Froth flotation
Froth flotation is a process for selectively separating hydrophobic materials from hydrophilic. This is used in mineral processing, paper recycling and waste-water treatment industries. Historically this was first used in the mining industry, where it was one of the great enabling technologies of the 20th century. It has been described as "the single most important operation used for the recovery and upgrading of sulfide ores". The development of froth flotation has improved the recovery of valuable minerals, such as copper- and lead-bearing minerals. Along with mechanized mining, it has allowed the economic recovery of valuable metals from much lower grade ore than previously. Froth flotation is applied to a wide range of separations. An estimated 1B tons of materials are processed in this manner annually. Froth flotation is a process for separating minerals from gangue by exploiting differences in their hydrophobicity. Hydrophobicity differences between valuable minerals and waste gangue are increased through the use of surfactants and wetting agents. The flotation process is used for the separation of a large range of sulfides, carbonates and oxides prior to further refinement. Phosphates and coal are also upgraded (purified) by flotation technology. "Grade-recovery curves" are tools in weighing the trade-off of producing a high grade of concentrate vs cost. These curves only compare the grade-recovery relations of a specific feed grade and feed rate. The flotation process is also widely used in industrial waste water treatment plants, where it removes fats, oil, grease and suspended solids from waste water. These units are called dissolved air flotation (DAF) units. In particular, dissolved air flotation units are used in removing oil from the wastewater effluents of oil refineries, petrochemical and chemical plants, natural gas processing plants and similar industrial facilities. The ore to be treated is ground into particles (comminution). In the idealized case, the individual minerals are physically separated, a process known as full liberation.
