Mutah University

Faculty of Engineering
Department of Chemical Engineering

Unit Operations Lab 0404533

A Report About Batch Froth Flotation

Experiment no. 1

Instructors: Prof. Dr. Nabeel Al Jarrah

Eng. Saja Al Awasa

Date of submission: 24th of March 2025

Student Name Student Number
Arwa Musallam Lassassmeh 120210414019
Rayan Othman Al Masri 120210414078
Ro’a Baker Al Btoush 120210414050
Sarah Muneer Abu Alkhair 120210414081
• Abstract
Froth flotation is a physicochemical method used in mineral processing to
separate valuable minerals from gangue based on differences in surface
properties. In this experiment, the separation of phosphate rock from silica
impurities was investigated using a nonpolar collector and air bubbles.
Phosphate particles, made hydrophobic by the collector, attached to the
rising bubbles and formed a froth layer at the surface, allowing them to be
skimmed off, while hydrophilic silica particles remained in the aqueous
phase. This process effectively demonstrated how surface chemistry and
flotation reagents influence the selective separation of minerals in an
industrially relevant scenario.

• Objectives
1. Demonstrate how surface properties are utilized to separate different solid
materials using a bubble-assisted technique.
2. Understand the fundamental principles of the froth flotation process.
3. Observe the separation of valuable minerals from gangue minerals
through practical application.
• Introduction

Froth flotation is a key process in mineral processing that is used to separate

valuable minerals from waste materials (gangue) based on differences in
how they interact with water and air. It is a physicochemical method that
relies on the fact that some minerals are water-repellent (hydrophobic) while
others are water-attracting (hydrophilic). In this process, reagents such as
collectors, frothers, depressants, and pH modifiers are added to a slurry of
crushed ore and water to enhance these surface differences.

Air is bubbled through the slurry, and the hydrophobic mineral particles
attach to the bubbles and float to the surface, forming a froth. This froth,
which contains the concentrated valuable minerals, is skimmed off, while the
hydrophilic gangue particles sink to the bottom as tailings. By adjusting
factors like reagent concentration, pH, and froth stability, the separation
process can be optimized for higher recovery rates.

Froth flotation is widely used in industries such as mining, metallurgy, and

recycling. It is especially important in the extraction of copper, lead, zinc,
and nickel from their sulphide ores. It is also used in the paper industry to
remove ink from recycled paper and in wastewater treatment to remove oils
and other contaminants.

This experiment demonstrates the principles of froth flotation and helps

students understand how process variables affect mineral recovery in real-
world applications.
• Theory
Froth flotation is a physicochemical separation process widely used in the
beneficiation of finely disseminated ores. It is based on the differences in
surface properties, particularly wettability, of mineral particles. The process
is commonly applied to phosphate rock to remove silica (SiO₂) and other
impurities, enhancing the phosphate content (P₂O₅) in the final concentrate.
Phosphate ores, such as apatite (Ca5(PO4)3 (F, Cl,OH), are often associated
with gangue minerals like silica. Since phosphate particles exhibit
hydrophobic behaviour under certain chemical conditions and silica remains
hydrophilic, froth flotation provides an effective means of separation.
To perform flotation, the ore is first ground and mixed with water to form a
pulp, which is a suspension of solid particles in water. Various reagents are
then introduced to modify the surface characteristics of minerals:
• Collectors: Organic compounds that adsorb onto the mineral surface,
increasing its hydrophobicity. For phosphate flotation, fatty acids are
commonly used as collectors.
• Frothers: Surfactants that stabilize the froth formed on the slurry surface,
allowing the hydrophobic particles to be collected.
• Modifiers: Chemicals (e.g., lime or sulfuric acid) that control the pH of
the pulp and enhance the selectivity of collectors.
• Activator: These reagents activate the mineral surface towards the action
of the collectors by enhancing their chemical properties
• Depressants: Reagents that prevent unwanted minerals, such as silica,
from attaching to air bubbles.

