ABSTRACT:

Froth flotation is a process used for selectively separating hydrophobic particles

fromhydrophilic utilising the physico-chemical surface properties of the particles of
differentminerals. The success of effective flotation process depends on a number of variables
such asthe type and quantity of chemicals added, the bubble size, residence time, stator and
rotorconfigurations etc. In commercial plants, an increase of 1% - 2% in recovery and/or grade
iseconomically remarkable. Hence, the optimisation of reagents is the most important aspect
offlotation strategy.Flotation experiments have been carried out on Rakha Copper ore under
different collectorand frother dosages. The collector and frother dosages were varied at four
levels each and theresults obtained have been analysed in terms of recovery and grade of
the different sizefractions constituting the bulk. The results indicate that the Rakha ore
responds well in terms of recovery and grade ofboth the bulk and individual size fractions at
lower and intermediate dosages of collector andfrother, the higher reagent dosages having
virtually no effect or even deleterious effect. Based on the analysis of results, it is suggested that
the floatability of individual size fractionsbe clearly understood in order to obtain desired
results rather than resorting to arbitrarychanges in reagent dosages.Keywords: Froth flotation,
collectors, frothers, recovery, grade1.

INTRODUCTION

Froth flotation is the most widely adopted process for concentration of metalsulphides. It
has been observed by many researchers that the process is a multi-phase, highly

interactive phenomenon (1-3).

The nature and extent of
interaction of the different
phases
involved significantly influence
the quality and quantity of the
concentrate and tailings.
The mutual interactions
between the solid, liquid, gas
and reagent phases result in
selectivity and improved
flotation activity. Of the
various interactions, the
interaction
between the solid particles of
various sizes with the reagents
added has been recognised as
the most crucial and significant
in the flotation response of the
material (4-6).
The reagent – material
interaction are generally studied
through
(i) flotation of feeds of different
size distribution
(ii) split feed flotation
(iii) Flotation of bulk material
and analysis of flotation activity
of particle size range
constituting the feed.
The research work
carried out the world over has
established the general features
of
the above types of
interactions. However, the
flotation response is
material-specific and
studies have been carried out to
understand the flotation
characteristics of each material
being
investigated.
Various studies have been
carried out on flotation with
respect to particle size .
Livshits and
Dudenkov (7) proposed that
there is an optimum particle
size range that promotes bubble
coalescence. Coarse and very
fine hydrophobic particles
may not destroy froth
because
coarse particles retard the
bubble coalescence by slowing
down the drainage of liquid
present
in the thin film, while very fine
particles drain back with liquid
to the pulp phase. Crawford
and Ralston (8) performed
experiments with quartz
particles in the size range of 15
to 125 μm
and reported that particles with
an average diameter of 71 μm
require only 35% of surface
coated with the collector for
around 80% recovery whereas
coarser 121 μm particles need
60% of the surface to be coated
to achieve the same recovery.
Several other works reported a
similar result for different
collector-mineral systems (9-
12). Muganda et al. (13)
investigated
the influence of particle size
and surface hydrophobicity on
flotation rates of chalcopyrite. It
was shown that for each size
fraction tested (−20+300 μm)
there is a critical contact angle
below which flotation is not
possible.
Theoretical analysis by
Stevenson et al. (14) showed
that the detachment of particles
during
oscillation is largely due to the
instability in the three phase
contact line over the
particle
surface which is closely
related to the bubble
surface deformation.
According to R.M.
Rahman et al. (15), the particle
recovery is not only by
attachment or true flotation, but
also
by mechanical entrainment.
Reduction of rate constant for
coarse particles can be
attributed
to the formation of composites
(16). Rate constant declines
with increasing particle size
(17).
According to G.J. Jameson (18),
neither liberation nor collector
concentration is the cause of
decline in recovery in the coarse
particle size range. This decline
is almost certainly due to
hydrodynamics effect. As per
the expression for critical bond
number given the detachment
force varies as the square of
the particle size (19-21). Rate
of collection is related to the
turbulent dissipation rate so that
low value of dissipation rate
will lead to low rate constant
and hence low recoveries (22).
It has been well established that
reagent dosages (particularly
collector and frother dosages)
are the most important
variables, which controls the
efficiency of the process (4, 5).
Chalcopyrite ore
from Rakha Concentrator has
been used as the feed material
to
study the response of the bulk
material and the size fractions
constituting the bulk, to changes
in reagent dosages.
2. EXPERIMENTAL
2.1 Material Preparation
Rakha copper concentrator
treats a feed material of size
100% passing 1mm with 50%
below
200 mesh in its flotation circuit.
Copper ore sample, collected
from the secondary crusher
was subjected to closed-circuit
crushing-grinding and sizing to
produce the feed material of
-1mm with 50% -200 mesh.
The procedure followed
during feed material
preparation is
illustrated in Fig.1
interactive phenomenon (1-3). The nature and extent of interaction of the different
phasesinvolved significantly influence the quality and quantity of the concentrate and tailings.
The mutual interactions between the solid, liquid, gas and reagent phases result inselectivity
and improved flotation activity. Of the various interactions, the interactionbetween
the solid particles of various sizes with the reagents added has been recognised asthe most
crucial and significant in the flotation response of the material (4-6).The reagent – material
interaction are generally studied through(i) flotation of feeds of different size distribution(ii) split
feed flotation(iii) Flotation of bulk material and analysis of flotation activity of particle size
rangeconstituting the feed. The research work carried out the world over has established
the general features ofthe above types of interactions. However, the flotation response is
material-specific andstudies have been carried out to understand the flotation characteristics of
each material beinginvestigated.Various studies have been carried out on flotation with respect to
particle size . Livshits andDudenkov (7) proposed that there is an optimum particle size
range that promotes bubblecoalescence. Coarse and very fine hydrophobic particles may
not destroy froth becausecoarse particles retard the bubble coalescence by slowing down the
drainage of liquid presentin the thin film, while very fine particles drain back with liquid to the
pulp phase. Crawfordand Ralston (8) performed experiments with quartz particles in the size
range of 15 to 125 μmand reported that particles with an average diameter of 71 μm require only
35% of surfacecoated with the collector for around 80% recovery whereas coarser 121 μm
particles need60% of the surface to be coated to achieve the same recovery. Several other works
reported asimilar result for different collector-mineral systems (9-12). Muganda et al. (13)
investigatedthe influence of particle size and surface hydrophobicity on flotation rates of
chalcopyrite. Itwas shown that for each size fraction tested (−20+300 μm) there is a critical
contact anglebelow which flotation is not possible.Theoretical analysis by Stevenson et al. (14)
showed that the detachment of particles duringoscillation is largely due to the instability in the
three phase contact line over the particlesurface which is closely related to the
bubble surface deformation. According to R.M.Rahman et al. (15), the particle recovery is
not only by attachment or true flotation, but also

