Flotation system

In beneficiation plant, Flotation, like all other separation processes, is imperfect in that simply by applying this process only once, very little separation may be achieved. For example, the underflow from a flotation machine unit may have many hydrophobic particles that have failed to encounter an air bubble, or the overflow may have hydrophilic particles that have simply been caught in the wake of an air bubble or in a collection of hydrophobic particles secured to a bubble. It is, therefore, common practice to operate many cells in complicated series – parallel arrangements, perhaps with adjustment of chemistry at some point. This is necessary because only a limited separation is usually attainable in a single device, and as such there is a need for roughing, cleaning, and scavenging components in a circuit.

Generally speaking, roughing is the primary operation, which utilizes a moderate separating force to remove the fully liberated valuables. Scavenging utilizes strong chemistry conditions to recover as much of the remaining valuables as possible. Finally, cleaning utilizes a low separating force which upgrades the rougher concentrate by removing misplaced waste material.

A simple arrangement of using these elements is shown in Figure 1. A series of rougher cells (with the underflow passing from one cell to the next) makes a rough separation of the slurry obtained after grinding(ball mill) into two streams. The mineral-rich stream then passes to a second series of cleaner cells whose objective is to remove as much residual gangue as possible, and yields a slurry of concentrate particles or heads that has much of the valuable mineral in the ore, and a second stream that is recycled to the rougher cells. The other stream from the rougher cells, having less of the valuable mineral (but not so minor as to be discarded), goes on to the scavenger cells where as much as possible of the valuable mineral is recovered from the tailings stream departing to the waste pond. This scavenged valuable mineral is put back to the rougher cells.

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