What is the difference between different flotation machine models?

You are trying to select a flotation machine, but the different model numbers and designs can be confusing. Choosing the wrong type of cell can lead to poor recovery, sending valuable minerals straight to the tailings pond.

The primary difference between flotation machine models is their method of air induction and slurry agitation. Models are designed to create specific hydrodynamic conditions suitable for different particle sizes and stages within the flotation process, such as roughing, cleaning, or scavenging.

To the untrained eye, they all look like tanks that mix slurry. But to an experienced metallurgist, a flotation circuit is a finely tuned instrument. Each cell model has a specific purpose. As a flotation machine manufacturer, we design these machines to solve specific challenges in mineral separation. This guide will clarify the key differences, helping you understand which model is the right tool for your job.

Table of Contents

• What types of flotation machines are there?
• How do you choose a flotation machine for different ores?
• Why are some flotation cells for roughing, and others for cleaning and scavenging?
• How much do models differ in power, wear, and reagent costs?
• How do I combine different models to build the most efficient flotation line?
• Conclusion

What types of flotation machines are there?

Different models of flotation machines have variations in their structure and application.

Here are the main differences:

1. KYF Type Flotation Machine:
   • Structure: U-shaped tank with a conical impeller and backward tilting blades.
   • Application: Suitable for large slurry handling capacity, low energy consumption, and efficient flotation.
2. XCF Type Flotation Machine:
   • Structure: Similar to KYF, with an additional stator above the impeller to create a negative pressure area for self-absorption of slurry.
   • Application: Often used in combination with KYF to form a joint unit, with XCF serving as the slurry suction tank and KYF as the direct current tank.
3. JJF Type Flotation Machine:
   • Structure: Shallow tank, small impeller diameter, and stator with an umbrella-shaped dispersion cover.
   • Application: Allows for the separation of the foam layer from the slurry while maintaining a smooth foam layer.
4. SF Type Flotation Machine:
   • Structure: Forward tilt tank with a false bottom device for double-cycle slurry circulation.
   • Application: Can self-absorb air and slurry, suitable for the floatation of coarse mineral particles, and serves as a slurry tank or used in conjunction with other types of flotation machines.
5. BF Type Flotation Machine:
   • Structure: Unique impeller design with double cone disks for strong downward circulation.
   • Application: Can self-absorb air and slurry, often used horizontally without requiring a pump for ore return.
6. XHF Type Flotation Machine:
   • Structure: Inflatable mechanical agitation flotation machine, developed by Zoneding Mineral Machinery Co.
   • Application: Typically used as a suction tank along with the BSF type flotation machine.
7. CLF Type Flotation Machine:
   • Structure: Available in DC tank and slurry suction tank options, with different impeller designs.
   • Application: Specifically designed for coarse particle mineral sorting, used individually or as a joint unit.

These models may have additional specific features or variations depending on the manufacturer. Users should consider factors such as energy efficiency, slurry handling capacity, and application requirements when selecting the appropriate flotation machine for their needs.

How do you choose a flotation machine for different ores?

The type of ore you are processing has a huge impact on machine selection. The size, density, and liberation characteristics of your valuable minerals dictate the hydrodynamic environment they need to float successfully.

Choosing the right machine for your ore is critical to recovery. You must match the machine’s mixing intensity and aeration characteristics to the physical properties of your mineral particles.

For coarse, heavy mineral particles (like some lead or copper ores), you need a cell with high agitation power to keep them suspended. For fine, slow-floating minerals (like some gold or molybdenum ores), you need a cell with gentle mixing and excellent fine bubble dispersion.

As a manufacturer of beneficiation equipment, we help clients make this choice every day.

Matching the Machine to the Mineral

• Coarse & Heavy Particles: Minerals like galena or coarse chalcopyrite will sink if the slurry is not mixed aggressively. A self-aspirating machine or a forced-air machine with a powerful, high-pumping impeller is needed to keep these particles suspended and give them a chance to attach to a bubble. Without sufficient suspension, you create “dead zones” at the bottom of the tank, losing valuable recovery.
• Fine & Light Particles: Very fine particles have low momentum and can be easily knocked off bubbles by excessive turbulence. For ores like molybdenum or fine-particle gold flotation, a modern forced-air cell is superior. It allows the operator to reduce the impeller speed for gentle mixing while maintaining a high flow rate of fine air bubbles, creating the ideal quiescent conditions needed for fine particle recovery.