by mechanical entrainment. Reduction of rate constant for coarse particles can be

attributedto the formation of composites (16). Rate constant declines with increasing particle size
(17).According to G.J. Jameson (18), neither liberation nor collector concentration is the cause
ofdecline in recovery in the coarse particle size range. This decline is almost certainly due
tohydrodynamics effect. As per the expression for critical bond number given the
detachmentforce varies as the square of the particle size (19-21). Rate of collection is
related to theturbulent dissipation rate so that low value of dissipation rate will lead to low rate
constantand hence low recoveries (22).It has been well established that reagent dosages
(particularly collector and frother dosages)are the most important variables, which controls the
efficiency of the process (4, 5). Chalcopyrite ore from Rakha Concentrator has been
used as the feed material tostudy the response of the bulk material and the size fractions
constituting the bulk, to changesin reagent dosages.2. EXPERIMENTAL2.1 Material
PreparationRakha copper concentrator treats a feed material of size 100% passing 1mm with
50% below200 mesh in its flotation circuit. Copper ore sample, collected from the secondary
crusherwas subjected to closed-circuit crushing-grinding and sizing to produce the feed material
of-1mm with 50% -200 mesh. The procedure followed during feed material preparation
isillustrated in Fig.1
 The feed material was thoroughly mixed and then sampled to smaller quantities by
rifflingand coning and quartering. A few bags were randomly chosen and subjected to
the sizeanalysis to establish the accuracy of sampling. After ascertaining the sampling accuracy,
arepresentative sample was subjected to size analysis. The individual size fractions were
thenanalysed for their copper content. The size analysis and size-wise copper content are
shownin Table 1.

