froth recovery in a way that is simple, inexpensive and non-intrusive. Plant engineers can use the estimate of froth
recovery in day to day trouble-shooting and circuit optimisation.
The current denition of froth recovery is given, along with a detailed description of the proposed methodology, equipment
required, assumptions and calculations. Advantages and limitations of the methodology are described and possible applications of
the froth recovery estimate in current otation circuit modeling are presented.

2003 Elsevier Ltd. All rights reserved.

Keywords: Flotation froths; Modelling; Process optimisation

1. Introduction Once validated, these sub-process models when com-

Recent advances in the modelling of the otation
process in industrial scale circuits have been based on
the development of sub-process models of bubble sur-
face area ux (Gorain et al., 1997; Deglon et al., 1999),
entrainment (Johnson, 1972; Savassi et al., 1998), ore
oatability (Harris, 1997; Runge et al., 1997; Alexander
and Morrison, 1998) and froth recovery (Vera et al.,
1999; Savassi et al., 1997; Mathe et al., 2000). However,
all the above sub-process models are in their industrial
scale infancy and extensive industrial trials are required
to collect data that will validate each sub-process model.
*
Corresponding author. Tel.: +617-3365-5984; fax: +617-3365-
5900.
E-mail addresses: d.alexander@jktech.com.au (D.J. Alexander),
j.franzidis@mailbox.uq.edu.au (J.P. Franzidis), e.manlapig@mail-
box.uq.edu.au (E.V. Manlapig).
1
Tel.: +617-3365-5888; fax: +617-3365-5999.
2
Australian Mineral Industries Research Association.
0892-6875/$ - see front matter
2003 Elsevier Ltd. All rights reserved.
doi:10.1016/j.mineng.2003.07.016
bined will provide the plant engineer with a tool for
optimising existing otation circuits.
A new method for measuring froth recovery in in-
dustrial otation cells is proposed. The technique allows
measurement of the froth performance in a otation cell
directly, with minimum eect on cell operation. It is
based on a combination of two published methods to
measure froth recovery; viz., Savassi et al. (1997) and
Vera et al. (2000). This combination provides plant en-
gineers a method that will allow froth performance
measurements to be made easily in large scale otation
cells. This paper outlines the previous work in this area
and describes the new experimental procedure to esti-
mate froth recovery.
2. Background
Flotation is usually modelled as a single separation
process with an overall rst order rate constant. In these
1198 D.J. Alexander et al. / Minerals Engineering 16 (2003) 11971203
generalised approaches, it is often dicult to correlate
numerous commonly used operating parameters (ex-
amples include air owrate, froth depth, etc.) with a
otation kinetic model. To overcome this problem, sev-
eral authors have suggested that the otation process
should be investigated by splitting the process into two
distinct phases; the pulp phase and the froth phase. Re-
cent studies into modelling the pulp phase in conven-
tional industrial otation cells have indicated that a
machine parameter (namely bubble surface area ux) and
distributed oatability components are a useful modeling
approach. A number of techniques have also been pro-
posed to model the froth phase, including direct estima-
tion (Falutsu and Dobby, 1989; Savassi et al., 1997), mass
balancing (Contini et al., 1988) and model tting (Moys,
1978; Yianatos et al., 1988). The majority of these tech-
niques were developed for batch otation cells or column
cells and are not applicable for continuously operated
industrial scale sub-aeration otation cells.
In a detailed critique of froth phase modelling, Mathe
et al. (2000) concluded that the most practical approach
to modelling the froth phase in an industrial mechanical
cell is to determine a froth recovery parameter. This
approach, developed for column cell otation, has been
used by a number of authors (Feteris et al., 1987; Lap-
lante et al., 1989; Finch and Dobby (1990); Mular and
Musara, 1991; Vera et al., 1999). Finch and Dobby
(1990) dene the froth recovery parameter as
k the method disturbs the performance of downstream
Rf 1 cells;
kc
where Rf is the froth recovery (%), k the overall rst
order rate constant (min
1 ) and kc the collection zone
rst order rate constant (min
1 ).
In AMIRA P9 otation testwork, the froth recovery
parameter is currently estimated using the technique rst
developed by Feteris et al. (1987) and later used by
Laplante et al. (1989), Mular and Musara (1991) and
Vera et al. (1999). The technique involves varying the
froth depth in a cell and taking samples of the feed,
concentrate and tailings. These samples are assayed and
the information used to calculate the rst order rate
constant for each froth depth, from the equation:
R that it was only applicable to rougher cells. This was
k 2
s  1
R
where R is the overall mineral recovery, and s the cell
residence time (min).
Note that Eq. (2) assumes that the system behaves as
a perfect mixer. Previous authors have validated this
assumption in large industrial otation cells (Burgess,
1997; Alexander et al., 2000).
The overall rst order rate constant is then plotted
against froth depth to produce a linear relationship as
shown in Fig. 1. The collection zone rst order rate
constant (kc ) is estimated by extrapolation to zero froth
y = -0.0019x + 0.113
First Order Rate Constant (min-1)
2
R = 0.9991
0.09
0.08
0.07
0.06
0.05
0.04
0.03
0.02
0.01
0
0 10 20 30 40 50
Froth Depth (cm)
Fig. 1. Linear relationship between overall rst order rate constant
and froth depth.
depth; i.e. y intercept. The collection zone rst order rate