Air is introduced into the pulp through

mechanical agitation or sparging.
Hydrophobic particles adhere to the rising
air bubbles and accumulate in the froth
layer, which is removed from the top.
Meanwhile, hydrophilic particles remain
in the slurry and are discarded as tailings.
Froth flotation is primarily a physical separation process that uses chemical
reagents to enhance selectivity. It is widely used not only in phosphate
beneficiation but also in the treatment of sulphide ores (e.g., galena (PbS),
sphalerite (ZnS), and chalcopyrite (CuFeS₂)), oxide ores, and industrial
minerals.
- Factors Affecting the Froth Flotation Process
1. Particle Size:
Optimum particle size ensures effective bubble-particle contact.
Extremely fine particles may slime and prevent attachment, while coarse
particles may detach easily due to gravity.
2. Pulp Density:
Affects froth stability and recovery. High pulp density can hinder bubble
rise and reduce separation efficiency; low density may reduce throughput.
3. pH of the Pulp:
Controls the charge on mineral surfaces and the ionization of reagents.
For phosphate flotation, acidic pH conditions are often required to
improve separation.
4. Reagent Type and Dosage:
Overuse or improper selection of reagents can lead to poor selectivity or
reagent wastage. Optimization is essential for cost-effective separation.
5. Air Flow Rate and Bubble Size:
Fine bubbles provide a larger surface area for attachment and improve
recovery. Air flow must be controlled to maintain froth stability.
6. Water Quality:
The presence of dissolved ions such as Ca²⁺ or Mg²⁺ can interfere with
reagent action and mineral surface properties.

- Applications in Industry
Froth flotation is applied across various industries. In phosphate
beneficiation, it removes silica and carbonates from apatite ores. It’s also
used to separate copper, lead, and zinc in sulphide ore treatment. For
industrial minerals, it purifies feldspar, barite, and fluorspar. Additionally,
it aids in wastewater treatment by separating oil and suspended solids.
 • Apparatus & Materials
- Apparatus

The froth flotation apparatus consists of several key components, each playing a
critical role in the separation process. The labeled image above identifies the
following parts:
1. Cell
The flotation process takes place in the cell, which contains the slurry.
It holds a water-based mixture of phosphate and silica particles.
2. Impeller
The impeller rotates to stir the slurry and distribute air bubbles evenly.
It ensures proper mixing of reagents with the mineral particles.
3. Air Flow System
This system injects air into the cell to produce fine bubbles.
Hydrophobic particles attach to the bubbles and float to the surface.
4. Control Panel (Speed Control & Switches)
It controls the impeller speed for effective agitation.

- Materials
1. Water & Mineral samples (ore – phosphate rock & silica).
2. Frothing Reagents (collectors, frothers, pH modifiers, etc.).
3. Weighing balance, a graduated glass pipette and a Graduated cylinder.
4. Personal Protective Equipment: Safety goggles, gloves and a lab coat.
• Procedure

1. Preparation of Materials
Gather all the required equipment and materials for the froth flotation
experiment, including the flotation cell, reagents, weighing balance, and
mineral samples.

2. Sample Preparation
Weigh approximately 150 grams of the mineral sample (phosphate and
silica mixture). If necessary, grind the sample to obtain a fine powder to
enhance flotation efficiency.

3. Pulp Formation
Transfer the prepared sample into the flotation cell. Add a predetermined
volume of water to form a uniform pulp suitable for flotation.
4. Equipment Setup
Ensure the flotation cell is properly assembled and ready for operation.
Activate the agitation mechanism to generate turbulent conditions within
the cell.

5. Reagent Addition and Conditioning

Add approximately 15 ml of the flotation reagents (including collectors
and frothers) to the pulp according to recommended dosages. Continue
stirring to allow uniform dispersion of reagents and to promote surface
modification of the mineral particles.
6. Froth Formation and Separation
Observe the formation of froth on the surface as air is entrained.
Hydrophobic phosphate particles will attach to the bubbles and rise with
the froth, while hydrophilic silica particles remain in the suspension.

7. Conditioning Time
Maintain agitation for a specified duration to ensure sufficient interaction
between reagents and mineral particles and to optimize the separation
process.
• Safety Precautions

- Wear Appropriate Personal Protective Equipment (PPE):

Always wear a lab coat, chemical-resistant gloves, and safety goggles
during the experiment. This protects you from chemical splashes and
contact with potentially harmful reagents.

