Integrated Electromagnetic Mill and Flotation Cell
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Solution Overview
Problem
Existing flotation and crushing processes in ore processing plants face inefficiencies due to the need for separate units and the oxidation of metal ores during processing, which affects flotation results and requires additional cooling systems and complex aerator mechanisms.
Innovation Solution
A crushing and flotation machine integrating an electromagnetic mill with a vertical working chamber and a built-in flotation cell, where air is supplied from the bottom, eliminates the need for a separate aerator and allows direct passage of metal ores to the flotation cell, using agitating grinders to mix air and reagents, and incorporates a controlled valve system for efficient foam product handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If separate flotation and crushing units are used, then each unit can be optimized independently, but the overall system occupies more space and requires additional cooling systems
Solution Approach 1:
The patent combines the electromagnetic mill (crushing unit) and flotation cell into a single integrated machine. The mill occupies the lower portion while the flotation cell is positioned above it, sharing common structural elements and the same working chamber space. This merging eliminates the need for separate cooling systems and reduces the overall footprint while maintaining the temperature benefits of the crushing process for enhanced flotation.
Solution Approach 2:
The integrated machine performs multiple functions within a single device: the electromagnetic mill crushes and grinds ore while simultaneously generating heat, and the flotation cell above it performs mineral separation. The system universally handles both size reduction and flotation operations, with the heat from crushing being utilized to improve reagent activity in flotation, eliminating the need for separate cooling infrastructure.
2Ease of operation
If traditional aerators with rotors are used to mix air with pulp, then air dispersal is achieved, but the device complexity increases and energy consumption rises
Solution Approach 1:
The electromagnetic mill's agitating grinders serve a dual purpose: they crush the ore and simultaneously mix the air bubbles with the pulp and flotation reagents. The rotating grinders create turbulence and circulation that naturally disperses air throughout the slurry without requiring a separate aerator rotor. This self-service approach simplifies the device by eliminating complex aerator mechanisms while maintaining effective mixing.
Solution Approach 2:
The agitating grinders of the electromagnetic mill perform multiple functions: size reduction of ore, generation of heat, and mixing of air with pulp and reagents. This multi-functionality eliminates the need for dedicated aerator components, reducing device complexity while achieving effective air dispersal and reagent mixing through the same mechanical elements already present for crushing.
3Reliability
If metal ores are exposed to air during processing, then oxidation occurs affecting flotation results, but separate units require additional transfer mechanisms
Solution Approach 1:
The flotation cell is positioned directly above the electromagnetic mill within the same integrated machine structure. The mill outlet collector is guided coaxially through the bottom of the flotation cell, creating a direct vertical pathway for material transfer. This merging of functions within a single device eliminates intermediate transfer points where oxidation could occur, ensuring that crushed ore moves directly into the flotation environment without exposure to external air.
Solution Approach 2:
The integrated design enables continuous operation where crushed material flows directly from the mill into the flotation cell without interruption or exposure to the external environment. The direct vertical connection maintains a continuous sealed pathway, preventing air ingress and oxidation during the transfer process, while the coordinated operation of the mill and flotation cell ensures uninterrupted processing.
4Reliability
If cooling systems are added to prevent oxidation, then oxidation is controlled, but energy consumption increases and device complexity rises
Solution Approach 1:
Instead of treating the heat generated by the electromagnetic mill as a harmful effect requiring active cooling, the invention converts this thermal energy into a beneficial factor. The heat from crushing is utilized to increase the temperature of the slurry, which enhances the activity of flotation reagents and improves flotation efficiency. This approach eliminates the need for energy-consuming cooling systems while maintaining oxidation control through the sealed integrated design.
Solution Approach 2:
The invention changes the temperature parameter of the processing system by utilizing the heat generated during crushing. Rather than maintaining a constant or low temperature through active cooling, the system allows and exploits the temperature increase from 20-30°C to 40-50°C, which improves reagent activity and flotation results. This parameter change eliminates the need for cooling energy consumption while achieving better flotation performance.
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 integrated solution reduces space requirements, prevents oxidation of metal ores, enhances flotation efficiency, and saves energy by eliminating the need for additional cooling and aerator components, while improving reagent activity at higher temperatures.
Implementation Method 1
Electromagnetic mills are known wherein the milling process is performed within a fixed working chamber by means of agitating grinders that are ferromagnetic elements moving within a rotating electromagnetic field
Implementation Method 2
Flotation devices are commonly employed in ore processing plants to enrich mineral raw materials
Data Source
Figure 1
Figure 2
AI summary
The crushing and flotation device is an electromagnetic mill with vertical working chamber that is fed with air from the bottom and is original in that the electromagnetic mill (3) has an integrated flotation cell (6) installed in its top part so that the outlet collector (5) of the electromagnetic mill (3) is passed centrally through the flotation cell (6) bottom that is fitted with the outflow nozzle (9) controlled via adjustment valve (10). Moreover, the overflow step (7) of the flotation cell (6) chamber is inside the overflow tank (17) that is discharged by way of overflow nozzle (8), and the slurry is supplied from the bottom part of the electromagnetic mill (3) via the supply stub pipe connected with pump (2). Furthermore, the control adjustment valve (10) and the pump (2) are connected using signal cables or wireless methods with the control unit, which is in turn connected using signal cable or wireless the pulp (11) level sensor.