constant can then be used to calculate the froth recovery
parameter at any froth depth using Eq. (1).
The advantages of this technique are that it is simple
and applicable to various cell sizes, types and duties.
However, the following factors have been found to limit
the applicability of this technique in most plant situa-
tions:
the method is intrusive on the overall cell perfor-
mance;
the method generates a large number of samples;
the method assumes that entrainment has a minimal
impact on the general form of the relationship.
Savassi et al. (1997) proposed a method to estimate
the froth recovery in large otation cells by collecting
samples of pulp just beneath the pulpfroth interface and
the concentrate, and mass balancing the ow of attached
particles over the froth phase. The advantages of this
technique are that it is non-intrusive on the operation of
the otation cell, removes the eect of entrainment, and
downstream cells are not aected. However, Savassi et al.
(1997) noted that the main limitation of the method was
likely due to:
the diculty in estimating the attached particle grade;
the low mass of samples taken which may have high
sampling errors; and,
the dierence between the attached and entrained
grade being typically too small in cells operated in
anything other than a rougher application, to allow
use of the method with any degree of condence.
In this study, a new technique is proposed that im-
proves the estimate of froth recovery in a cell by com-
 D.J. Alexander et al. / Minerals Engineering 16 (2003) 11971203
bining the methods of both Savassi et al. (1997) and
Vera et al. (1999).
3. Experimental technique
The following procedure is used to estimate froth
recovery in industrial cells:
Measure supercial gas velocity (Jg ) and air hold-up
(eg ) at various locations across the cell;
Take samples of feed, concentrate, tail, air hold-up
and top of the froth using appropriate sampling
equipment (see below);
Measure slurry weight, solids weight and percent sol-
ids, and assay all samples (by size if required);
Conduct a mass balance over the entire cell with the
appropriate sample standard deviations;
Conduct a mass balance over the concentrate stream
with the appropriate sample standard deviations;
Conduct a mass balance over the air hold-up with the
appropriate sample standard deviations;
Calculate the ow of attached particles entering and
leaving the froth (the ratio of these is dened as the
froth recovery).
Cell characterisation measurements (i.e. the super-
cial gas velocity and air hold-up measurements) are
made at several locations across the otation cell. The
experimental techniques required are well documented
in Power et al. (2000).
Feed, concentrate and tail samples of individual cells
are taken using appropriate sampling equipment. These
samples are assayed and percent solids noted. The air
hold-up is dened as the ratio of the volumetric fraction
of air to the overall volumetric fraction of air and pulp.
Fig. 2 illustrates the measuring equipment used (note
that the air hold-up equipment is operated vertically).
Briey, the device comprises a cylindrical tube with two
air operated pinch valves at each end. The device is
lowered to about 10 cm below the pulp/froth interface
with the pinch valves closed. The pinch valves are then
opened and air and pulp travels through the device for
approximately 30 s. After this period, the pinch valves
are closed and the volume of pulp is measured. This
sample is analysed for percent solids and assayed. Fig. 3
Rubber tube Rubber tube
Plastic cylindrical tube
Compressed air Three-way valve
Air line
The atmosphere Pinch valve 1 Pinch valve 2
Fig. 2. Air hold-up sampling device.
1199
Fig. 3. Plant demonstration of the air hold-up probe.
demonstrates the use of the air hold-up probe in taking a
sample 10 cm below the pulpfroth interface.
Vera et al. (2000) proposed that a sample taken at the
very top of the froth and well away from the lip of the
cell should represent the grade of attached particles in
the pulp. This top of froth sample has been incorporated
into this method for measuring froth recovery.
Mass balances over the cell, concentrate and pulp (air
hold-up) are required to estimate the mass owrate of
attached particles entering the froth and the mass
owrate of attached particles in the concentrate. Each
mass balance uses a least squares minimization tech-
nique to estimate balanced ows and assays.
4. Theory
The technique is based on three key assumptions:
The grade of the froth sample represents the grade of
particles attached to bubbles;
The average grade of particles attached to bubbles
does not change over the froth phase;
The grade of the tail sample is equivalent to the grade
of particles that are entrained in the water.
All three assumptions can be tested on a cell, bank or
circuit basis. Varying the froth level in a cell and de-
termining the maximum concentrate grade produced
from the cell can test the rst assumption. This is illus-
trated in Fig. 4 where the maximum grade in this in-
dustrial rougher cell is approximately 9.2%. This gure
compared very well to the grade of the top of froth
sample of 9.3%. In other cases, this result may not be
valid and hence this should be tested on a regular basis.
Recently, several authors have suggested that the
froth is non-selective in terms of attached particles, i.e.,
that particles do not break their bonds with air bubbles
in the froth phase due to their hydrophobicity but rather
that the dropback of particles to the pulp phase is
caused by bubble breakage and coalescence. A simple
1200 D.J. Alexander et al. / Minerals Engineering 16 (2003) 11971203

