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Effect of comminution on particle shape and surface roughness and their relation to
otation process
Mahmoud M. Ahmed
Mining and Metallurgical Engineering Department, Faculty of Engineering, Assiut University, Assiut 71516, Egypt
a r t i c l e
i n f o
Article history:
Received 23 July 2008
Received in revised form 8 February 2010
Accepted 22 February 2010
Available online 1 March 2010
Keywords:
Particle shape
Surface roughness
Fractal
Comminution
Flotation
Wettability
a b s t r a c t
The essential physical characteristics of the distinction of particles are size, shape and surface roughness.
Particle shape and surface roughness are considered important parameters in the prediction of the behavior
of particles individually or collectively. These parameters are of great importance to industries employing
various materials in a powder form. These parameters have not been currently reviewed satisfactory in the
mineral processing eld. Therefore, this research is concerned with the different methods used to estimate
the particle shape and surface roughness and also to relate these parameters with the behavior of some
mineral processing operations, especially comminution and otation processes.
The surface roughness of mineral particle inuences the fundamental processes of particlebubble
attachment and the other sub-processes in froth otation. The contact angle is dependent on the surface
roughness. The modication of the wettability due to surface roughness can be greatly enhanced in the
fractal surface; that is the fractal surface will be superrepellen (superwettable) to a liquid when the contact
angle is greater (less) than 90. Correlations were found between the shape properties, surface roughness
values and wettability.
The dry grinding produces relatively rough particle surfaces with a high concentration of microstructural
defects while the wet grinding produces smoother cleaner surfaces. The dry ground samples exhibited more
stable, higher loaded froths and faster otation kinetics.
2010 Elsevier B.V. All rights reserved.
1. Introduction
In addition to process variables, the processing of powder depends
to a large extent on the materials (purity, structure, density, etc.), bulk
properties, and the morphological characteristics (size, shape, texture,
etc.). Material characteristics are well understood and almost
completely known because the chemistry and physics of the materials
are highly developed. The morphological characteristics are not yet
developed and explored completely. The denitions of some
morphological characteristics like particle shape, size, and surface
roughness are still also evolving (Singh and Ramakrishnan, 1996).
The geometry of particle has a pronounced inuence on the
physical and chemical actions occurring on the particle surface
during the technological processes. This illustrates the importance of
the exact geometrical evaluation of the particles by means of
quantied particle parameters. These parameters can be used to
differentiate between different materials and to correlate them with
the different processes. The essential characteristics of the distinction of particles are size, shape and surface roughness (Castellini
by mathematical procedures (Meloy and Williams, 1994). Development of these methods may give a way to optimize the mineral
processing ow sheets not only on the basis of particle size
distribution but also by introducing the particle fractal properties
(Burstein et al., 1995).
Numerous factors inuence otation. Although particle hydrophobicity and size are important and have received much attention in
research, particle shape and roughness play a signicant role also, but
they have received much less attention.
The interaction between a solid particle and a gasliquid interface
controls the efciency of the otation process and has been
considered in detail (Ahmed, 1999; Ahmed et al., 1999).
The bubbleparticle interaction involves many stages, i.e. the
before-contact and after-contact interactions (Scheludko et al., 1968/
1969). The before-contact bubbleparticle interaction is strongly
affected by the long-range hydrodynamics when the bubble and the
particle are far from each other. It is controlled by the interfacial
physics e.g. interfacial dynamics, capillarity and colloidal interaction if
they are close enough.
The particle shape has a signicant inuence on otation behavior.
Many researchers have studied this relation qualitatively (Varbanov,
1984; Blake and Ralston, 1985; Ducker et al., 1989; Schmidt and Berg,
1996; Schmidt and Berg, 1997).
A few researchers have studied the effect of the surface roughness
on the otation process (Anfruns and Kitchener, 1997; Silverstein and
Breuer, 1993; Burstein et al., 1995; Ahmed, 1999; Ahmed et al., 1999;
Stechemesser and Ahmed, 1999).
The surface roughness of mineral particle inuences the fundamental processes of particlebubble attachment and the other subprocesses in froth otation.
