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Abstract
The effect of impeller speed on the air flow in a self-aerated Denver laboratory flotation cell was investigated using
computational modelling. Air is induced into the slurry by the impeller's rotating action. The rate of air flow is determined by the
suction pressure created by the impeller, the hydrostatic head of the slurry and the frictional losses along the delivery shaft from the
inlet valve to the impeller. From two-phase simulations of the flotation cell at varying impeller speeds, the predicted air flow rates
have been found to compare favourably against measured values reported in the literature. The effect of increasing impeller speed is
to increase the air flow rate and gas holdup in the cell. Simulations with flotation kinetics showed that the gravitational force acting
on the attached particles is significant. The effect is a decrease in the bubble rise velocity which in turn affects the flotation rate as
predicted by the model. The effects of the local turbulence level on the local attachment rate and bubble loading have been
discussed and quantified.
Crown Copyright © 2007 Published by Elsevier B.V. All rights reserved.
0:0791
f ¼ ð4Þ
Re0:25
De V qg
Re ¼ : ð5Þ
l
pulp interface, gas bubbles with attached particles are transient simulation uses variable time steps such that
transferred from the pulp zone to the froth layer at the rate the mass error is less than 0.1% for each time step. The
bubbles arrive at the interface. An average bubble diame- equations used in the model for collision frequency and
ter of 1 mm is applied in the model based on measure- attachment probability reported previously (Koh and
ments by Girgin et al. (2006) in the air–water system at a Schwarz, 2006) are shown in Table 1.
frother concentration of 50 ppm. At this relatively high
frother concentration, the bubble sizes remain fairly 3. Results
constant over the range of impeller speeds reported
because coalescence is reduced. Results of two-phase simulations have been obtained for
the Denver cell at different impeller speeds, and a typical mid-
For simulations with flotation kinetics, the transfer of
plane plot of the liquid velocity vectors at impeller speed of
particles between the pulp and bubbles is achieved by
1200 rpm is shown in Fig. 4. CFD predictions indicate a
applying source terms for particle number concentration complex flow field within the flotation cell and large fluid
ni in the transport equation as follows: velocities observed in the impeller region.
Table 1
Bubble–particle equations used in the CFD model as reported previously (Koh and Schwarz, 2006)
Net attachment rate dnp1
¼ k1 np1 nbT ð1 bÞ þ k2 nbT b
dt
Attachment rate constant k1 ¼ Z1 Pc Pa Ps
Detachment rate constant k2 ¼ Z2 ð1 Ps Þ
Bubble loading 2
np2 db
b¼ where Smax ¼ 0:5S and S ¼ 4
Smax nbT dp
Collision frequency across eddies
dp þ db 2 2 1=2
Z1 ¼ 5:0 ðUp þ Ub2 Þ
2
Critical diameter of particle or bubble 15lf Uf2
di2 Ndcrit
2
¼
qi e
rffiffiffiffiffiffi
Collision frequency within eddies 8k dp þ db 3 e1=2
Z1 ¼
15 2 m
Turbulent fluctuating velocity of particle or bubble 7=9
0:4e4=9 di qi qf 2=3
Ui ¼
m 1=3 qf
Detachment frequency pffiffiffiffiffiffiffiffiffiffiffiffiffi
C1 e 1=3
Z2 ¼
ðdp þ db Þ2=3
Probability of collision 2
4 dp
Pc ¼ 1:5 þ Re0:72 b
15 db2
Bubble Reynolds number db Ub
Reb ¼
m
Probability of adhesion
ð45 þ 8Reb0:72 ÞUb tind
Pa ¼ sin 2 arctan exp
2
15db ðdb =dp þ 1Þ
Induction time 75 0:6
tind ¼ dp
h
Probability of stabilisation
1
Ps ¼ 1 exp As 1 T
Bo
Bond number " #
2=3 dp db 1=3 4r h
dp Dqp g þ 1:9qp e
2
þ þ 1:5dp db qf g sin2 k
2 2 db 2
BoT ¼
h h
j6rsin k sin k þ j
2 2
20 P.T.L. Koh, M.P. Schwarz / Int. J. Miner. Process. 85 (2007) 16–24
Fig. 5. Comparison of CFD predictions against measured air flow rate Fig. 6. Aggregate density of a 1-mm bubble with fractional surface
at different frother concentrations plotted against impeller speed. coverage of particles plotted against particle diameter.