Why are some flotation cells for roughing, and others for cleaning and scavenging?

A flotation circuit is not a single step; it is a multi-stage process. Each stage—roughing, cleaning, and scavenging—has a different objective. The machine design must reflect that objective.

Different stages of the flotation process have conflicting goals. Machine models are specialized to meet these specific goals, from maximizing recovery in roughers to maximizing grade in cleaners.

Rougher cells are designed for high recovery and fast kinetics to capture as much valuable mineral as possible. Cleaner cells are designed for high selectivity and grade, using features like deep froth beds to wash out impurities. Scavenger cells are designed to recover the last remaining particles, often handling a coarser feed.

Using the right machine in the right position is key to an efficient flotation process.

Machine Roles in the Circuit

How much do models differ in power, wear, and reagent costs?

The initial purchase price of a flotation cell is only one part of the equation. The Total Cost of Ownership (TCO) is dominated by ongoing operational costs. Different models can have vastly different TCO profiles.

The differences in operational costs between models can be enormous. A machine’s design directly impacts its power consumption, the wear rate of its components, and its efficiency in using expensive reagents.

Forced-air cells are typically more energy-efficient per cubic meter than self-aspirating cells. Wear on the impeller and stator is the largest maintenance cost, and their design and material composition are critical. An efficient cell with good mixing can also reduce reagent consumption.

At ZONEDING, we design our machines to minimize these long-term costs.

Comparing Operational Costs

• Power Consumption: This is often the largest single operational cost. The impeller and stator (the “heart” of the cell) are designed to be hydrodynamically efficient. A well-designed forced-air system uses the external blower for the work of aeration, allowing the impeller to focus on suspension, which lowers overall power draw compared to a self-aspirating machine doing both jobs.
• Impeller and Stator Wear: The impeller and stator are high-wear parts that require regular replacement. Their lifespan depends on the abrasiveness of the slurry, the impeller tip speed, and the materials used (e.g., rubber, polyurethane, high-chrome alloys). A machine that can achieve good mixing at a lower impeller speed will have a significantly longer wear life for these components.
• Reagent Consumption: Reagents are expensive. A flotation cell with poor mixing and air dispersion will have “dead zones” where reagents are not effectively used, leading to waste. An efficient cell ensures that every drop of collector and frother is properly mixed, which can lead to a 5-10% reduction in reagent consumption for the same recovery.

How do I combine different models to build the most efficient flotation line?

A single type of flotation cell is rarely the best solution for an entire circuit. The most effective mineral processing plants use a combination of different models, leveraging the specific strengths of each.

You cannot build a truly optimized flotation circuit with just one type of machine. The best practice is to combine different models to create a “hybrid” circuit that matches the machine to the specific task at each stage.

A common and highly effective strategy is to use a suction-type cell (like our XCF model) at the head of a flotation bank, followed by a series of standard forced-air cells (like our KYF model). This design eliminates the need for feed pumps between banks.

This is an example of smart circuit design.

Building a Hybrid Circuit

• The Suction Cell (XCF Model): The XCF flotation machine is a unique type of forced-air cell. Its impeller is designed not only to mix and aerate but also to create a strong suction effect. This allows it to draw slurry directly from the previous stage or from a sump without needing a separate pump. It is installed at a slightly lower elevation.
• The Standard Cell (KYF Model): The KYF is a standard forced-air cell optimized for mixing and aeration efficiency. It cannot suck slurry on its own.
• The XCF/KYF Combination: By placing an XCF cell at the start of a row, it can lift the slurry and feed it directly into the subsequent KYF cells. This creates a self-contained bank that flows via gravity. This intelligent combination saves you the capital cost, maintenance cost, and power consumption of an entire slurry pump system, making the overall circuit more efficient and reliable.

Conclusion

The differences between flotation machine models are based on fundamental engineering principles. By understanding these differences, you can build a circuit that maximizes your recovery and profitability. Contact us to discuss your specific ore and process goals.