Ahmed et al. (1998); Ahmed (1999); Ahmed et al. (1999) and
Stechemesser and Ahmed (1999) illustrated a modern and useful
approach, which was considered the rst attempt, to study the
quantitative effect of the surface roughness and shape of particle on
the detachment process of particle from the airliquid-interface by
means of a centrifuge technique and also on particle oatability
(under ideal conditions) using a modied Hallimond tube. It can be
supposed that the roughness of the solid surface has a decisive
inuence on otation effectiveness (Burstein et al., 1995). The
higher the surface roughness, the stronger is the detachment force
required to separate the particle from the bubble and hence a higher
otation recovery is obtained (Ahmed, 1999 and Ahmed et al.,
1999).
In froth otation, the probability of otation and hence the rate of
otation is directly determined by three microprocesses: collision,
adhesion and detachment (Trahar and Warren, 1976). To obtain an
improved understanding of the complete otation process, it is
necessary to analyze these three microprocesses quantitatively. The
ease with which the particle can be attached to the bubble and the
strength of detachment are considered very important when the
effectiveness of otation process is studied.
The differences in the values of detachment forces and hence the
otation effectiveness were markedly clear at the different degrees of
hydrophobicity for the same surface roughness (Ahmed, 1999 and
Ahmed et al., 1999). In addition, the difference in the values of
detachment forces increases with the increasing of the surface
roughness. At the lowest roughness, the difference in the value of
detachment force between the low and high hydrophobicity does not
exceed 1.5 * 105 N. This difference reached 7.1 * 105 N at the
highest roughness. This behavior may be attributed to the chemical
effects caused by adsorption of the silane lms on the surfaces having
different roughness. A surface with a lower roughness has a smaller
surface area compared to the surface of higher roughness and
therefore it reaches a maximum surface coverage at a lower
methylation time (lower contact angle) (Ahmed, 1999; Ahmed et al.,
1999).
181
182
Flatness ratio =
Elongation ratio =
length L
:
breadth B
diameter of a circle of equal area 2
DA 2
=
:
diameter of embracing circle
DEm
6
Chunkiness (Kaye, 1981 and Kaye et al., 1992):
Chunkiness =
Bm
:
Lm
avg
i=1
180
11
12
This measure has a zero value for the convex particle and increases
with the increase of fracturing.
FO =
LENG
:
LCNV
13
Jaggedness =
FK =
180
1 RDi
1F
14
Lm
:
Bm
15
Ri = ncor
Roundness =
i=1
10
By plotting log [L(r)] against log [r], the fractal dimension (F) can
be calculated from the absolute slope (1 F) of the best-tting line of
data in the plot. Such graph is known as Richardson plot and is
illustrated in Fig. 1 where 1.0 F 2.0. A fractal dimension value equal
to 1.0 is related to a Euclidean prole while the Brownian movement
will approximate to a fractal dimension value equal to 2.0. Large
slopes on the Richardson-graph correspond to a strong fracturing and
an irregular surface.
Fig. 1. Richardson plot of a particle prole (after Clark, 1987; Kaye, 1991; Brown et al.,
1993; Sarkar and Chaudhuri, 1994; Meloy and Williams, 1994; Brown et al., 1994a and
Lee and Chou, 1994).
183
Fig. 3. Richardson plot showing the change in fractal dimension with the step length
where the perimeter estimated and step lengths have been normalized with respect to
Feret's diameter of the particle (after Kaye et al., 1987; Kaye and Clark, 1989; Graf,
1991; Kaye, 1991; Brown et al., 1993 and Brown et al., 1994a).
Fig. 2. A particle prole with a maximum step length of 0.3 of Feret's diameter (after
Clark, 1987; Kaye, 1991; Brown et al., 1993; Sarkar and Chaudhuri, 1994; Meloy and
Williams, 1994; Brown et al., 1994a and Lee and Chou, 1994).
One of the most popular methods for shape analysis is the Fourier
analysis which determines the shape prole using Fourier coefcients
(Kaya et al., 1996). In Fourier analysis, rstly a reference point at the
center of prole is chosen. It is preferred to choose the centroid of the
prole treated as a useful reference point. Secondly, a point on the
periphery of the prole is chosen as the starting point for exploration of
the prole with a rotating vector. The maximum distance is then used as
a normalizing factor to summarize the magnitude of the vector as it
moves around the periphery of the prole with a uniform angular
velocity to generate what looks like a waveform (Schulze et al., 1989).
