Frothers, separation

Flotation reagents are used in the froth flotation process to (/) enhance hydrophobicity, (2) control selectivity, (J) enhance recovery and grade, and (4) affect the velocity (kinetics) of the separation process. These chemicals are classified based on utili2ation collector, frother, auxiUary reagent, or based on reagent chemistry polar, nonpolar, and anionic, cationic, nonionic, and amphoteric. The active groups of the reagent molecules are typically carboxylates, xanthates, sulfates or sulfonates, and ammonium salts. 

Sulfide Ores ores. In the Zairian ores, cobalt sulfide as carroUite is mixed with chalcopyrite and chalcocite [21112-20-9]. For processing, the ore is finely ground and the sulfides are separated by flotation (qv) using frothers. The resulting products are leached with dilute sulfuric acid to give a copper—cobalt concentrate that is then used as a charge in an electrolytic cell to remove the copper. Because the electrolyte becomes enriched with cobalt, solution from the copper circuit is added to maintain a desirable copper concentration level. After several more steps to remove copper, iron, and aluminum, the solution is treated with milk of lime to precipitate the cobalt as the hydroxide. 

Primary molybdenum ores at a relatively coarse grind go through an initial stage of flotation. At Climax Molybdenum, for example, the first separation is made at 35% + 100 mesh. The flotation system uses vapour oil as a promoter and pine oil as frother. A sulfonated coconut oil (syntax) is added to the system to emulsify the oil. 

Flotation of pyrite using either ethyl xanthate or potassium butyl xanthate as collector. Glycol frother is also usually employed in this separation. 

When the sulfide ore carroUite, CuS C02S3, is the starting material, first sulfides are separated by flotation with frothers. Various flotation processes are applied. The products are then treated with dilute sulfuric acid producing a solution known as copper-cobalt concentrate. This solution is then electrolyzed to remove copper. After the removal of copper, the solution is treated with calcium hydroxide to precipitate cobalt as hydroxide. Cobalt hydroxide is filtered out and separated from other impurities. Pure cobalt hydroxide then is dissolved in sulfuric acid and the solution is again electrolyzed. Electrolysis deposits metallic cobalt on the cathode. 

The common gangue material quartz (silica) is naturally hydrophilic and can be easily separated in this way from hydrophobic materials such as talc, molybdenite, metal sulphides and some types of coal. Minerals which are hydrophilic can usually be made hydrophobic by adding surfactant (referred to as an activator ) to the solution which selectively adsorbs on the required grains. For example, cationic surfactants (e.g. CTAB) will adsorb onto most negatively charged surfaces whereas anionic surfactants (e.g. SDS) will not. Optimum flotation conditions are usually obtained by experiment using a model test cell called a Hallimond tube . In addition to activator compounds, frothers which are also surfactants are added to stabilize the foam produced at the top of the flotation chamber. Mixtures of non-ionic and ionic surfactant molecules make the best frothers. As examples of the remarkable efficiency of the process, only 45 g of collector and 35 g of frother are required to float 1 ton of quartz and only 30 g of collector will separate 3 tons of sulphide ore. 

Hydrotalcite is often too fine grained to produce treatment columns with suitable permeability. As an alternative, the sorbent may be mixed with contaminated water in a tank (Lazaridis et al, 2002). The spent sorbent is then separated from the treated water by flocculation, flotation, or other separation methods (see Section 7.2.4). Lazaridis et al. (2002) investigated the use of surfactants with dispersed-air flotation to separate spent hydrotalcites from treated water. At ionic strengths of 0.1 M using KNO3, effective flotation and separation could be obtained by using a mixture of dodecylpyridinium chloride, sodium dodecylhydrogen sulfate, and a cetyltrimethyl ammonium bromide frother (Lazaridis et al., 2002,322,323). 

Froth flotation is an application of foams that is used to separate mineral components from each other based on their having different surface properties, typically their wettability and surface electrical charge. For example, froth flotation is the classic process used to separate copper from lead ore. The process involves having hydrophobic particles attach to gas bubbles which rise through a turbulent suspension to create a surface foam called a froth. Figure 10.2 shows an illustration of a mechanical flotation cell. This is the classic flotation device [53,91,625], First, the flotation feed particles are well dispersed into a particle suspension. Together with chemical flotation aids, such as collectors and frothers, this constitutes what is called the flotation pulp. In a mechanical flotation cell, air is fed in the form of fine bubbles and introduced near the impeller (see Figure 10.2). In addition to mechanical flotation cells, there are also pneumatic cells and cyclone flotation cells. Pneumatic... 

Flotation is commonly employed for beneficiation of minerals. Frothers are added to the vigorously agitated mixture. Air bubbles attach to the collector-mineral particles, which then rise and are removed along with the froth or foam. The valuable components are separated from the waste or gangue by preferential floating of one of the components to the top while the other sinks to the bottom. 

Condition the solids to alter the wettability of the mineral and the gangue. The fundamental surface wettability for sulfide ores is different from oxides, silicates, and salt-type minerals. pH is a critical variable. Typical conditioning chemical additions include collector about 0.01 to 0.1 kg/Mg solids frother about 0.01 to 0.5 kg/Mg solids activator about 1 to 4 kg/Mg solids depressant about 0.02 to 2 kg/Mg solids. Allow 6-min contact for conditioning. Bubble size about 1000 pm. Flotation rate constant is 0.2 to 1 min sink rate constant is 0.005 min-. Flotation cells mechanical cell for fast float, sequential separation, and relatively coarse particle diameter 1.6 to 2.4 kW/m cell volnme. Pneumatic cell for relatively dilute feed concentrations and smaller particle diameters. Air blower 0.5 kW/m cell volume. Typical solids throughput 0.4 to 0.8 kg/s m feed concentration 10 to 40% w/w. Air escape velocity 0.02 m/s. Float times 6 to 20 min. Feed concentration to rongher or scavenger 30% w/w to cleaner 10% w/w. 

Flotation has been used for more than 100 years to separate sulphides, oxides and other salts from ores, as well as to obtain phosphates, barite, chromite and other materials. Up to 90% of copper, lead, nickel, zinc are extracted using flotation in the USA [152 - 153]. In Russia, flotation is widely used to additionally obtain apatite, barite and phosphates. Flotation of iron oxides is not used in practise yet, but the number of experiments carried out in this direction is rather large. The main physicochemical principles of flotation have been discussed above [59 -74]. Here, only some practical problems will be discussed. In [153], requirements are pointed out which apply to three-phase flotation foams, and the main components of the process are defined, i.e. surfactant - collector surfactant - frother activator, depressants, colligend, gangue. The peculiarities of flotation and foam separation in batch and continuous modes are outlined as well as the structure and properties of the main types of flotation agents described. As surfaces of the majority of mineral particles are hydrophilic in nature, hydrophobisation of particles is necessary for a selective separation. 

In addition to collectors, a number of other chemical additives ate used in flotatioa to aid separation by this process. They include frothers, activators, depressants, deactivalots, flooculanis, and diqrersants. 

Mineral Formula pH regulator Depressant ActivahM Main collector Frother Assist collector Assist agent fcM separation... 

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