Branched Fatty Alcohol Emulsification in Flotation
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Solution Overview
Problem
Current secondary collectors used in froth flotation processes for non-sulfidic ores, particularly phosphate ores, face environmental concerns and inefficiencies, with nonylphenol ethoxylates being suboptimal in terms of mineral recovery and environmental impact, and existing technologies do not effectively utilize branched fatty alcohols or their alkoxylates with varying degrees of ethoxylation.
Innovation Solution
A secondary collector composition combining branched fatty alcohols with 12-16 carbon atoms and their alkoxylates having a degree of branching of 1-3.5, along with alkoxylates of nonionic hydrocarbon compounds with higher degrees of ethoxylation, is used in conjunction with an amphoteric or anionic primary collector to enhance mineral recovery and stability, with the latter acting as an emulsifier to improve the efficiency of the former.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If nonylphenol ethoxylates are used as secondary collectors, then mineral recovery is improved, but environmental harm increases
Solution Approach 1:
The patent changes the chemical parameters of the secondary collector by using branched fatty alcohols with specific carbon numbers (12-16) and controlled degrees of branching (1-3.5), along with their alkoxylates having specific degrees of ethoxylation (1-4). This parameter modification maintains the collector's effectiveness for mineral recovery while eliminating the environmental harm associated with nonylphenol ethoxylates.
Solution Approach 2:
The patent employs readily available branched fatty alcohols and their alkoxylates as secondary collectors, replacing the persistent and environmentally harmful nonylphenol ethoxylates. These alternative compounds provide the necessary flotation performance without the long-term environmental persistence and toxicity issues.
2Productivity
If branched fatty alcohol alkoxylates are used as secondary collectors, then collector performance is improved, but emulsification and stability are insufficient
Solution Approach 1:
The patent combines branched fatty alcohol alkoxylates (compounds with DE 1-4) with additional alkoxylates of nonionic hydrocarbon compounds (compounds with DE higher than 3) in a specific ratio (99:1 to 1:99). This combination merges the collector performance benefits of the branched fatty alcohol alkoxylates with the emulsification and stability properties of the additional alkoxylates, achieving both objectives simultaneously.
Solution Approach 2:
The additional alkoxylates of nonionic hydrocarbon compounds act as intermediaries that enhance the emulsification and stability of the branched fatty alcohol alkoxylates. These intermediary compounds facilitate better dispersion and stability in the flotation system without compromising the primary collector function.
3Productivity
If higher amounts of secondary collector are used, then mineral recovery is improved, but cost and inefficiency increase
Solution Approach 1:
The patent optimizes the effectiveness of the secondary collector by carefully controlling the degree of branching (1-3.5) and degree of ethoxylation (1-4) of the branched fatty alcohol alkoxylates. These parameter optimizations ensure that the collector acts efficiently at lower concentrations, improving mineral recovery without requiring excessive amounts of the substance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This combination achieves similar mineral recovery efficiency to traditional secondary collectors while offering a better environmental profile and improved emulsification, allowing for more efficient use of the branched fatty alcohol alkoxylates in smaller amounts, thereby enhancing the froth flotation process.
Implementation Method 1
compound (ii) has as a benefit that it helps to emulsify compound (i) in the collector composition, enabling compound (i) to be used more efficiently
Implementation Method 2
separate the valuable phosphate minerals from the gangue by using a froth flotation process where the phosphate minerals are enriched in the float
Implementation Method 3
a combination of, on the one hand, a good separation of the valuable mineral from the gangue by using a selective collector
Data Source
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AI summary
The present invention relates to secondary collector mixtures containing at least one compound (i) selected from the group of branched fatty alcohols with 12-16 carbon atoms having a degree of branching (DB) of 1-3.5 and their alkoxylates with a degree of ethoxylation (DE) of up to 4, and at least one compound (ii) selected from the group of alkoxylates of nonionic hydrocarbon compounds with a degree of ethoxylation of higher than 3 and carbohydrate-based surfactants, wherein if both compounds (i) and (ii) are ethoxylated alcohols, the mixture has a bimodal degree of ethoxylation distribution; to the use of compound (ii) as an emulsifier for compound (i) in a liquid; to collector compositions containing the secondary collector mixtures together with a primary collector that is an amphoteric or anionic surface-active compound; and to the use of the above compositions in a process for froth flotation of non-sulfidic ores.