Two main procedures based on the Fourier analysis of a prole
may be applied to the morphologic characterization of a particle
(Singh and Ramakrishnan, 1996). The rst method is based on Fixed
Angular Boundary Sampling (FABS) (Luerkens et al., 1987) and the
184
185
Fig. 5. Fractal distribution data, for the FGD limestone fragments, illustrated on a
Gaussian probability graph paper (size = 38 m) (after Brown et al., 1994b).
Fig. 6. Topographic of the sulde particle surfaces by SEM: (a) wet grinding with 66% solids (% 75 m = 58.0, surface area = 1.23 m2/g) (b) wet grinding with 90% solids
(% 75 m = 57.5, surface area = 1.29 m2/g) and (c) dry grinding (% 75 m = 58.5, surface area = 1.25 m2/g) (after Feng and Aldrich, 2000).
186
Fig. 7. Variations of sulfur recovery with otation time (after Feng and Aldrich, 2000).
Fig. 8. Variations of sulfur content with otation time (after Feng and Aldrich, 2000).
Fig. 9. Flotation result of sand samples under different milling environments: (a) wet
milling with 66% solids (% 75 m = 75.0, surface area = 1.76 m2/g) and (b) dry
milling (% 75 m = 75.0, surface area = 1.68 m2/g) (after Feng and Aldrich, 2000).
187
188
steps) for the before-contact stage which may occur for successful
particle/bubble attachment:
1. thinning of the intervening liquid lm to a critical thickness where
the lm rupture begins,
2. rupture of the intervening liquid lm, i.e. formation of the threephase contact of a critical wetting radius (a hole) and,
3. expansion of the three-phase contact line from the critical radius to
form a stable wetting perimeter.
Schulze et al. (1989) have decided that in the technological
otation process, the three microprocesses mentioned above occur
simultaneously. Therefore it is impossible to determine unambiguously from the temporal course and the efciency of the total process
which one of the microprocesses is signicant in the course of the
process. Consequently this problem must be solved by investigating
the individual microprocesses separately.
Fig. 10 illustrates the effect of the surface roughness of particle
(quantied by the textural fractal dimension) on otation recovery at
different degrees of hydrophobicity. From this gure, it can be seen
that as the textural fractal dimension increases, the otation recovery
increases linearly at different degrees of hydrophobicity. Similar
relationships between the surface roughness (quantied by the factor
of convexity and the factor of concavity) and otation recovery were
also obtained (Ahmed, 1999 and Stechemesser and Ahmed, 1999).
From Fig. 10, it can be seen that the differences in the values of
otation recovery between the roughest material (quartzite) and the
smoothest material (soda-lime-glass ballotini) range from 24% (at
contact angle = 71) to 33.5% (at contact angle=78). This means
that although the small differences in the values of textural fractal
dimension of materials were examined, very great signicant
differences in the values of otation recovery between the smoothest
and the roughest material were obtained. This assures that the effect
of the surface roughness on the otation recovery is signicantly
effective.
From the previous results, it can be concluded that the roughness has
a signicant effect on the otation recovery. This may be attributed to
the fact that larger detachment forces are required to separate the rough
particle from bubble than to separate the smoother particle. The larger
detachment forces will indicate a strong adhesion force for the bubble
particle aggregates, which could reserve these aggregates to reach
the oat receiver and hence higher recovery is obtained (Ahmed et al.,
1999; Ahmed, 1999 and Stechemesser and Ahmed, 1999).
Fig. 10. Effect of the surface roughness of particles (quantied by the textural fractal dimension) on the otation recovery at different degrees of hydrophobicity (after Ahmed, 1999).
189
Fig. 11. Effect of the shape of particles (quantied by the structural fractal dimension) on the otation recovery at different degrees of hydrophobicity (after Ahmed, 1999).
hence the particle is submerged into the liquid. This contraction needs
a longer time and then larger detachment forces (larger three-phase
contact perimeter) in the case of rough particles.
