Flotation Cell Pressurized Blast Tubes Fine Particle Recovery
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Solution Overview
Problem
Traditional flotation cells face challenges in recovering fine and ultrafine particles due to large bubble sizes and turbulence, leading to reduced recovery rates and increased use of frothers, which can destabilize the process and affect particle size distribution recovery.
Innovation Solution
The use of a flotation cell with pressurized blast tubes that create smaller, ultra-fine bubbles and optimize frother usage, allowing for improved bubble-particle interaction and reduced turbulence, enhancing the recovery of fine and coarse particles without compromising bubble formation or froth stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mechanical agitation is used to introduce flotation gas, then the flotation cell can operate with simple structure, but the generated bubbles are relatively large (0.8 to 2.0 mm) and cause turbulence that reduces recovery of fine particles
Solution Approach 1:
The patent replaces the traditional mechanical agitation system with a pressurized gas injection system. Gas is introduced under pressure (3-10 bar) through nozzles or spargers, creating fine bubbles (0.3-1.5 mm) without mechanical turbulence. This substitution eliminates the harmful turbulence while maintaining effective gas-liquid mixing for fine particle flotation.
Solution Approach 2:
The patent changes the pressure parameter of the flotation gas from atmospheric to pressurized (3-10 bar). This pressure increase forces gas through narrow nozzles or spargers, creating much finer bubbles that are more effective for fine particle recovery. The pressure parameter transformation directly addresses the bubble size issue without introducing mechanical turbulence.
2Reliability
If more frother is added to stabilize the process and improve froth formation, then froth stability improves, but fine and ultrafine particles are lost in the tailings due to excessive turbulence and large bubble sizes
Solution Approach 1:
The patent changes the physical state and size parameters of the bubbles by introducing pressurized gas through restricted nozzles or spargers. This creates fine bubbles (0.3-1.5 mm) that provide sufficient surface area for fine particle attachment while minimizing turbulence. The fine bubble regime maintains froth stability without requiring excessive frother addition.
Solution Approach 2:
The patent replaces mechanical agitation with pressurized gas injection, eliminating the turbulence that causes fine particle loss. The gas injection system creates gentle, controlled bubble rise that maintains froth stability while preventing the harmful turbulence associated with mechanical agitators.
3Productivity
If the flotation tank volume is increased to improve particle residence time and recovery, then more particles can be processed, but the device complexity and operational challenges increase
Solution Approach 1:
The patent replaces complex mechanical agitation systems with simple pressurized gas injection through nozzles or spargers. This substitution simplifies the overall cell structure while maintaining effective mixing and bubble generation. The system requires no moving parts, reducing mechanical complexity and operational challenges.
Solution Approach 2:
The patent uses pneumatic principles to introduce pressurized gas (3-10 bar) through nozzles or spargers for bubble generation and mixing. This pneumatic system replaces complex mechanical components with simpler pressure-driven gas injection, reducing device complexity while maintaining effective particle-bubble interaction.
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 of valuable material by creating a thicker froth layer and improving the distribution of bubbles, leading to higher bubble surface area and efficient entrapment of particles across various sizes, while minimizing frother dosage and process water recirculation issues.
Implementation Method 1
an elongated chamber arranged to receive under pressure the slurry infeed; and an outlet nozzle configured to restrict flow of slurry infeed from the outlet nozzle, and to maintain slurry infeed in the elongated chamber under pressure
Implementation Method 2
the blast tubes are disposed at a position relative to the bottom structure so as to induce mixing at the mixing zone
Implementation Method 3
the attachment of particles to bubbles occurs in the sparger unit
Data Source
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AI summary
A flotation cell (1) is disclosed for treating particles suspended in slurry and for separating the slurry into an underflow (400) and an overflow (500). The flotation cell comprises a flotation tank (10) with a centre (11), a perimeter (12), a substantially horizontal level bottom (13), and a side wall (14); a launder (2) and a launder lip (21) surrounding the perimeter (12) of the tank (11); and a bottom structure (7) arranged on the bottom (13), and having a shape that allows particles suspended in slurry to be mixed in a mixing zone (A) over the bottom structure, and to settle down in a settling zone (B) surrounding the bottom structure. The flotation tank further comprises blast tubes (4) for introducing slurry infeed (100) into the tank. In addition, a flotation line and use of the flotation line are disclosed.