Flotation Equipment Tank Issues: Analysis of 8 Common Problems and Solutions

Flotation equipment, as a core component in mineral processing technology, directly impacts the production efficiency and concentrate quality of processing plants. In daily operations, various issues frequently occur with flotation machine tanks. If not addressed promptly, these problems not only reduce processing efficiency but may also lead to economic losses. This article analyzes eight common flotation tank problems and their corresponding solutions.

Structural Tank Issues: Analysis and Solutions

Structural problems in flotation tanks typically occur during installation or after extended use, manifesting in several ways:

After installation or long-term operation, flotation tank connecting surfaces often develop water seepage or leakage, primarily due to poor sealing or loose connectors.

- Seal Optimization: Ensure connecting surface rubber gaskets remain intact while using high-quality sealant to enhance sealing effectiveness

- Fastener Inspection: Regularly check the tightness of pre-tensioned bolts and promptly adjust any loose sections

- Encapsulation Treatment: For difficult-to-locate leakage points, apply sealant around the entire flow plate or use welding for permanent sealing

During long-term operation, intense slurry agitation causes severe wear on tank bottoms, while chemical reagents accelerate the corrosion process.

- Regular Inspection: Establish a regular thickness monitoring system to detect wear conditions promptly

- Partial Reinforcement: Apply welding repairs or attach wear-resistant plates to areas with minor wear

- Tank Replacement: When wear or corrosion becomes severe, replace the entire tank assembly promptly

Common Tank Anomalies During Operation

During daily operation, flotation machine tanks may exhibit various functional abnormalities that directly affect mineral separation efficiency.

High-speed impeller rotation creates strong circulation currents in the tank, sometimes causing bottom protection plates to loosen or lift, potentially overloading the motor in severe cases.

- Startup Parameter Optimization: Operators should precisely adjust pneumatic valve positions to ensure smooth startup

- Protection Plate Reinforcement: Increase fixing points or improve mounting methods to enhance impact resistance

- Regular Maintenance: Conduct periodic inspections of protection plates and immediately repair any loosening

Slurry frequently overflows from tanks during flotation, usually related to multiple operational parameter imbalances.

- Reagent Adjustment: Precisely control frother dosage to prevent excessive bubble formation

- Air Volume Control: Appropriately adjust aeration rates based on ore characteristics and flotation requirements

- Liquid Level Management: Maintain appropriate tank liquid levels to prevent overflow

- Concentration Optimization: Control feed concentration and particle size to avoid excessive coarseness or density

Foam and Liquid Level Abnormality Management

Foam conditions and liquid level changes during flotation are important process indicators; abnormalities often signal system issues.

When foam continuously accumulates in flotation tanks preventing normal mineral discharge, multiple factors must be investigated:

- Flow Inspection: Ensure intermediate boxes and level adjustment plates remain unobstructed to maintain normal slurry flow

- Parameter Adjustment: Reasonably control feed rate and aeration to prevent system overload

- Equipment Maintenance: Check suction tank functionality and wash water pressure to ensure coordinated system operation

Tank level drop manifests as sudden decreases in flotation tank liquid levels, typically caused by upstream equipment abnormalities or improper gate adjustment.

- Upstream Optimization: Adjust grinding and classification operations to ensure uniform feeding

- Liquid Level Adjustment: Scientifically set front tank liquid levels to maintain system balance

- Regular Cleaning: Periodically clear coarse sand holes to prevent blockages

- Gate Maintenance: Standardize gate operation procedures to avoid misadjustment

When abnormally large foam with reflective surfaces appears in flotation tanks, it typically signals reagent proportion imbalances.

- Reagent Optimization: Precisely adjust dosage ratios of various flotation reagents

- Indicator Monitoring: Observe changes in foam color, size, and stability

- Process Adjustment: Promptly modify process parameters based on foam conditions

When one flotation tank's liquid level is significantly higher than others, localized drainage restrictions are usually responsible.

- Pipe Clearing: Stop the machine to inspect and clear blockages in suction pipes

- Regular Cleaning: Establish periodic cleaning protocols to prevent blockages

- Design Improvement: Structurally optimize areas prone to blockage to improve flow

Through comprehensive understanding of these eight common flotation tank problems and their solutions, operators can more efficiently maintain equipment operational status, ensure continuous and stable mineral processing, and maximize concentrate recovery and quality. Timely and effective fault management not only extends equipment service life but also generates significant economic benefits for enterprises.