10 The three assumptions outlined above allow a set of

9 mass balance equations to be formed over the froth
8 phase. The air hold-up sample taken directly below the
7
Grade (%)

pulpfroth interface and the supercial gas velocity

6
5
4
3
2 Pulp
1
0 where MATT
0 100 200 300 400
Froth Depth (mm)
Fig. 4. Typical industrial otation cell response of valuable mineral
grade to variation in froth depth.
test to determine the validity of this assumption is to
plot the froth recovery of one mineral against another
mineral under the same conditions. This is illustrated in
Fig. 5 from data collected using the change in froth
depths method described previously. A 45 line through
the origin and passing through the experimental results
supports the hypothesis of non-selective drop-back in
this case. Selectivity to mineral type in the froth phase
would be indicated by deviation of the data from the 45
line. There is evidence in the literature that this as-
sumption may not always be valid for some mineral
systems.
The third assumption can be tested using the en-
trainment analyser developed by Savassi et al. (1998) or
by determining the mixing characteristics (i.e. plug ow
of perfect mixing) of the cell using a soluble tracer. The
entrainment analyser sample is the preferred method
because it is simple, direct and requires one extra sam-
ple. The grade from the entrainment sample can be
compared directly to the grade of the tail sample and if
there is a discrepancy the entrainment sample grade
should be used.
measurement are used to estimate the mass owrate of
attached particles entering the froth phase, based on the
following equation:
MATT 3:6  QAir  BPulp 3
Pulp
is the mass owrate of attached particles in
500 the pulp zone (t/h), QAir the volumetric owrate of air
(m3 /s) and BPulp the bubble load in the pulp phase
(grams of solids/litre of air).
The volumetric owrate of air can be measured di-
rectly in each cell or estimated using the supercial gas
velocity measurements across the cell cross sectional
area:
QAir A  Jg 4
where Jg is the supercial gas velocity (cm/s) and A the
open area of cell (m2 ).
The bubble load is dened as the mass of attached
solids per volume of air. Numerous authors have at-
tempted to measure bubble load in laboratory environ-
ments with limited applicability to industrial scale
performance. Savassi et al. (1997) proposed a method to
estimate the bubble load in industrial otation cells. In
this method, samples are collected just below the pulp/
froth interface using a funnel connected to a vacuum
(see Fig. 6). This technique was shown by Savassi et al.
(1997) to be very good for obtaining reliable bubble load
C
P V

