Design of Jet Diffuser Flotation Column

PROCEEDINGS OF 14th INTERNATIONAL
MINERAL PROCESSING SYMPOSIUM
October 15 - 17, 2014
Kuşadası – Turkey
Mineral Processing in Everything !
Editors
Üner İPEKOĞLU, Vedat ARSLAN and Sezai ŞEN
Dokuz Eylül University, Department of Mining Engineering
Turkish Mining Development Foundation
Kuşadası - Turkey
October 15 - 17, 2014
Website: www.imps2014.org
The proceedings are also available in USB flash memory.
Publisher
: Turkish Mining Development Foundation
ISBN
: 978-975-441-436-3
Edited by
: Üner İPEKOĞLU, Vedat ARSLAN, Sezai ŞEN
Printing Layout
: Sezai ŞEN, Baran TUFAN
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: Üç Adım Matbaa-Reklam Ltd. Şti. Izmir/Turkey
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ORGANIZING COMMITTEE
Symposium Presidents
Dr. Nevzat KAVAKLI
Mustafa AKTAŞ
Deputy Undersecretary, Ministry of Energy &
Natural Resources
General Director of The Turkish Coal Enterprises
Symposium Chair
Prof. Dr.Üner İPEKOĞLU
Dokuz Eylül University
Institutional Advisory Committee (in alphabetical order)
Ayhan YÜKSEL
President, Chamber of Mining Engineers of Turkey
Burhan İNAN
G. Director of The Turkish Hard Coal Enterprises
Prof. Dr. Ercüment YALÇIN
Dean, Faculty of Eng., Dokuz Eylül University
Prof. Dr. Güven ÖNAL
President, Turkish Mining Development Foundation
Prof. Dr. Mehmet FÜZÜN
Rector, Dokuz Eylül University
Mehmet Hamdi YILDIRIM
G. Director of The Mining Affairs
M. Ümit AKDUR
Turkish Gold Miners Association
Mehmet ÜZER
G. Director, Mineral Res. & Expl.
Dr. Orhan YILMAZ
General Manager, Eti Mine Works
Prof. Dr. Turan BATAR
President, Mineral Processing Society of Turkey
Industrial Advisory Committee (in alphabetical order)
Ahmet TEZCAN
Eti Copper Inc.
Alp GÜRKAN
Soma Coal Inc.
Arif KURTEL
İmbat Mining Inc
Bülent TÜFEKÇİOĞLU
Tüfekçioğlu Rubber, Mac. and Min. Ind. Co.
David A. BICKFORD
Tüprag Metal Mining Industry & Trade
Ergun TUNCER
Bilfer Mining Inc.
İsmet SİVRİOĞLU
Koza Gold Operations Company
Jeremy SHORT
Anagold Mining Inc.
Murat Zekeriya AYDIN
Kolin Construction
Oktay Rıfat KUŞOĞLU
Coal Enterprises Inc.
Özlem ÖNAL
Dedeman Mining
Sabri KARAHAN
DAMA Engineering Co.
Savaş ŞAHIN
Demir Export Inc.
Serdar NİŞLİ
Aksa Enerji
Şeyda ÇAĞLAYAN
Türk Maadin Inc.
STEERING COMMITTEE
Prof. Dr. A. Üner İPEKOĞLU
Prof. Dr. Hüseyin ÖZDAĞ
Prof. Dr. Güven ÖNAL
Prof. Dr. Ümit ATALAY
Prof. Dr. Gülhan ÖZBAYOĞLU
Prof. Dr. Özcan GÜLSOY
Prof. Dr. Çetin HOŞTEN
Prof. Dr. Levent ERGÜN
Prof. Dr. A. İhsan AROL
Prof. Dr. Volkan BOZKURT
Prof. Dr. Gündüz ATEŞOK
Prof. Dr. Neşet ACARKAN
HONORARY MEMBERS
Prof. Dr. M. Zeki DOĞAN
Prof. Dr. Ali AKAR
Dr. H. Avni YAZAN
Prof. Dr. Yaşar ÇILINGIR
Prof. Dr. Suna ATAK
Prof. Dr. Halim DEMIREL
Prof. Dr. Erdoğan YIĞIT
Prof. Dr. İrfan BAYRAKTAR
Prof. Dr. Mevlüt KEMAL
Prof. Dr. Mehmet CANBAZOĞLU
Sabri KARAHAN
LOCAL COMMITTEE (Dokuz Eylül University)
Prof. Dr. Vedat ARSLAN
Prof. Dr. İlknur CÖCEN
Prof. Dr. Erol KAYA
Prof. Dr. Mehmet TANRIVERDİ
Assoc. Prof. Dr. Tayfun ÇİÇEK
Assoc. Prof. Dr. Abdullah SEYRANKAYA
Assoc. Prof. Dr. Ufuk MALAYOĞLU
Assoc. Prof. Dr. Sezai ŞEN
Assist. Prof. Dr. Hatice YILMAZ
Lecturer Dr. Özge GÖK
Lecturer Dr. Baran TUFAN
Resc. Assist. Dr. Erkan GÜLER
Resc. Assist. Dr. Gül Akar ŞEN
Resc. Assist. Dr. Vedat Taylan ENGİN
Resc. Assist. Ebru TUFAN
Resc. Assist. Çağrı ÇERİK
Resc. Assist. Ümit HORASAN
Evaluation Of Mayer Curve Validity On The Tki-Geli Coal At
The Washery Plant (Muğla, Turkey) ............................................................................ 151
Z. Altınçelep, O. Bayat
Evaluation Of Ömerler Coal Washing Plant Performance Using
