A flotation machine is a critical piece of equipment in mineral beneficiation, particularly for separating copper (Cu) and hematite (Fe₂O₃) from ores. The process relies on differences in surface hydrophobicity to selectively recover valuable minerals.
Flotation of Copper and Hematite
1. Copper Flotation:
– Typically involves sulfide ores (e.g., chalcopyrite, bornite).
– Collectors like xanthates (e.g., potassium amyl xanthate) are used.
– Frothers (e.g., MIBC) help stabilize bubbles.
– pH modifiers (lime or sulfuric acid) optimize conditions (~pH 9-11 for sulfide flotation).
2. Hematite Flotation:
– Hematite is an iron oxide mineral and is usually processed via reverse flotation.
– Silica/gangue is floated while hematite remains in the underflow.
– Cationic collectors (e.g., amines) or anionic collectors (fatty acids with depressants like starch) may be used.
Types of Flotation Machines
1. Mechanical Flotation Cells:
– Agitated impellers generate bubbles (e.g., Denver, Wemco cells).
– Common in copper flotation circuits.
2. Column Flotation Cells:
– Used for cleaner stages, especially for hematite reverse flotation.
– Provides better selectivity with deep froth zones.
3. Jameson Cells & Pneumatic Flotation:
– High-intensity systems for fine particle recovery.
Key Considerations for Beneficiation
– Particle Size: Optimal grinding to liberate minerals (~150 µm for copper, finer for hematite).
– Reagents: Proper selection of collectors, frothers, and modifiers.
– pH Control: Critical for selectivity between copper 
fides and hematite.
– Froth Stability: Adjust air flow and frother dosage.
Applications in Copper-Hematite Ores
– If the ore contains both copper sulfides and hematite, sequential flotation may be used:
– First float copper sulfides at alkaline pH.
– Then process tailings for hematite via magnetic separation or reverse flotation.
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