1.00 2 B
R = 0.9967
0.90
0.80 (a)
0.70
Rf Mineral 1

0.60
0.50
180
0.40
0.30
0.20
0.10
0.00
0.00 0.20 0.40 0.60 0.80 1.00
(b)
Rf Mineral 2
Fig. 6. (a) Sketch of the bubble load analysergeneral layout (after
Fig. 5. Typical plant data showing that the froth is non-selective Savassi et al., 1997). (b) Sketch of the bubble load analyserfunnel
within experimental error. layout (after Savassi et al., 1997).
 D.J. Alexander et al. / Minerals Engineering 16 (2003) 11971203
measurements in industrial cells. However, Savassi et al.
(1997) also showed that the technique was not accurate
in low bubble load environments (scavengers) or in high
grade pulp environments (cleaners and recleaners). This
limited the application of the technique to the rougher
sections of otation circuits. In addition, the method-
ology was dicult to use in most plant applications
since it was time consuming and the equipment was not
particularly robust.
A new method of obtaining bubble load is proposed
which is based on the Savassi technique, but uses more
robust equipment and a more accurate method. It in-
volves obtaining a sample using the air hold-up probe
and using the assumptions outlined above. Fig. 7 illus-
trates that air bubbles (with particles attached) and pulp
(with particles entrained) pass through the air hold-up
sample in the open position. When the air hold-up probe
is closed, the attached particles become detached from
the air bubbles and are included with the pulp con-
taining entrained particles and water. The volume of air
and the mass and grade of the pulp sample are noted.
The bubble load can then be calculated using:
matt  1000
BPulp 5 Rf
V mPulp
where matt is the mass of attached particles in the air
hold-up probe (g), V the volume of air measured in the
air hold-up probe (ml).
The mass of attached particles in the air hold-up
probe is estimated using the following mass balance
equation:
mtotal  Gtotal
Gent
matt
Gatt
Gent
where mtotal is the total mass of particles in the air hold-
up probe (g), Gent the grade of entrained particles in the
air hold-up probe, Gtotal the grade of all particles in the
air hold-up probe and Gatt the grade of attached parti-
cles in the air hold-up probe.
In order to calculate the mass of attached particles
(matt ), the grade of attached particles (Gatt ) is taken as
that of the grade of the top of froth sample, while the
Fig. 7. Simple illustration of the use of the air hold-up probes in ob-
taining fast, robust and reliable bubble load estimates in large scale
otation cells.
1201
grade of entrained particles (Gent ) is taken to be equiv-
alent to the grade of the tailings. This is in accordance
with the assumptions made at the beginning of this
section.
The estimate of the mass of attached particles in the
air hold-up sample obtained from Eq. (6) can then be
used to calculate the mass owrate of attached particles
into the froth phase (Eqs. (3) and (5)).
The mass owrate of attached particles in the con-
centrate can be calculated using a similar mass balance
equation to Eq. (6) applied to the concentrate sample:
mConc
total  Gtotal
Gent
mconc
att 7
Gatt
Gent
where mConc
att is the mass owrate of attached particles in
the concentrate stream (t/h), mConc
total the mass owrate of
all particles in the concentrate stream (t/h), Gent the
grade of entrained particles in the concentrate, Gtotal the
concentrate grade and Gatt the grade of attached parti-
cles in the concentrate.
The froth recovery of attached particles can then be
calculated using the following equation:
mConc
att
8
att
where Rf is the froth recovery of attached particles, mConc
att
the mass owrate of attached particles in the concen-
trate stream (t/h) and mPulp
att the mass owrate of attached
particles in the pulp (t/h).
4.1. Case studycentury zinc concentrator, Australia
6
The new froth recovery technique was used to mea-
sure froth recovery in a rougher and scavenger appli-
cation. In both cases, the otation cells were
Outokumpu 100 m3 tank cells in the zinc circuit. Sam-
ples of feed, concentrate, tail, air hold-up and top of
froth were taken from each of the cells and analysed for
percent solids, lead, zinc, iron and silica. The supercial
gas velocity was measured at several locations across the
cell with the average supercial gas velocity calculated at
1.43 and 1.30 cm/s in the rougher and scavenger, re-
spectively. Measurements of the average air hold-up
were estimated at 12% and 15% in the rougher and
scavenger, respectively. Froth depths of 50 cm in the
rougher and 20 cm in the scavenger were also recorded.
The bubble load was calculated using Eqs. (5) and (6).
Bubble load estimates of 46.8 and 29.2 g/l were calcu-
lated in the rougher and scavenger, respectively. The
rst point to note from these results is that the magni-
tude of the bubble loads are in a similar range to that
reported by Savassi et al. (1997). Secondly, the bubble
load attained in the rougher was signicantly higher
than the scavenger. This follows the logical argument
that more attached particles would be present in the
rougher section of the circuit than the scavenger. Finally,
1202 D.J. Alexander et al. / Minerals Engineering 16 (2003) 11971203