Density Tracers ................................................................................................................ 157
E.C. Orhan, Ö. Gülsoy, L. Ergün, M. Can, A. Özer
Evaluation Of Tki Ömerler Coal Washery ................................................................... 167
D. Kalyon, E. Alpay, M. Gülsoy, A. Tefek
Experimentation On Beneficiation Of Oxidized Zinc Ore
By Gravitational Methods .............................................................................................. 175
E. Tufan, E.İ. Cöcen, E. Güler, A. Seyrankaya, B. Tufan
Investigation Of The Enrichment Possibilities Of Tekcrom Mining
Company Tailings ............................................................................................................ 183
H. Vapur, S. Top, S. Demirci, Y. Develi, A.A. Sirkeci
Production Of High Quality DRI Pellet Feed Suitable For Sponge
Iron Production ............................................................................................................... 191
T. Çiçek, H. Cengizler, M. Tanrıverdi, E.E. Özçelik, H.İ. Çiçen
The Enrichment Of Chromite Ores In Finer Sizes By Using Gravity
Separation Methods......................................................................................................... 201
Ş.B. Aydın, M. Özer, A.E. Yüce
The Evaluation Of Low Quality Mugla-Yatagan Region Lignites As
Power Plant Fuel.............................................................................................................. 205
S. Koca, A. Erdem, A. Gülmez, O. Altun, Z. Olgun, A. Gitmez
The Treatment Of High Grade Chromium Ores In Albania ...................................... 209
G. Demi
Utilization Of Copper Slag As Heavy Media In Coal Washing .................................. 215
S. Kantarcı, İ. Alp
FLOTATION & SURFACE CHEMISTRY
An Overview Of Bubble Size Measurement In Flotation And Related
Automation Systems ........................................................................................................ 223
C.N. Bozbay, O. Kangal
Apatite’s Froth Flotation Using Pequi’s Yellow Pulp Oil As Collector ..................... 231
T.C. Silva, A.C. Silva, E.M.S. Silva, B.E. Alves
Application Of Work Plan Factorial For Flotation Of
Phosphate Of Djebel-Onk ............................................................................................... 239
B. Abdellali
Beneficiation Of Görgü (Malatya) Complex Lead-Zinc Ores By Flotation ............... 247
H. Sis, M. Coşkun, E. Tenekecigil, M. Birinci
Design Of Jet Diffuser Flotation Column ...................................................................... 255
B. Öteyaka, O. Şahbaz, A. Uçar, K. Bilir, H. Gürsoy
Proceedings of 14th International Mineral Processing Symposium – Kuşadası, Turkey, 2014
DESIGN OF JET DIFFUSER FLOTATION COLUMN
Bahri Öteyaka 1, Oktay Şahbaz 2,a, Ali Uçar2, Kemal Bilir1 and Hakan Gürsoy1
1. Department of Mining Engineering, Osmangazi University, Eskisehir, Turkey
2. Department of Mining Engineering, Dumlupinar University, Kutahya, Turkey
a. Corresponding author (oktay.sahbaz@dpu.edu.tr)
ABSTRACT: Having an essential change in the downcomer, Jet diffuser flotation column
(JDFC) is a device which resembles Jameson flotation cell (JC) in terms of general
operational principles. By taking into account the hydrodynamic and fluid mechanics
principles (Şahbaz et al., 2013) downcomer was changed as a diffuser, therefore turbulence
at the end of the downcomer was reduced to provide better aggregate stability and
homogeneous dissipation of the bubbles in the separation tank.