P.T.L. Koh, M.P. Schwarz / Int. J. Miner. Process. 85 (2007) 16–24 21
Fig. 7. Rise velocity of bubble–particle aggregate with fractional Fig. 9. CFD predictions of rate constant plotted against particle
surface coverage on a 1-mm bubble plotted against particle diameter. diameter, with and without the effect of buoyancy reduction due to
attached particles, and comparison with literature data for quartz
(Ahmed and Jameson, 1985).
The gravitational force acting on particles attached to bubbles
decreases the rise velocity of the aggregate especially with larger for bubbles in a quiescent fluid. One can expect a similar effect in
particles at higher loadings. The additional body force on the turbulent flow where the bubble rise velocity is reduced by the
attached particles is incorporated in the present model by a source attached particles. The bubble–particle aggregates can sink if the
(Bp) in the gas phase as follows: particles are large and the bubble load also is high. The
2 calculations assume that the aggregate shapes are spherical and
db the effect is greater on the rise velocity if the bubble–particle
Bp ¼ 4fc ðqp ql Þgnb ð7Þ
dp aggregates are markedly different from spherical.
From CFD simulations with flotation in the Denver cell, the
where fc is the fractional surface coverage, nb the local number total number of particles remaining in the cell is determined by
concentration (m− 3) of bubbles, ρp the density of particles, and db summing particles in all the finite volumes. The results for
and dp are the diameters of bubble and particles respectively. The different particle diameters are shown in Fig. 8 where the sum
effects of the particle diameter on both the rise velocity and the of free and attached particles remaining in the cell operating at
density of bubble–particle aggregates are illustrated in Figs. 6 1200 rpm is plotted as a function of time. The rate constants
and 7 where values have been calculated using a spreadsheet. are obtained from this diagram assuming first order kinetics
The aggregate density increases with particle diameter and plotted against particle diameter in Fig. 9.
because the total mass of attached particles and bubble increases
more than the total volume of particles and bubble for larger
particles. The aggregate rise velocity approaches zero for particles
of 250 μm size with a surface coverage of 0.5 because the
effective aggregate density is close to that of water as shown in
Fig. 6. The rise velocity at various loadings in Fig. 7 is obtained
Fig. 8. CFD prediction of the fraction of free and attached particles Fig. 10. CFD predicted net attachment rates (m− 3 s− 1) after flotation
remaining in the cell plotted against time for different particle time of 129 s for particles of 15 μm size. Negative values indicate net
diameters (μm). detachment.
22 P.T.L. Koh, M.P. Schwarz / Int. J. Miner. Process. 85 (2007) 16–24
Fig. 11. CFD predicted net attachment rates (m− 3 s− 1) after flotation
Fig. 13. CFD predicted bubble loading after flotation time of 129 s for
time of 129 s for particles of 60 μm size. Negative values indicate net
particles of 15 μm size.
detachment.
The effect of incorporating Eq. (7) into the model is shown buoyancy confirms indirectly that transport rate of attached
in Fig. 9 where flotation rates with and without body force at particles to reach the froth–pulp interface is an important
different particle sizes are compared. The effect is greater at contributor to the overall flotation rate.
intermediate particle size range of 100 to 300 μm where the In the present simulations, the maximum loading on a bubble
particle mass and particle loading on the bubble contribute has been assumed to be equal to a half mono-layer coverage
significantly to reduce the buoyancy. For very large particles of (fc = 0.5) in the absence of experimental data. Flotation rates of
about 400 μm, the net attachment rates are smaller and the quartz particles in a Rushton-turbine stirred tank reported in the
particle loadings on the bubble are also smaller, resulting in literature (Ahmed and Jameson, 1985) are also plotted in Fig. 9
lower reductions in the buoyancy. Hence, the flotation rate for for comparison. The CFD predicted rates are higher because
large particles remains almost the same with or without this power consumption is greater in the Denver cell (impeller speed
body force. The reduction in rise velocity due to reduced
Fig. 12. CFD predicted net attachment rates (m− 3 s− 1) after flotation
time of 129 s for particles of 120 μm size. Negative values indicate net Fig. 14. CFD predicted bubble loading after flotation time of 129 s for
detachment. particles of 60 μm size.
