Flotation Cell Segmented Feed for Particle Recovery
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Solution Overview
Problem
Conventional flotation cells face challenges in efficiently recovering both coarse and fine particles, with coarse particles causing wear and maintenance issues, and fine particles being difficult to entrain due to large flotation gas bubbles, leading to suboptimal recovery rates and increased energy consumption.
Innovation Solution
The flotation cell design incorporates a primary slurry feed of fresh slurry fed into the upper part and a secondary slurry feed of recirculated slurry fed below, forming a fluidized bed, allowing for efficient bubble-particle agglomeration and reducing fluid volume, while avoiding the need for classification and minimizing wear, thus enhancing recovery of various particle sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional flotation cells use large flotation gas bubbles, then the structure is simple, but fine particles are difficult to entrain and recovery is poor
Solution Approach 1:
The invention segments the flotation cell into two distinct zones: a fluidized bed zone at the bottom for fine particle flotation and a settling zone at the top for coarse particle recovery. This segmentation allows each zone to use optimized bubble sizes - fine bubbles in the fluidized bed for fine particles and larger bubbles in the settling zone for coarse particles - thereby resolving the contradiction between recovery rate and structural simplicity.
Solution Approach 2:
The invention applies local quality by providing different bubble characteristics to different regions of the flotation cell. The fluidized bed zone receives fine flotation gas bubbles optimized for fine particle attachment, while the settling zone allows larger bubbles to form for coarse particle recovery. This localized optimization enables high recovery rates for both fine and coarse particles without requiring complete structural redesign.
2Productivity
If conventional flotation cells treat coarse particles, then they can handle a broader size range, but coarse particles cause wear and maintenance issues
Solution Approach 1:
By segmenting the flotation process into a fluidized bed zone for fine particles and a settling zone for coarse particles, the invention protects the wear-prone fluidized bed components from coarse particle damage. Coarse particles are introduced later in the settling zone where they do not cause the same level of wear to spargers and distributors, thereby maintaining reliability while preserving the ability to recover coarse particles.
Solution Approach 2:
The invention applies preliminary action by pre-flotating fine particles in the fluidized bed zone before the slurry enters the settling zone. This sequential processing allows fine particles to be removed first, protecting downstream components from their abrasive effects, while coarse particles are then handled in a separate zone designed to minimize wear.
3Productivity
If conventional flotation cells use a single feed inlet, then the structure is simple, but it cannot optimize recovery for both fine and coarse particles simultaneously
Solution Approach 1:
The invention introduces a secondary feed inlet that feeds slurry directly into the fluidized bed zone, separate from the main feed inlet that feeds the settling zone. This segmentation of feed entry points allows fine particles to be introduced into the fine-bubble environment of the fluidized bed while coarse particles enter the settling zone, optimizing recovery for both size ranges without requiring excessive structural complexity.
Solution Approach 2:
The fluidized bed zone serves multiple functions: it acts as both a flotation zone for fine particles and a pre-treatment zone that protects the settling zone from fine particle interference. The secondary feed inlet similarly serves dual purposes by introducing fresh slurry while also maintaining fluidized bed operation. This multi-functionality achieves enhanced recovery without proportional increases in complexity.
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 design improves the recovery of valuable particles across all size ranges, reduces energy consumption, and simplifies the flotation cell structure, enhancing operational efficiency and cost-effectiveness.
Implementation Method 1
fluidized bed flotation gas bubbles adsorb to hydrophobic particles to form bubble-particle agglomerates
Implementation Method 2
a fluidized bed formed by fluid feed configured to supply a fluid to the flotation cell
Data Source
AI summary
A flotation cell for treating particles suspended in slurry. The flotation cell includes a fluidized bed, a recovery zone at the upper part of the flotation cell, a launder lip and a recovery launder, and a tailings outlet. A primary slurry feed including fresh slurry is arranged to be fed into the flotation cell by a first feed inlet at a first position; and a secondary slurry feed including at least slurry recirculated from a flotation cell is arranged to be fed into the fluidized bed by a second feed inlet at a second position, below the first position. The slurry recirculated from the flotation cell is obtained at a third position between the recovery launder and the tailings outlet. A use of the flotation cell as well as a method for treating particles suspended in slurry are also disclosed.