Dual-Lip Flotation Unit for Coarse Particle Recovery
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Solution Overview
Problem
Conventional mechanically agitated flotation cells are inefficient for recovering coarse mineral ore particles larger than 150 μm, requiring energy-intensive grinding and increased raw ore volume to maintain production levels.
Innovation Solution
A froth flotation unit comprising a flotation tank with a froth collecting launder and a near coarse launder, where the near coarse launder's lip is positioned closer to the bottom of the tank than the froth overflow lip, allowing for simultaneous recovery of particles within the 20 μm to 150 μm range and coarse particles greater than 150 μm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mechanical flotation cells are used, then particles within size range of 20 μm to 150 μm can be recovered, but coarse particles greater than 150 μm cannot be recovered efficiently
Solution Approach 1:
The flotation cell is divided into two distinct functional zones: an upper froth collection zone with a froth overflow lip for fine particles (20-150 μm) and a lower near-coarse zone with a near-coarse launder lip positioned closer to the bottom for coarse particles (>150 μm). This segmentation allows each zone to optimize for its specific particle size range simultaneously.
Solution Approach 2:
The invention adds a vertical dimension to particle separation by positioning launders at different heights within the flotation cell. The near-coarse launder lip is positioned at a lower vertical level than the froth overflow lip, creating height-based separation pathways that enable recovery of both fine and coarse particles through different overflow mechanisms.
2Productivity
If grinding is applied to recover coarse particles, then recovery efficiency improves, but energy consumption increases significantly
Solution Approach 1:
The invention extracts the near-coarse particle recovery function from the conventional single-zone flotation cell by introducing a dedicated lower zone with a separate near-coarse launder lip positioned closer to the tank bottom. This extracted zone specifically captures coarse particles (>150 μm) that would otherwise be missed, eliminating the need for energy-intensive grinding operations.
3Productivity
If raw ore volume is increased to maintain production, then production level is maintained, but processing complexity and cost increase
Solution Approach 1:
The flotation cell is designed with multi-functionality to handle both fine particle flotation (20-150 μm) and near-coarse particle recovery (>150 μm) within a single unit. The dual-laurer configuration with lips at different heights enables the same device to perform multiple separation functions simultaneously, eliminating the need for separate processing lines for different particle sizes.
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 solution enables efficient recovery of both fine and coarse particles without the need for energy-intensive grinding, improving the sustainability and efficiency of mineral ore processing.
Implementation Method 1
a froth flotation unit comprising: a flotation tank having a top, bottom and one or more wall(s); a froth collecting launder having a froth overflow lip; and a near coarse launder having a second lip; wherein the second lip is arranged closer to the bottom of the flotation tank than the froth overflow lip
Data Source
AI summary
A froth flotation unit including a flotation tank, a froth collecting launder having a froth overflow lip and a near coarse launder having a second lip. The second lip is arranged closer to the bottom of the flotation tank than the froth overflow lip. A froth flotation method for treating coarse particles suspended in slurry in the froth flotation unit is also provided.