Column Flotation Cell Down Pipe Aeration for Phosphate Recovery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional column flotation cells for phosphate recovery face issues such as choking due to impurity plugging, algae growth, high maintenance needs, and high energy consumption, leading to reduced efficiency and increased operational costs.
Innovation Solution
The use of a column flotation cell design with down pipes for aerated water distribution and a cell density control process, which eliminates choking, reduces energy consumption, and allows for easier maintenance, while also incorporating a compact design to minimize capital and maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional air sparger systems with orifices are used to aerate the flotation cell, then air dispersion is achieved, but the orifices become choked by impurities over time requiring maintenance
Solution Approach 1:
The invention removes the constriction plate with orifices from the system entirely. Instead of using a plate that can become choked, aerated water is introduced through down pipes that discharge into the cell, eliminating the component that causes choking while maintaining air dispersion functionality
Solution Approach 2:
Aerator stones are introduced as intermediary components at the discharge points of the down pipes. These stones provide the air dispersion function previously achieved by orifices, but without the choking problem, as they can be easily replaced or cleaned
2Reliability
If high velocity air bubbles are used to prevent impurity plugging, then choking is reduced, but energy consumption increases
Solution Approach 1:
The down pipes are positioned to discharge aerated water at the bottom of the cell where the natural upward flow of rising air bubbles provides sufficient velocity to prevent impurity deposition. The system uses the flotation process itself to maintain pipe clearance rather than requiring additional high-energy air injection
3Ease of operation
If feed well is located under water level to distribute slurry, then slurry distribution is improved, but algae growth is promoted in low turbulence areas
Solution Approach 1:
The feed well is designed with adjustable positioning capabilities, allowing it to be moved to different depths and locations within the cell. This dynamic adjustment enables optimization of slurry distribution while avoiding stagnant low-turbulence areas where algae would grow, adapting to different operational conditions
4Productivity
If constriction plate with multiple orifices is used to separate flotation and distribution compartments, then aerated water passage is enabled, but orifices become plugged by sand impurities
Solution Approach 1:
The constriction plate is completely removed from the system. The patent replaces this component with down pipes that discharge aerated water directly into the cell without requiring a separating plate, thereby eliminating the orifices that become plugged and reducing maintenance needs
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 enhances phosphate recovery efficiency, reduces downtime, and lowers operational costs by preventing choking and promoting continuous operation, with improved air dispersion and energy efficiency.
Implementation Method 1
The phosphate suspended in the aqueous slurry adheres to the rising air bubbles and collects at the upper end of the flotation compartment as a froth
Implementation Method 2
Air bubbles are introduced into the bottom of the fluid vessel 12 by flowing aerated water through the air sparger 14
Implementation Method 3
The impurities including sand and clay contained within the slurry along with any residual phosphate that is not captured by the levitating air bubbles percolates downwardly through the aqueous slurry by gravity
Data Source
AI summary
An apparatus for separating a mineral from a slurry of mineral and impurities, including a fluid vessel having a first, open end and a second end and a feed well disposed near the first end. The feed well has a first, open end, for receiving the slurry, and a second end. At least one first member is received through the first ends of the vessel and the feed well for providing aerated water, creating a froth in the feed well including substantially the mineral. The mineral froth substantially separates from the impurities and floats out of the feed well towards the first end of the vessel, and a collection unit receives the mineral froth. The impurities and any remaining mineral fall toward the second end of the vessel. A measurement unit is placed within the vessel for measuring at least one of density and pressure of the fluid in the vessel. A related process includes introducing the slurry into the first, open end of the feed well, providing aerated water to the feed well and the vessel in a direction from the first ends to the second ends, respectively, creating a froth in the feed well including substantially the mineral, substantially separating the mineral froth from the impurities, collecting the mineral froth, and allowing the impurities and any un-separated mineral to fall towards the second end of the vessel. Further, the process includes measuring at least one of density and pressure of the fluid in the vessel.