Flotation equipment is a key equipment in the mineral processing process, and its operating status directly affects the mineral processing efficiency and product quality. The following are some common problems and their solutions:

Abnormal flotation foam

1.Excessive or sticky foam

Causes

Excessive reagents (such as frothers), abnormal pulp pH value, changes in ore properties.

Solutions

Adjust the dosage of reagents and gradually reduce the frother or collector.

Monitor and adjust the pulp pH value to an appropriate range (such as copper ore pH 8-10).

Check whether the ore particle size is too fine and adjust the grinding parameters if necessary.

2.The foam layer is thin or fragile

Causes

Insufficient frother, low pulp concentration, uneven bubble size.

Solutions

Add appropriate amount of frother or adjust the reagent ratio.

Increase the pulp concentration to the process requirements (usually 20-40% solid content).

Check the impeller speed and aeration volume to ensure uniform distribution of bubbles.

Low mineral recovery rate

1.Useful mineral loss

Reason

Improper reagent selection, insufficient flotation time, poor bubble mineralization effect.

Solution

Optimize reagent system (such as replacing collector or activator).

Extend flotation time or increase the number of flotation cells.

Adjust the gap between impeller and stator (usually 1-5mm) to improve bubble mineralization.

2.Low concentrate grade

Reason

Gangue minerals float, excessive reagents, and excessive pulp concentration.

Solution

Add inhibitors (such as water glass to inhibit quartz).

Reduce the amount of collector or increase the number of fine selections.

Reduce pulp concentration and enhance pulp dispersion.

Equipment operation failure

1.Severe wear of impeller or stator

Reason

Slurry is highly abrasive, material does not meet standards, and installation gap is improper.

Solution

Regularly check and replace wear-resistant parts (such as rubber or polyurethane lining).

Choose an impeller made of high-hardness alloy.

Correct the gap between the impeller and the stator to avoid overload operation.

2.Insufficient air volume

Reason

Fan failure, air pipe blockage, high liquid level.

Solution

Clean the air pipe and air valve, and check the fan pressure.

Lower the liquid level of the flotation tank to ensure effective gas entry.

Clean the air distributor regularly.

Excessive energy consumption

1.Motor overload or heat

Reason

Too high slurry concentration, impeller blockage, poor bearing lubrication.

Solution

Control the slurry concentration to avoid overload operation.

Clean the impeller attachments to maintain smooth operation.

Regularly add grease (such as lithium-based grease) and check the bearing status.

Other common problems

1.Slurry short circuit (not fully floated)

Reason

Unstable flotation tank level, damaged partition.

Solution

Adjust the liquid level controller, repair or replace the partition.

2.Delayed reagent reaction

Reason

Unreasonable reagent addition point, insufficient stirring.

Solution

Optimize the dosing point (such as adding to the mixing tank in advance) and enhance pre-mixing.