The Magnitude and Significance of Flotation in the Mineral Industries of The United States

No metallurgical process developed in the 20th century compares with froth flotation in its effect on the mineral industry. Processes like gravity - concentration, amalgamation, and pyrometallurgical reduction are of ancient origin; others like cyanidation and electrolytic reduction were well established by 1900. Such metallurgical processes as heavy-media separation, ion-exchange, and solvent extraction belong to this century, but their influence is small compared with froth flotation. Data collected by the U. S. Bureau of Mines* in a canvass of 202 froth flotation plants reveal that, in 1960, 198- million tons of material was treated to recover 20-million tons of concentrates which contained approximately $1 billion in recoverable products. SIGNIFICANCE OF FLOTATION Froth flotation as described in this chapter refers to a wet process for separating properly ground mineral particles into two or more products. It involves the separation of mineral particles from each other in a liquid pulp by means of air bubbles. Finely crushed ore is agitated in water with the addition of air or other gases. Various chemicals and oils are added to cause the selected mineral particles to attach themselves to the air or gas bubbles. These bubbles, carrying the mineral particles, rise to the surface where they are removed in a froth, while the other particles remain suspended in the pulp. The earliest flotation divided the raw material into two products: a bulk concentrate that was removed as a froth and a tailing that remained in the flotation machine. The froth usually contained the valuable constituents. The successful application of such a process depended on the recovery of a single concentrate from which one or more valuable constituents could be recovered by a chemical or smelting process. With the advance of the art, however, the principle of selective flotation, by which two or more relatively pure products could be recovered from complex raw materials, was evolved. Other chapters in this volume describe the developments during the last 50