Flotation Line Blast Tubes for Fine Particle Recovery

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Traditional mechanical flotation cells struggle with recovering fine and ultrafine particles due to large bubble sizes and turbulence, which leads to reduced recovery rates and increased use of frothers, causing unstable process conditions and inefficiencies in coal operations.

Innovation Solution

The use of a flotation line with blast tubes that introduce flotation gas under pressure, creating smaller bubbles and optimizing frother usage, allowing for improved bubble-particle engagement and reduced turbulence, enhancing the recovery of fine and coarse particles without compromising bubble formation or froth stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If traditional mechanical flotation cells are used, then the flotation process can operate with simple equipment, but the recovery rate of fine and ultrafine particles deteriorates due to large bubble sizes and turbulence

Engineering Contradiction:

Improverecovery rate of fine and ultrafine particlesVSAvoidturbulence and large bubble sizes

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The flotation cell is divided into multiple compartments (roughing compartment, cleaning compartment, scavenging compartment) with distinct functions. Each compartment handles specific particle size ranges and flotation stages, allowing optimized bubble-particle interaction in each section while managing turbulence locally rather than throughout the entire cell.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A froth layer is introduced as an intermediary medium between the slurry and the overflow. The froth layer captures fine and ultrafine particles through bubble-particle agglomeration while dampening turbulence effects. Frothers are added to stabilize this intermediary froth phase, improving particle recovery without requiring high turbulence throughout the system.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If traditional mechanical agitation is used to introduce flotation gas, then the equipment structure remains simple, but bubble sizes become large and fine particle recovery deteriorates

Engineering Contradiction:

Improvefine particle recoveryVSAvoidbubble size distribution

Core Design Contradiction:

ProductivityVSShape

Solution Approach 1:

The traditional mechanical agitation system (rotor-stator) is replaced with a pneumatic gas introduction system using spargers and diffusers. Gas is introduced through porous elements at the bottom of each compartment, creating fine bubbles through pressure differential and gas flow control rather than mechanical shear. This substitution produces smaller, more uniform bubble sizes suitable for fine particle flotation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system controls bubble size by adjusting gas flow rate, pressure differential across spargers, and frother concentration rather than mechanical agitation speed. These parameter changes enable precise control of bubble-particle interaction for fine particles while maintaining stable froth formation and avoiding excessive turbulence.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If increased mechanical agitation is applied to improve mixing, then bubble-particle contact may improve, but turbulence increases and fine particle recovery deteriorates

Engineering Contradiction:

Improvebubble-particle engagementVSAvoidprocess stability and froth stability

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

Gas is introduced in periodic pulses through the spargers rather than continuous high-intensity agitation. This periodic gas introduction creates gentle mixing and bubble-particle contact while allowing the froth layer to stabilize between pulses. The periodic action maintains adequate bubble-particle engagement while preventing excessive turbulence that would destabilize the process and reduce fine particle recovery.

Inventive Principle:

Principle #19Periodic action

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 approach increases the recovery rate of valuable minerals by generating smaller bubbles, improving bubble-particle agglomeration, and reducing frother usage, leading to higher recovery rates and more stable froth formation across various particle sizes.

Implementation Method 1

a blast tube configured to restrict flow of slurry infeed from an outlet nozzle, and to maintain slurry infeed under pressure in the blast tube

Methodology Applied

Scientific EffectPressure gradient: Pressure Gradient

Implementation Method 2

The flotation line is provided for treating mineral ore particles suspended in slurry

Methodology Applied

Scientific EffectFroth flotation: Froth Floatation

Data Source

PatentUS12083539B2Flotation line

Publication Date: 2024.09.10 METSO OUTOTEC FINLAND OY

AI summary

A flotation line for treating mineral ore particles suspended in slurry is disclosed. The flotation line includes a scavenger part and a scavenger cleaner part. The flotation line is characterized in that the scavenger part or the scavenger cleaner part includes a flotation cell with blast tubes for introducing slurry infeed into the flotation cell; or in that the scavenger part or the scavenger cleaner part is followed by a flotation cell with blast tubes for introducing slurry infeed into the flotation cell. Further, a use of the flotation line is presented, as well as a flotation plant including a flotation line according to the invention.