According to experimental results carried out in pilot scale JDFC, not only higher flotation
performance comparing with Jameson cell was obtained specifically for coarse particles,
but also quiescent froth layer was acquired with the given conditions. In these tests,
vertical pipe of JDFC having inlet diameter of 6 cm and outlet diameter of 11.5, 12.5 and
13.5 cm was used with separation tank having the diameter of 39 cm. By using the data,
pilot scale JDFC having 4100 mm vertical pipe integrated with separation tank was
produced and flotation tests were carried out by using the talc. Finally, the talc recovery
obtained as about 90% by the use of JDFC for the particle size of 360 µm.
1. INTRODUCTION
Successful flotation separation depends
on the interrelation among the various
physical, chemical and mechanical
factors in the system [Fuerstenau, 1999].
One of the most important parameters
which affect the flotation performance is
particle size. In conventional flotation
cells, flotation performance for coarse
and fine grained minerals is generally
low. Problem of the coarse particle
flotation is turbulence, while the problem
is low collision probability for fine
particle. The possible increase of
collision depends on the presence of fine
air bubble (smaller than 1 mm) [Öteyaka,
1993]. Therefore; Jameson cell has
significant flotation performance on fine
particles [Jameson, 1999] due to the very
fine bubble production (200-1000 µm)
[Şahbaz,
2010].
However,
the
performance of the device starts to
decrease with the feeding the coarser
particle [Cowburn et al., 2006; Şahbaz,
2010]. In some applications, such as coal
flotation, the particle size in the feed is
sometimes greater than 0.5 mm
[Cowburn et al., 2006] and it causes
insufficient flotation in the Jameson cell
[Şahbaz et al, 2013]. It is necessary to
modify the Jameson cell to increase the
application range of it in terms of particle
size.
In this study, new flotation device can be
called as Jet Diffuser Flotation Column
(JDFC) was designed by using the
mathematical model improved by Şahbaz
(2010) and his experimental studies. The
investigation was performed to determine
the performance of this new column by
the use of talc mineral.
2. DESIGN OF THE JDFC
Jet diffuser flotation column (JDFC) is a
flotation device resembles Jameson cell
in terms of general operational principles,
but it has significant difference structural
points of view. This difference is a
radical change in the downcomer to
255
supply an increase of performance of the
cell for the both coarse and fine particles.
JDFC is a device whose pre-designation
was performed resulting from the
experimental and theoretical studies were
performed by Şahbaz (2010) and Şahbaz
et al (2013). The main difference in the
downcomer is the shape of the
downcomer outlet which is diffuser.
Mathematical calculation and shape of
the outlet was performed by the use of
fluid mechanic principles to provide
uniform flow as seen in (Figure 1-I). The
experimental study with this new design
was carried out in two-phase system to
confirm the theoretical studies with real
operation.
diameter was used. In the light of this
previous study, the new JDFC in pilot
scale, in which height, inlet and outlet
diameter were 4100 mm,60 mm and 115
mm respectively, was designed and set up
in the Mining Engineering Laboratory of
Eskisehir Osmangazi University-Turkey
(Figure 2). The nozzle used in this design
was 10 mm.
Figure 2: Jet diffuser flotation column
(JDFC)
Figure 1. Laminar and turbulent flow in
diffusers (White, 2005)
The main aim of the new design of
downcomer is to provide quiescent flow
and homogenous dissipation of bubbles
and decrease the turbulence occurring at
the separation tank. It is thought that this
supplies higher performance for flotation
of both coarse and fine particles (Şahbaz
2010, Şahbaz et al 2013).
The newly designed device, JDFC, had
better performance comparing with
Jameson cell according to experimental
results obtained by Şahbaz (2010). In this
study (Şahbaz, 2010) JDFC having 180
cm height, 2 cm inlet and 3.5 cm outlet
256
3. EXPERIMENTAL
The present experimental study was
carried out to determine the performance
of the JDFC. The convenient level of
operational parameters was determined
by using talc which was naturally
hydrophobic. All the flows were
controlled by feed, tailing and washing
water flow meters. Feeding was
performed from the tank having capacity
of 150 L, while washing water tank had
130 L capacity. The size and level of
parameters used in the experiments were
given in (Table 1).
Proceedings of 14th International Mineral Processing Symposium – Kuşadası, Turkey, 2014
Table 1:
Parameter
Value
Downcomer
Nozzle diameter
Hold-up
4100 mm
10 mm
51.4 % (Ɛ= 0.322y3 –
Particle size
400-300 μm, -300+
212 μm, -212 + 106
μm and -106 + 20 μm
0.5 – 1.5 mm (Figure 3)
2.5%
10 min
15 (for +106 μm)
and
20 ppm
71L/min
56.8 L/min
0.80
Bubble size
Solid ratio (%)
Flotation time
Frother(AF65)
1.07y2 + 1.29y, (y = APR,
Harbort et al, 2002)
Pulp flow
Air flow
Air to pulp ratio
(APR)
Superficial
gas 0.79 cm/s
velocity
60 cm
Downcomer
plunging length
110 kPa (Figure 3)
Feeding pressure
In the experiments, firstly levels of the
flows (feed, tailing and washing water)
were fixed with water + frother mixture.
