Flotation machines are a common type of mineral processing equipment, mainly used for purifying and beneficiating magnetic minerals such as iron ore and copper ore. They can also be used for removing impurities from non-metallic minerals. Their applications are very wide. This article briefly explains common flotation machine malfunctions and maintenance methods.

Common Flotation Machine Faults

Faults in flotation machines are often caused by prolonged operation or normal wear and tear. If not addressed promptly, they can lead to accidents and disrupt normal production to varying degrees. Common faults include:

1. During operation, impacts and vibrations can sometimes cause the cover plate or stator screws to fall off, affecting normal operation. Therefore, during maintenance and installation, it is essential to ensure the machine’s stability and to conduct a thorough inspection before starting the machine.

2. The bottom guard plate protects the bottom of the tank. Sometimes, the strong agitation of the impeller accelerates the internal circulation of the slurry, causing the guard plate to be pried up, suddenly increasing the motor load and potentially causing an accident. Therefore, when starting the machine, adjust the gate to maintain a stable slurry level for normal flotation machine operation.

3. Due to long-term wear and corrosion, the gap between the impeller and the cover plate increases, reducing the air intake. The solution is to perform regular maintenance or replacement. If abnormal conditions occur during the foam flotation process, such as localized frothing of the foam layer or instability of the foam layer, inspection and adjustment should be carried out to ensure that the gap size is within the allowable range.

Flotation Machine Troubleshooting and Repair Methods

1. Vertical Shaft

Before installing the impeller, check if the rubber hose protecting the vertical shaft is worn. If worn, replace it with a new hose.

2. Impeller and Cover Plate

The impeller and cover plate are core components of the flotation machine and are also easily worn parts. They affect the aeration and mixing of the slurry during the flotation process. Due to long-term operation, wear and corrosion can cause them to lose their production efficiency. In this case, lift the entire impeller and vertical shaft assembly out of the flotation tank and replace it with a newly assembled assembly. When replacing worn impellers and cover plates, use shims to adjust the shaft clearance between the impeller and cover plate, keeping it within the specified range. Simultaneously, maintain the concentricity of the impeller and cover plate to ensure the radial clearance is uniform around all four sides. (Usage of the Flotation Machine)

3. Bearing Clearance

If the vertical shaft bearing experiences excessive clearance due to wear, simply adjust the tightness of the inner and outer washers. If the oil seal on the lower cover of the bearing housing leaks oil, replace it promptly, and be careful not to overtighten it. (Flotation machine operation)

4. Tank Body and Tank Body Guard Plates

During long-term operation of the flotation machine, the strong rotation of the slurry causes wear and corrosion, leading to deformation and wear of the tank body guard plates and potential damage or leakage to the tank body. Repair welding should be performed promptly, and in cases of severe damage, the entire tank should be replaced.