7.2. Effect of the particle shape on oatability
Fig. 11 shows the effect of the particle shape (quantied by the
structural fractal dimension) on otation recovery of the materials
examined at different degrees of hydrophobicity. From this gure, it
can be seen that as the structural fractal dimension increases from
1.020 to 1.043, the otation recovery slightly increases. Above this
value, any increase in the structural fractal dimension causes
signicant increase in otation recovery. This behavior is the same
at all the degrees of hydrophobicity (Ahmed, 1999 and Stechemesser
and Ahmed, 1999). Fig. 12 illustrates the effect of particle shape
(quantied by the factor of circularity) on otation recovery at
different degrees of hydrophobicity. From this gure, it can be seen
that as the particle shape increases (decreasing of the factor of
circularity), the otation recovery increases up to a certain point
above which an excessive increase in the particle shape will result in a
Fig. 12. Effect of the shape of particles (quantied by the factor of circularity) on the otation recovery at different degrees of hydrophobicity (after Ahmed, 1999).
190
decrease in the nal otation recovery. It can be also noticed that the
relationship between the particle shape and otation recovery has the
same behavior at all degrees of hydrophobicity (Ahmed, 1999 and
Stechemesser and Ahmed, 1999).
Comparison of the results shown in Figs. 11 and 12 displayed that
there is a clear difference in the behavior of otation recovery with the
particle shape (if this shape is quantied by the structural fractal
dimension or the factor of circularity). This means that the particle
shape is not as effective as the surface roughness in controlling the
otation recovery. This result may be ascertained also from Fig. 11. In
this gure, it can be observed that although the structural fractal
dimensions of ground ballotini and quartzite are almost the same
(these materials have the same shape), they have different otation
recoveries (Ahmed, 1999 and Stechemesser and Ahmed, 1999).
Figs. 11 and 12 showed also that the otation recoveries of ground
ballotini are higher than that of spherical ballotini at all degrees of
hydrophobicity. One of the possible explanations of this result may be
attributed to the increase of the particle surface with the rise of
structural fractal dimension of ground ballotini which leads to more
adsorption of surfactant (Burstein et al., 1995) and hence the increase
of otation recovery (Ahmed et al., 1999 and Ahmed, 1999). Other
reasons for this behavior are that the attachment with bubble is more
difcult for the spherical particles compared to the non-spherical
particles. The second reason is that the retreatment in the liquid phase
causes easier wetting on spherical particles than on non-spherical
particles (Wotruba, 1991). Ducker et al. (1989) interpreted these
differences to the difference in the surface roughness between glass
ballotini and ground ballotini and not to the difference in their shapes.
8. Conclusions
1. Particle shape and surface roughness are considered important
parameters in the prediction of the behavior of particle and powder.
2. The methods used to assess the particle shape and surface
roughness range from very simple methods such as the aspect
ratio, elongation ratio or circularity to very modern methods such
as Fourier analysis, delta analysis and fractal geometry.
3. The development of automated microscope techniques linked to
computer data-processing systems (image analysis techniques)
facilitate the possibility of specifying the particle shape and surface
roughness by mathematical procedures.
4. Particles of the impact crushing have higher boundary fractal
dimensions than the rotary milled particles.
5. The dry ground samples are more stable and have higher loaded
froths and faster otation kinetics. These samples have relatively
rough particle surfaces while the wet ground samples have
smoother and cleaner surfaces.
6. The contact angle is dependent on the surface roughness. At sharp
corners, the contact angle is assumed as a range of values. The
fractal surface will be superrepellent (superwettable) to a liquid
when the contact angle is greater (less) than 90.
7. There are large differences in the otation properties of glass
ballotini and ground ballotini due to the difference in surface
roughness.
8. The particle shape does not control clearly the otation recovery.
The surface roughness is responsible for the detachment process of
particle and the nal otation recovery more than its shape.
Nomenclature
maximum breadth of the prole projection on a direction at
BM
a right angle in which LM is measured
c
constant
DA
particle diameter of a circle of equal area
DEM
diameter of the embracing circle
D(Fmax.) Feret's diameter of the particle
Di
distance from the centroid of a particle to its edge
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