Flexible Perforated Membrane Sparger for Uniform Bubble Distribution

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing flotation machines face challenges in achieving homogeneous bubble size distribution, improving particle-bubble contact, and maintaining self-cleaning functionality, which affects the efficiency of mineral separation and recovery in industrial processes.

Innovation Solution

A flexible perforated membrane sparger is introduced to optimize bubble size distribution and enable periodic self-cleaning, combined with a method of dual-shearing aerated fluids to enhance the introduction of reagentized slurry into the flotation apparatus, ensuring uniform aerated fluid distribution and maintaining feed density and water balance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If a solid porous sparger is used to entrain air into feed slurry, then aeration function is provided, but bubble size distribution becomes non-uniform and sparger clogs over time

Engineering Contradiction:

Improveair entrainmentVSAvoidbubble size distribution uniformity

Core Design Contradiction:

Quantity of substanceVSManufacturing precision

Solution Approach 1:

The patent employs a porous sparger structure with controlled pore sizes and distributions to generate uniform fine bubbles. The porous material is selected and engineered to provide consistent bubble nucleation sites, ensuring homogeneous bubble size distribution while maintaining effective air entrainment in the feed slurry.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent optimizes sparger parameters including pore size, pore density, and sparger geometry to control bubble formation. By adjusting these parameters, the system achieves uniform bubble size distribution and prevents clogging while maintaining effective aeration function.

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If sparger structure is simplified for ease of manufacture, then manufacturing cost decreases, but self-cleaning functionality is lost

Engineering Contradiction:

Improvesparger fabricationVSAvoidself-cleaning capability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The sparger design incorporates self-cleaning functionality through its geometric structure and operational characteristics. The sparger geometry promotes fluid flow patterns that prevent particle accumulation, and the system can be purged periodically to maintain performance without requiring complex mechanical cleaning mechanisms.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent implements periodic purging cycles where reverse flow or high-velocity fluid is introduced to the sparger to dislodge and remove accumulated particles. This periodic maintenance action restores sparger performance without requiring complex continuous cleaning mechanisms.

Inventive Principle:

Principle #19Periodic action

3Productivity

If bubble size is reduced to improve particle-bubble contact, then flotation efficiency increases, but energy consumption increases

Engineering Contradiction:

Improveflotation efficiencyVSAvoidaeration energy

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The porous sparger generates fine bubbles passively through its structure without requiring high-energy input. The pore geometry and distribution are designed to create uniform fine bubbles that provide excellent particle-bubble contact efficiency, achieving high flotation performance with low energy consumption compared to mechanical bubble generators.

Inventive Principle:

Principle #31Porous materials

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 results in improved flotation efficiency by achieving finer bubble sizes, enhanced mineral attachment, and maintaining self-cleaning capabilities, leading to increased recovery rates and optimized bubble-mineral contact within the flotation process.

Implementation Method 1

a method of dual-shearing of aerated fluids comprising liquid and reagent

Methodology Applied

Scientific EffectShear stress: Shear Stress

Implementation Method 2

a solid porous sparger may be used to entrain air into feed slurry entering a separation device capable of flotation

Methodology Applied

Scientific EffectAir entrainment: Air Entrainment

Implementation Method 3

separations may be made by particle minerology, composition, density, and/or hydrophobicity

Methodology Applied

Scientific EffectHydrophobicity: Hydrophobe

Implementation Method 4

A flexible perforated membrane sparger is introduced to optimize bubble size distribution and enable periodic self-cleaning

Methodology Applied

Scientific EffectFlexible deformation: Elasticity

Data Source

PatentUS20240375122A1Apparatus and method for reagentizing and aerating feed to flotation machines

Publication Date: 2024.11.14 F L SMIDTH & CO AS

AI summary

A flotation circuit (1) is characterised in that it comprises a sparger (8) having a sparging mix conduit or chamber (45); and a tube (31) comprising a flexible perforated membrane disposed within the sparging mix conduit or chamber (45). The tube (31) is configured to receive an aerated fluid (27) comprising a combination of sparger water (13), reagent (17), and sparger air or gas (21) therein, shear the aerated fluid (27) upon passing of the aerated fluid (27) through the flexible perforated membrane of the tube (31), and disperse sheared aerated fluid (27) into the sparging mix conduit or chamber (45) where it is combined with incoming feed slurry (2) or diluted incoming feed slurry (4) moving within the sparging mix conduit or chamber (45) to form reagentized aerated slurry (29) for feeding a flotation apparatus (30).