This paper studies the effect of the type and concentration of selected frothers, the gas flowrate, and the pore size of the porous frit on the bubble sizes (Sauter mean diameter, SMD) of bubbling flow produced in a micro-flotation cell, and the determination of bubble size distribution (BSD) in the presence of the frothers. The commercial frothers polypropylene glycols (PPG 200, 400, and 600), tri propylene glycol (BTPG), triethylene glycol (BTEG), dipropylene glycol (BDPG), and Methyl Isobutyl Carbinol (MIBC) were used in the present investigation. The frother concentration varied from 1 to 1000 ppm. The flow rate varied in the range of 25 to 100 cm3/min. The pore sizes of the frit were selected as 10–16 μm, 16–40 μm, and 40–100 μm. Each frother exhibited its own unique ability in preventing coalescence of the bubbles in the order of BTEG < BDPG < PPG 200 < MIBC < BTPG < PPG 400 < PPG 600. The factorial experiments established that the type of the frother and its concentration have a major effect on the size of the bubbles. The bubbles decreased twice their size when the frother concentration was increased from 1 ppm to 1000 ppm. The pore size of the frit is a significant factor as well. The size of the bubbles can be reduced from about 10% to about 40% by decreasing the pores from 40–100 μm to 10–16 μm but the level of this decrease depends on the type of the frother. The increase of the flowrate from 25 cm3/min to 100 cm3/min produced bubbles smaller by 25% to 50% for the case of BTEG, BDPG, PPG 200, MIBC, BTPG, while a minimum of the bubble sizes was reached for the case of PPG 400 and PPG 600, beyond which the bubbles enlarged their size. The BSD in the presence of PPG 600 varied around 0.3 mm, whereas BTEG gave a wider BSD which indicated that the type of frother affected the bubble production. Our analysis shows that the first group of frothers adsorbs instantly on the bubbles, once they leave the porous frit, thus reaching equilibrium. PPG 400 and PPG 600 adsorb significantly slower on the bubbles, possibly not reaching equilibrium during their resident time.
This work analyses the basic problems of the fine particles flotation and suggests new ways to overcome them. It is well accepted that the poor recovery of fine particles is due to the small collision rate between them and the bubbles due to the significant difference between their sizes. This common opinion is based on a theory, assuming in its first version a laminar regime, but later has been advanced to intermediate turbulence. It accepts that the particles are driven by the streamlines near the bubbles. In reality, the high turbulence in the flotation cells causes myriads of eddies with different sizes and speeds of the rotation driving both bubbles and particles. Yet, a theory accounting for high turbulence exists and states that the collision rate could be much higher. Therefore, we assumed that the problem consists of the low attachment efficiency of the fine particles. Basically, two problems could exist (i) to form a three-phase contact line (TPCL) the fine particle should achieve a certain minimal penetration into the bubble, requiring sufficient push force; (ii) a thin wetting film between the bubble and the particle forms, thus increasing the hydrodynamic resistance between them and making the induction time larger than the collision time. We assumed particles with contact angle θ = 80°, and established a lower size flotation limit of the particles depending mostly on the size of the bubbles, with which they collide. It spans in the range of Rp = 0.16 m to Rp = 0.40 m corresponding to bubbles size range of Rb = 50 m to Rb = 1000 m. Hence, thermodynamically the particle size fraction in the range of Rp = 0.2 m to Rp = 2 m are permitted to float but with small flotation rate due to the small difference between the total push force and maximal resistance force for formation of TPCL. The larger particles approach slowly the bubbles, thus exceeding the collision time. Therefore, most possibly the cavitation of the dissolved gas is the reason for their attachment to the bubbles. To help fine particles float better, the electrostatic attraction between bubbles and particles occurred and achieved about 92% recovery of fine silica particles for about 100 sec. The procedure increased moderately their hydrophobicity from θ ≈ 27.4° to θ ≈ 54.5°. Electrostatic attraction between bubbles and particles with practically no increase of the hydrophobicity of the silica particles ended in 47% recovery. All this is an indication of the high collision rate of the fine particles with the bubbles. Consequently, both, an increase in the hydrophobicity and the electrostatic attraction between particles and bubbles are key for good fine particle flotation. In addition, it was shown experimentally that the capillary pressure during collision affected significantly the attachment efficiency of the particles to the bubbles.
In recent years, most of the studies have been adapted to determine the optimum conditions for the flotation of very fine minerals. In this context, besides parameters such as particle size, morphology, and pH, the effects of frother type and its concentration present a very significant role in optimizing the flotation conditions. Therefore, the effects of froth stability during flotation can be considered one of the most important issues. Considering that knowledge in mind, in this study, the foamability and froth decay rate of six frothers (PPG200, PPG400, PPG600, BTEG, BTPG, and BDPG) having different molecular weights but similar polyglycol structures were investigated. In addition, methyl isobutyl carbinol (MIBC) which is a well-known frother type in the industry was also used as a reference. Additionally, a series of tests were also performed in the presence of collectors (Dodecylamine hydrochloride, DAH, and sodium oleate, NaOL) + frother mixtures to mimic the flotation conditions. The results of these tests indicated that the bubble size became finer at even low concentrations of PPG600 and PPG400 frothers. Following that, a significant decrease in bubble size was also found for the collector + frother mixtures system regardless of the concentration of the frothers.
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