YPT Flotation Cells

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Optimizing Mineral Processing Through Advanced Flotation Technology.

YPT Flotation Cells-FABCELLS

A flotation cell is a piece of mineral processing equipment used in the unit operation of Froth Flotation — a process by which finely ground ore particles are separated from gangue based on their hydrophobicity and ability to attach to gas bubbles in a liquid medium

During operation, the slurry (aqueous pulp of ore + water) is aerated (air introduced) to form bubbles; hydrophobic mineral particles attach to these bubbles, rise through the pulp and form a froth layer which is then removed as the concentrate, while hydrophilic gangue particles remain in the pulp and discharge as tailings.

Flotation cells may be of mechanical (agitator) type, column type, or high-intensity types and are arranged in banks or series in a flotation circuit.

Areas of Application

YPT Flotation Cells-FABCELLS are used widely in mineral processing and bulk materials handling,
  • Concentration of sulphide ores (e.g., copper, nickel, lead-zinc) where flotation remains one of the core unit operations.
  • Treatment of coal fine particles by flotation for recovery of clean coal and removal of ash/fines.
  • Recovery of fine minerals, mineral sands, heavy minerals, phosphate, and also in recycling and wastewater treatment applications (for example, removal of fine hydrophobic particles).
  • Many specialized flotation cells (e.g., columns, Jameson cells) are used for fine particle flotation, improving recovery of particles < 20 µm

Principle of Operation

The fundamental steps in YPT Flotation Cells-FABCELLS operation are:

  • Pulp preparation:

    Ore is ground to the required liberation size (typically 20-150 µm for many flotation circuits) and conditioned with reagents (collectors, frothers, modifiers) to render the target mineral hydrophobic.

  • Air introduction / bubble generation:

    In a mechanical cell, an impeller or diffuser introduces air bubbles and disperses them throughout the pulp. In a column cell, the slurry flows down while air rises up through spargers.

  • Particle–bubble attachment:

    Hydrophobic particles collide with air bubbles, attach, and are carried upward; hydrophilic particles remain in suspension or sink. The probability of attachment depends on bubble size, particle size, surface chemistry, and hydrodynamics.

  • Froth phase / collection:

    The bubble-particle complex rises to form a froth layer at the top. The froth is washed (in some designs) and removed via a launder as the concentrate. Tailings remain below.

  • Tailings discharge:

    Material which does not attach or which detaches is discharged as tailings. Re-cleaning or scavenging may follow to maximise recovery.

Innovative Air Distribution for Maximum Recovery

YPT Flotation Cells-FABCELLS Highlights

Reliable Under Pressure. Built for Production

Design Criteria

Particle size distribution:

The size range of the feed influences required residence time, bubble size and cell design. Cells must handle fine particles without excessive entrainment of gangue.

Air/volume and bubble size: :

Bubble size distribution and air flow rate influence the surface area of bubbles and hence the particle-bubble contact rate. Smaller bubbles increase surface area but may also cause higher energy consumption and turbulence.

Fre-volume and cell geometry

Tank depth, aspect ratio, cell volume, launder width, pulp depth, etc all influence hydrodynamics, residence time and recovery/grade tradeoffs.

Residence time:

Ensuring sufficient time for particles to attach to bubbles, float to the froth and be recovered is critical. The design must avoid short-circuiting or dead zones.

Reagent system and froth stability

Collector/frother selection and dosage, pH control, surfactants, and froth washing/de-entrainment all affect concentrate grade.

Hydraulics and mixing:

In mechanical cells, agitator design, diffuser geometry, and baffle arrangement matter; in column or Jameson cells, downcomer design or sparger design is critical.

Banking and circuit layout:

Multiple cells in series or parallel, with rougher, scavenger and cleaner functions, must be arranged considering feed conditions, plant capacity, grade/recovery targets.

Maintenance access and wear parts:

Wear liners, impellers, drive units must be accessible; cells often handle abrasive slurries.

Scale-up and modularity:

Many plants preference larger cells (e.g., 300 m³+ size) for lower footprint and reduced installation costs; however hydrodynamic similarity must be maintained.

Technical Specifications

Pulp depth:

~1.0 m – 3.0 mDepends on cell size & type

Bubble size targeted

~0.2 mm – 3.0 mmFine bubble for fine particle flotation

Air flow rate (m³/min per m²)

Varied by cell size/design-

Cell volume (m³)

Tens to hundreds of m³Larger cells reduce footprint

Recovery rate

Up to ~95%+ (application-dependent)Fine particle circuits may be lower

Concentrate grade / selectivity

Application specificTrade-off with recovery

Froth zone height:

~0.2 m – 1.5 mDeeper froth gives stable layer

Impeller speed/drive power

Depends on cell size/lumpsMechanical energy drives mixing

Important Considerations:

  • Entrainment vs true flotation:

    For fine particles (< 10 µm) entrainment (water carrying fines) may dominate and reduce selectivity; bubble size, froth washing and cell design are critical.

  • Hydrodynamic similarity/scale-up issues:

    When scaling from pilot to full size, geometric and dynamic factors (mixing, bubble dispersion) may not scale linearly; ensure proper data and modelling.

  • Bank arrangement and recycles:

    The arrangement of rougher, cleaner, recleaner cells and recycles (tailings return) significantly affects overall circuit performance; cell selection must consider circuit design.

  • Feed variability:

    Changes in grind size, pulp density, chemistry or temperature can affect flotation cell performance rapidly; instrumentation and control of flotation cells is becoming more important.

  • Footprint vs energy trade-off:

    Larger cells reduce number of installations and floor space but may increase power or mixing complexity; fine particle recovery cells may require taller columns (more height).

  • Maintenance and internals wear:

    Variable operation and abrasive slurries cause wear; impeller/diffuser replacement can be major downtime items; design for maintenance access.

  • Instrumentation & optimisation:

    Modern flotation uses sensors (froth cameras, bubble size monitors, digital control) to optimise cell performance — neglecting this may mean under-performance.