- Handle Chemicals with Care:

Use flotation reagents carefully, avoiding skin contact and inhalation. Work
under a fume hood when using volatile or odorous substances.

- Ensure Proper Ventilation:

Conduct the experiment in a well-ventilated lab to prevent the buildup of
fumes. This reduces the risk of inhaling harmful vapours.

- Operate Electrical Equipment Safely:

Make sure all flotation equipment is dry and properly connected before
use. Avoid touching electrical parts with wet hands to prevent shock.

- Know Emergency Procedures:

Familiarize yourself with the location of the nearest eye wash station,
safety shower, and fire extinguisher. Be prepared to act quickly in case of
an accident.

• Results
In the flotation process used for phosphate ore beneficiation, selective
separation is achieved by exploiting differences in surface chemistry. The
phosphate rock particles become coated with a nonpolar collector, which
promotes their attachment to introduced air bubbles within the slurry. As the
bubbles rise, the phosphate particles adhere to them and accumulate at the
surface, forming a froth layer. This froth, which is enriched with phosphate
minerals, is then removed by skimming. On the other hand, the undesired
gangue material—primarily silica—remains hydrophilic and does not
interact with the collector. As a result, it stays dispersed in the aqueous phase
and is effectively left behind, allowing for efficient separation of phosphate
from the silica impurities.
• Analysis & Discussion
The flotation experiment revealed clear separation between phosphate and
silica based on surface characteristics. The collector, being nonpolar,
preferentially adsorbed onto the phosphate particles, rendering them
hydrophobic. Upon the introduction of air into the slurry, these treated
phosphate particles adhered to the air bubbles and were transported to the
surface, forming a stable froth. This froth was rich in phosphate content,
confirming successful mineral recovery.
In contrast, the silica particles—naturally hydrophilic and unaffected by the
collector—remained dispersed in the slurry and settled as tailings. This
behaviour is in line with flotation theory, where the interaction of reagents
with mineral surfaces is key to selective separation.

- Several factors were crucial to the success of this separation:

a. Reagent addition: Proper dosage of collectors and frothers ensured
that enough phosphate was rendered hydrophobic while maintaining a
stable froth.

b. pH control: Slightly acidic conditions are favourable for phosphate

flotation, as they enhance collector effectiveness.

c. Air flow and agitation: Adequate bubble formation and mixing

helped improve collision chances between bubbles and hydrophobic
particles.

Moreover, the experimental procedure mirrored industrial applications,

especially in phosphate beneficiation where removing silica is essential for
producing high-grade phosphate concentrate. The reproducibility and clarity
of the results also highlighted the robustness of the flotation process.
• Conclusion
The experiment successfully demonstrated the principle of froth flotation as
a selective separation technique. Phosphate minerals were effectively floated
and collected as froth due to their modified hydrophobic nature, while silica
remained in the pulp due to its hydrophilic properties. This separation
highlights the importance of reagent selection, pH control, and bubble-
particle interactions. The froth flotation process remains a vital method in the
mineral industry, offering efficient recovery of valuable minerals and helping
optimize the quality of final products.

• References
- Fuerstenau, M. C., Jameson, G. J., & Yoon, R. H. (2007). Froth
Flotation: A Century of Innovation. SME.
- Wills, B. A., & Finch, J. (2015). Wills’ Mineral Processing Technology
(8th ed.). Elsevier.
- Bulatovic, S. M. (2007). Handbook of Flotation Reagents: Chemistry,
Theory and Practice. Elsevier.
- Sis, H., & Chander, S. (2003). Reagents used in the flotation of phosphate
ores: A critical review. Minerals Engineering, 16(7), 577–585.
- Kawatra, S. K., & Eisele, T. C. (2001). Coal Desulfurization: High-
efficiency preparation methods. Taylor & Francis.
- Zhang, Y., Liu, W., Yu, L., & Feng, Q. (2018). A review of phosphate
mineral processing using froth flotation. Minerals, 8(4), 132.