Why is froth pumps warman Better?

Handling mineral froth with centrifugal slurry pumps presents significant engineering challenges for end users and pump manufacturers due to unstable pump performance. These issues primarily arise from improper pump selection and poorly designed suction tanks. Traditional methods involve oversizing the pump for managing mineral froth. However, innovative horizontal slurry froth pump designs enhance the management of high Froth Volume Factor minerals while maintaining efficiency, longevity, and stable performance. This article delves into the flotation process and the design features of froth pumps that enable them to tackle this demanding task effectively.

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Froth pumping is one of the most intricate engineering tasks in mineral processing. Weir Minerals offers guidance on managing primary challenges in this domain, optimizing pump availability, and minimizing maintenance within flotation circuits.

To counteract diminishing ore grades, many mine operators adopt advanced techniques to enhance mineral recovery from froth pumping. However, using these techniques without considering the froth pump equipment's design can lead to loss of valuable minerals and reduced profits.

Froth pumping challenges stem largely from air management issues within the hopper, sump, and pump, leading to inefficient pumping, increased maintenance needs, and product loss.

"We've detected a pattern among customers struggling with froth pumps," said Les Harvey, regional product manager for Slurry Pumps at Weir Minerals. "By using more flocculants and other chemicals designed to enhance mineral recovery, they exacerbate existing circuit design problems, diminishing returns."

Analyzing the froth's makeup and physical properties is crucial for resolving issues. Ensuring that froth handling equipment adheres to best design practices is essential for mitigating challenges.

Maintaining Pump Pressure The main issue in froth pumping is dealing with air in the pump, as it tends to accumulate in the impeller's eye, causing an "air lock" that obstructs slurry movement.

The air build-up reduces pump efficiency, lowers flow, and increases the slurry level in the suction hopper, potentially pushing air pockets through the pump, causing surges and excessive vibration. "Investing in a froth pump with a continuous air removal system (CARS), as found in our Warman AHF, MF, and LF pumps, is the best way to handle air," says Harvey.

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This system directs air from the pump's impeller eye to an air collection chamber in the back through a vent hole. A flow inducer then removes the air through a vent pipe. Positioning the discharge pipe at the pump's top or at a 45° angle helps trapped air escape from the casing.

Problem Solving in Froth Pumping "A persistent issue is using hoppers designed for slurry pumping in froth applications. Turbulence necessary in slurry hoppers inhibits air escape in froth pumps, leading to blockages," said Harvey.

Froth-specific tanks encourage continuous circular motion, sending solids and liquids to the outside of the sump while air moves to the center for removal. Introducing slurry tangentially from the top of the tank and using conical designs enhances mineral and froth flow into the pump.

Simplifying Operation To prevent blockages, intake pipes linking the tank to the pump should be large in diameter and slope downward. This design allows escaped air to travel back up the pipe, preventing blockages.

"A shorter intake pipe reduces blockage risks. Additionally, a maintenance spool, isolation valve, and space for a water injection port help flush out solids build-up," said Harvey.

"Including a dump valve on the suction side of the pump allows slurry drainage from the pump and discharge pipe during maintenance."

Managing Tenacious Froths Froths are classified based on bubble stability, with brittle froths having easily broken bubbles and tenacious froths having tightly bound air bubbles. Excessively tenacious froths often cause blockages as the air is difficult to remove.

"Two trends are prominent today: finer product grinding for mineral liberation, and the use of flocculants creating smaller, more air-tight bubbles," said Harvey. "We collaborate with customers to manage tenacious froths, optimizing circuit design and addressing potential air accumulation points, particularly in pumps, pipes, and sumps."

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