Wide-size-fraction coal slime flotation via cyclone pre-classification
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Solution Overview
Problem
Conventional coal slime flotation processes have low processing capacity and limited selective recovery range, leading to inefficiencies in coal resource utilization, high energy consumption, and environmental concerns due to complex and costly operations.
Innovation Solution
A wide size fraction flotation system and process that involves pre-classification using a classifying cyclone, followed by separation in a flotation column and hydraulic flotation machine, utilizing a foaming agent and collecting agent to form a stable foaming layer, enhancing the recovery of both fine and coarse particles while reducing energy consumption and environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional slime flotation process is used, then fine particles can be separated, but processing capacity is low and selective recovery range is narrow
Solution Approach 1:
The flotation process is segmented into two distinct stages: a first flotation machine handles fine particles (≤0.125mm) while a second flotation machine handles coarse particles (>0.125mm). This segmentation allows each machine to be optimized for its specific particle size range, thereby expanding the overall selective recovery range while maintaining high processing capacity for both size fractions simultaneously
2Manufacturing precision
If fine particles (≤0.125 mm) are floated, then they can be separated, but they may entrain fine slime seriously and have poor selectivity
Solution Approach 1:
The process separates fine particle flotation from coarse particle flotation into two distinct stages using two different flotation machines. The first flotation machine is specifically optimized for fine particles with parameters tuned to minimize slime entrainment, while the second handles coarse particles. This segmentation allows each stage to operate at optimal selectivity for its particle size range without interference from the other size fraction
Solution Approach 2:
Different flotation conditions and machine configurations are applied locally to different particle size fractions. The first flotation machine uses parameters optimized for fine particles (lower air flow, different reagent dosing), while the second uses parameters optimized for coarse particles. This local optimization of quality parameters ensures high selectivity for each fraction while minimizing harmful entrainment effects
3Productivity
If coarse particles (>0.25 mm) are floated, then recovery can be achieved, but they are prone to be desorbed from bubbles and have low recovery rate
Solution Approach 1:
Coarse particle flotation is separated into a dedicated second flotation stage that occurs after fine particle removal. This segmentation allows the second flotation machine to operate with parameters specifically optimized for coarse particles, including higher air flow rates and different bubble size distributions that enhance stable adhesion. The sequential arrangement ensures coarse particles are not desorbed because they are processed in an environment optimized for their size characteristics
Solution Approach 2:
The fine particles are removed in a preliminary flotation stage before the coarse particle flotation stage. This preliminary action prevents fine slime from interfering with coarse particle flotation, creating cleaner bubble-coarse particle interactions. The pre-conditioning of the slurry in the first stage improves the reliability of adhesion in the second stage by eliminating competing fine particles that would otherwise cause desorption
4Adaptability or versatility
If wide size fraction flotation is implemented, then processing range is expanded, but process complexity and cost increase
Solution Approach 1:
The wide size fraction flotation is achieved through segmentation into two parallel flotation lines (first flotation machine for fine particles, second flotation machine for coarse particles) that process different size fractions simultaneously. This segmentation approach is more efficient than a single complex flotation process because each machine can be independently optimized and operated, reducing overall process complexity while expanding the processing range to cover both fine and coarse particles effectively
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
The process achieves efficient and selective recovery of fine and coarse particles, expanding the processing range, reducing costs, and minimizing environmental harm, with a simple and energy-efficient system that complements the performance of both flotation devices.
Implementation Method 1
feeding the mixture into a classifying cyclone by means of a first feeding pump for pre-classifying
Implementation Method 2
after the coal slime is classified in the classifying cyclone
Implementation Method 3
feeding the overflow from the classifying cyclone into a flotation column by means of a second feeding pump for flotation
Implementation Method 4
feeding the underflow in the classifying cyclone into a hydraulic flotation machine by means of a third feeding pump for recovery by flotation
Implementation Method 5
a certain amount of collecting agent and foaming agent are added and supplied to the hydraulic flotation machine as rising water flow of the hydraulic flotation machine to form a foaming layer
Implementation Method 6
collecting the flotation concentrate through an overflow port of the flotation column and feeding the collected flotation concentrate into a bubble generator
Data Source
AI summary
A wide-size-fraction flotation system and process includes feeding coal slime to be floated into a stirrer, adding water to the floating coal slime in the stirrer, stirring, then feeding same into a grading cyclone through a first feeding pump for pre-grading; after grading of the coal slime in the grading cyclone, feeding overflow in the grading cyclone into a flotation column through a second feeding pump for flotation, discharging flotation tailings through an underflow port of the flotation column, collecting flotation concentrates through an overflow port of the flotation column and feeding same into a bubble generator through a fourth feeding pump, and the flotation concentrates passing through the bubble generator and being fed from the bottom of a hydraulic flotation machine; and feeding underflow in the grading cyclone into the hydraulic flotation machine through a third feeding pump, for flotation and recovery.