P.T.L. Koh, M.P. Schwarz / Int. J. Miner. Process. 85 (2007) 16–24 23
1200 rpm) than in the stirred tank (impeller speed 600 rpm). particle diameters of 15, 60 and 120 μm are plotted in Figs. 13, 14
Besides, there is no froth in the model: the reported rates include and 15 respectively. Bubble loading is defined as a fraction of
recovery through the froth layer and would therefore be lower the maximum coverage available on a bubble; the maximum
than the predicted rates which account only for flotation to the coverage is assumed to be equal to a half mono-layer (fc = 0.5) in
pulp–froth interface. There are other possible reasons for the the present simulations. The effect of particle size on bubble
high predictions including the assumed maximum loading of loading is significant. For smaller particles of 15 and 60 μm, the
half monolayer which was used as a first approximation. It is also bubble loading is close to the maximum coverage everywhere in
possible that detachment rates in the model may be too low. With the flotation cell indicating there is very little detachment of
higher rates of detachment, the maximum flotation rate constant particles from the rising bubbles. For larger particles of 120 μm,
could occur at less than 100 μm as normally observed in flotation the loading varies more across the flotation cell and is generally
tests. Work on this aspect of the model is still in progress. lower in value in comparison to smaller particles. The dis-
The distributions of net attachment rates in the Denver cell tribution of bubble loading in Fig. 15 indicates that the loading
operating at 1200 rpm after a flotation time of 129 s for three reaches a maximum in the region around the shroud and
particle diameters of 15, 60 and 120 μm are plotted in Figs. 10, decreases as the bubbles rise towards the surface. In this
11 and 12 respectively. The negative values represent detach- situation, detachment of particles from the rising bubbles is
ment. For small particles of 15 μm, the net attachment rates are occurring. The effect is greater for larger particles than it is for
highest near the impeller tip and in regions of highest shear. smaller particles.
There is little detachment for 15 μm particles. For larger particles The variation in bubble loading within the flotation cell is
of 60 and 120 μm, the locations of highest net attachment rates caused by the different bubble–particle attachment and
are away from the impeller. In fact, for 120 μm particles, the detachment rates in different parts of the cell. The local
highest rates are outside the shroud. The high detachment rates turbulence level affects both the attachment and detachment
for 60 μm particles are near the impeller tip, while the high processes occurring in each region and there is a balance
detachment rates for 120 μm particles are around the impeller between the two rates. For a given particle size, the local
and outside the shroud. attachment rate can be greater than the local detachment rate in a
The results indicate that the smaller particles need higher particular region, while the reverse may be true in other regions
impeller speeds for flotation while larger particles float best at resulting in negative net attachment rates. Thus, the bubble
lower speeds. Thus, in plant operations, flotation cells should loading can vary between regions in the flotation cell and is
operate with impeller speeds that perform best for a given dependent on whether the local attachment or detachment rates
particle size. This agrees with practice in many mineral plants predominate.
where the feed streams are sized into coarse, fines and slimes and
treated separately in customised flotation cells where the speeds
are adjusted to suit the particle size. 4. Conclusions
The distributions of bubble loadings in the Denver cell
operating at 1200 rpm after a flotation time of 129 s for three The hydrodynamics and flotation kinetics in the
Denver laboratory cell have been studied using CFD
modelling. From two-phase simulations at different
impeller speeds, the predicted air flow rates have been
found to compare favourably against measured values
reported in the literature. The model provided detailed
hydrodynamics of the Denver cell that are very useful for
understanding batch flotation test results and for inves-
tigations in the design and operation of larger flotation
cells.
Simulations with flotation kinetics showed that the
gravitational force acting on the attached particles is
significant. The effect is a decrease in the bubble rise
velocity which in turn causes the flotation rate to decrease.
Model predictions showed that net bubble–particle
attachment for coarse particles occurs mainly outside the
shroud. Near the impeller, both attachment and detach-
ment rates are high with the net effect being detachment.
The coarse particles have been shown to detach from
rising bubbles. For fine particles, the attachments occur
Fig. 15. CFD predicted bubble loading after flotation time of 129 s for predominately inside the shroud with high loading on the
particles of 120 μm size. bubbles carrying particles to the surface.
24 P.T.L. Koh, M.P. Schwarz / Int. J. Miner. Process. 85 (2007) 16–24
Subscripts
1 free particle or attachment
2 attached particle or detachment
b bubble
f fluid
i phase index
p particle
T total