the measurement was easily attained and time required to validate the proposed method at numerous sites and
for calculation was dependent only on the assay turn applications. Included in these studies will be a statisti-
around time. cal analysis to estimate the statistical reliability of these
The bubble load was used to calculate the mass measurements.
owrate of attached particles in the pulp phase (rougher
68.1 t/h; scavenger 38.7 t/h). In addition, a mass balance 4.2. Proposed areas of froth recovery technique use
of the concentrate sample was conducted to estimate the
mass owrate of attached particles in the concentrate The proposed froth recovery technique can be used in
(rougher 27.8 t/h; scavenger 35.5 t/h). The froth recovery the following areas:
was then calculated using Eq. (8). The estimate of the
froth recovery in the rougher cell was 40.8% and 91.6% For plant engineers to estimate froth recovery in op-
in the scavenger cell. The large dierence in the froth erating plant cells, to assist with operational trouble
recovery values measured was due to the dierence in shooting;
the froth depths in each of the cells (rougher 50 cm; For project engineers to estimate froth recovery in
scavenger 20 cm). Gorain et al. (1997) showed that operating plant cells, to assist with plant diagnosis
strong relationships between froth recovery and the and future project areas;
froth residence time of air and slurry existed. Examples For engineering consultants to measure froth recov-
of these relationships in a 100 m3 plant operating cell are ery in plant cells, to provide better models and simu-
shown in Figs. 8 and 9 from work previously conducted lators of otation circuits.
by the authors at another site. These relationships show
that small dierences in froth depth can have a large 4.3. Future work
impact on the froth recovery and is the likely reason for
the dierence in froth recovery between the two cells. The following work is proposed by the authors to
The study at Pasminco Century shows that the new improve the reliability of the froth recovery technique:
technique provides froth recovery and bubble load val-
ues which are similar to reported values in similar ap- Collect froth recovery measurements in dierent ap-
plications in the literature. Extensive testwork is planned plications to better dene the main areas of use.
These applications should include various cell types
and sizes, duties (i.e. rougher, cleaner scavenger,
etc.) and ore types (zinc, copper, nickel, etc.);
Measured Froth Recovery (%)

100.0%
90.0% Test the three main assumptions to determine the sit-
80.0%
70.0% y = 0.6862e-0.0046x uations where they do not apply;
60.0%
2
R = 0.6843 Conduct an error and statistical analysis on the froth
50.0% recovery technique by
40.0%
30.0%  Multiple measurements at similar conditions;
20.0%  Using a Monte Carlo simulation.
10.0%
0.0% Investigate the usefulness of the entrainment and
0.00 50.00 100.00 150.00 200.00 250.00 300.00 350.00 bubble load estimates in determining the impact
Froth Residence Time of Slurry (s) of various operating variables including reagent ef-
fects.
Fig. 8. Typical relationship between measured froth recovery and the
froth residence time of slurry in a 100 m3 Outukumpu tank cell.

5. Conclusion
Measured Froth Recovery (%)

100.0% A practical methodology for measuring the froth

90.0%
80.0% y = 1.4357e
-0.0519x
performance in plant scale otation cells has been pro-
2
70.0% R = 0.9079 posed. The technique was developed to improve the
60.0%
50.0%
practicality of two previous methods of measuring froth
40.0% recovery, namely, Savassi et al. (1997) and Vera et al.
30.0% (1999). The improvements were based on:
20.0%
10.0%
0.0% Measuring the froth performance in a sub-aerated
0.00 10.00 20.00 30.00 40.00 50.00
plant scale otation cell directly, with minimum eect
Froth Residence Time of Air (s)
on cell, bank or plant performance;
Fig. 9. Typical relationship between measured froth recovery and the Reducing sample numbers and time required to take
froth residence time of air in a 100 m3 Outukumpu tank cell. measurement.
 D.J. Alexander et al. / Minerals Engineering 16 (2003) 11971203
The technique requires three assumptions which can be
easily tested in each application of the technique. Future
work will be conducted to conrm the validity of these
assumptions under various conditions and cell duties.
The froth recovery technique was used to measure the
froth recovery in a 100 m3 rougher and scavenger cell at
Pasminco Century lead/zinc mine in North Queensland.
The results of this application show that the technique
can be applied to both a zinc rougher and zinc scavenger
duty. Both the bubble load and froth recovery estimates
were in a similar range to previous results reported by
other authors. Further studies at various sites are plan-
ned to test the validity of the technique in other duties.
Acknowledgements
The assistance of sta from Pasminco Century Mine,
in the development of this technique is gratefully ac-
knowledged. The authors would also like to acknowl-
edge the members of the AMIRA P9 otation group
especially Kym Runge, Marco Vera and Robert Cole-
man for their contribution in developing this technique.
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