Solids content : 22% solids by weightpH of the slurry : 7.0 A total of 16

experiments, comprising four levels each of freshly prepared 1%solution of sodium
isopropyl Xanthate (as collector) and pine oil (as frother) , were carriedout. The dosages of the
collector and frother are given in Table 2.2.3

Flotation Test ProcedureThe pre-determined quantity of chalcopyrite

ore was transferred to the laboratory cell andwater was then added to the cell to maintain
the pulp density at the level of 22% solids byweight. The pH of the slurry, impeller speed and
aeration rate were kept constant throughoutthe study. The pulp was mixed thoroughly
and then the collector was added. Afterconditioning the slurry for 5 minutes, the
frother was added. The aeration was done afteranother conditioning period of 5 minutes. The
concentrate was collected after 180 secondsand dewatered. The dry solid concentrate was then
screened over 212, 105 and 63 micronsieves respectively. The representative sample of
each fraction was taken for copperestimation. The copper content in each fraction was
estimated. From the assay value andweights, the percent recovery values of each size fraction
as well as bulk of each concentratewere calculated.3. RESULTS AND DISCUSSIONSAmong
all the parameters affecting flotation kinetics, particle size is supposed to be theimportant
one. In order to understand the flotation behaviour of the bulk and individual sizefractions as
well as to find out which of the size fractions contribute to the response of bulkmaterial, the
experiments were carried out.Recovery and grade of the bulk concentrate and the individual
size fractions havebeen calculated. The flotation response of bulk concentrate and the
size fractions as afunction of the collector and frother dosages is described in the following:
3.1 Effect of collector dosageThe recovery and grade of the bulk and individual size fractions
have been plotted against thecollector dosages, at different frother dosages (Figs 2 (a) to 2 (d)
and 3(a) to 3(d)).

3.1.1 Effect of collector dosage on recovery0 0.04 0.08 0. 12 0.

160102030405060708090100BulkSize: -1000+212Size: -212+1050 0.04 0.08 0. 12 0.
160102030405060708090100BulkSize:-1000+212Size:-212+105Figure 2 (a)
Figure 2 (b)0 0.04 0.0 8 0.12 0.160102030405060708090100BulkSize :-1000+212Size :-
212+1050 0. 04 0. 08 0.12 0.160102030405060708090100BulkSize:-1000+212Size:-
212+105Size:-105+63Figure 2 (c) Figure 2 (d) It may be
noted from figs.2(a) to 2(d) that with increase in collector dosage from C1to C2 , at all frother
levels, the recovery increases substantially but with further increase to C3and C4 , it depicts a
decreasing trend. Because at C1, when there is no collector, the absence ofcollector may have
resulted in low rate of attachment of the air bubble to mineral particlesurface and thus reduce
the probabilities of adhesion per encounter. So it records lowrecovery. With the
increasing collector dosage, the hydrophobicity increases and thus the rateof collection may
have increased due to high probability of adhesion between collidingparticles and air
bubble. This may be the reason for the high recovery at C2 level. Thedecreased trend
of recovery, after C2, may be due to the formation of multilayer on the

mineral surfaces, which, in turn, reduces the recovery of particles to the concentrate launder.This
is consistent with the previous study by Rahman et al. (16) which suggests that at highcollector
concentrations, the particles are expected to be more hydrophobic resulting
indestabilisation of the froth to such an extent that the particles start to fall down through thefroth
layer.The same trend is observed for both the bulk concentrate and all the size fractions except
thefinest size (-63 microns) at higher levels of frother (i.e., F3 and F4). In case of the finest size
(-63 micron), the recovery increases with increase in collector dosages at lowest frother level(F1
level). However, at increased frother dosages the recovery decreases initially
withincrease in collector dosage and then records a slight increase.The reason may be due to the
fact that size of the particle and being finer higher dosage offrother, the collector activity might
have been hindered. Further increase in collector dosageto C3 level, the recovery is enhanced
due to better collector activity.3.1.2 Effect of collector dosage on grade 0 0.04 0.08 0.12
0.16051015202530BulkSize:-1000+212Size:-212+105 0 0.04 0.08 0.12 0.
16024681012141618BulkSize:-1000+212Size:-212+105