Scale-Up and Design of Large-Scale Flotation Equipment

With continuing pressure from stockholders not only to maintain but to increase mineral revenues, producers have increased plant capacity. Depressed mineral prices have accentuated the trend toward higher production rates to maintain consistent cash flow, and these same trends have promoted the development of large-scale processing equipment. In addition to the need to handle increased throughput, larger flotation equipment can result in decreased capital-equipment and operating costs. The development of larger column and conventional flotation equipment relies, in part, on suitable scale-up procedures. To properly scale-up large flotation cells and columns, certain constraints and design parameters must be taken into consideration, including velocities in the vessel, residence time, solids suspension, and lip loading. This paper will review the design constraints and scale-up criteria for WEMCO® flotation cells. Scale-up criteria are augmented with computational-fluid- dynamics analyses and high-speed imaging techniques, as well as multiple regresesion analysis of in-plant operational data.