System was operated with bypass. In the
experiments, conditions were fixed for
both JDFC and Jameson cell.
Figure 3. Bubble size, pulp flow, feeding
pressure and airflow
tailing stream (Şahbaz et al., 2008). It is
estimated using the expression given by
Mohanty and Honaker (1999).
Bias factor = (Qw-QF)/Qww, where Qw is
the flow rate of tailing, QF is flow rate of
feed and Qww is the flow rate of wash
water.
Figure 4: Comparison of talc recovery
with positive bias by using JDFC and JC
It can be stated from the Figure 5, the
recovery of talc in both cell increases
with negative bias. For all conditions
(negative and positive bias) JDFC had
higher performance than Jameson cell for
the given conditions (Figure 4 and 5).
When the feeding size increased to 250
µm from the 50 µm in bias positive case,
the recovery started to decrease to 75%
from the 85% for Jameson cell (Figure 5).
However, for the JDFC, the recovery
increase was observed. Similar trend was
obtained for bias negative case, as well.
The main reason for this increase is that
the increase of the outlet size of
downcomer provides turbulence decrease
at the separation tank.
4. REULST AND DISCUSSION
The results of the experiments carried out
to compare the JDFC to Jameson cell are
shown in (Figure 4 and 5). (Figure 4)
includes the result of talc recovery in bias
positive while (Figure 5) includes
negative bias results. Bias factor is
defined by the fraction of the wash water
flowing downward and reporting to
257
higher recovery for coarse particle size
fractions while the recovery was higher
with diffuser having diameter of 11.5 cm
for fine particles (50 µm).
Figure 5: Comparison of talc recovery
with negative bias by using JDFC and JC
According to (Figure 4 and 5), JDFC has
significant performance for coarse
particles and negative bias condition
improves the recovery. The increase at
the outlet of the downcomer provides
turbulence decrease at the discharge point
to separation tank and supplies quiescent
flotation condition (Şahbaz, 2013). Total
velocity gradient referred as turbulence
decreases theoretically at the end of the
downcomer due to the increase of outlet
diameter according to Şahbaz et al.
(2013). This theoretical determination
also corrected with experimental works.
Plunging length of the aggregate
discharging
from
downcomer
to
separation tank was about 10-12 cm in
JC, while it was 2-3 cm in the JDFC. The
advantage of the negative bias is to
prevent coarse particle loss due to the
froth zone acting as barrier for that
particle [Öteyaka,1993; Öteyaka and Soto
1995].
To determine the effect of diffuser
diameter on flotation recovery series of
experiments were carried out by three
different JDFC having the diffuser
diameter of 11.5 cm, 12.5 cm and 13.5
cm. Figure 6 express the results of effect
of diffuser diameter on flotation recovery
of talc. According to Figure 6; the greater
the diffuser outlet diameter provided the
258
Figure 6: Effect of diffuser diameter on
flotation recovery
5. CONCLUSION
In the study, the newly designed flotation
device called as Jet Diffuser Flotation
Column was presented. The experimental
and theoretical studies showed that the
diameter of nozzle, downcomer and
separation tank were suitable for
quiescent flotation condition and less
turbulence. According to results;
 New design provides higher recovery
for the coarse particles due to diffuser
structure of the new downcomer
contributes to turbulence decrease.
 Diffuser structure prevented the
fluctuation of froth zone because of
homogenous dispersion of bubbles in
tank.
 The height of downcomer can be
shortened without any recovery loss.
 The studies have been started to
perform to determine the performance
of the JFDC by using the real ore from
different plants, and the first results
are positive.
 To compare the JDFC with other
devices it is necessary to perform
industrial scale experiments.
The device can be made with stainless
steel and apply to the industry. The
higher capacity of JDFC with 8-10
Proceedings of 14th International Mineral Processing Symposium – Kuşadası, Turkey, 2014
downcomer can be
industrial application.
established
for
Acknowledgement: Authors acknowledge
the Eskişehir Osmangazi University
Scientific Research Project Unit for
providing financial support. The authors
are also thankful to Prof.Dr. Graeme J.
Jameson for his help for designing the
laboratory scale Jameson cell which is the
basic device and source of inspiration of
our new design.
REFERENCES
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coal particles in Jameson cell.Miner. Eng. 19,
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Harbort, G.J., Manlapig, E.V., DeBono, S.K.,
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259

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