Froth Flotation Collector Emulsion Stability
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Solution Overview
Problem
Froth flotation separation processes face challenges in effectively dispersing water-immiscible collectors in slurry due to the contradictory chemistry between hydrophobic collectors and the aqueous medium, leading to impaired hydrophobicity and reduced performance, which interferes with other additives like frothing agents.
Innovation Solution
A method involving the creation of a stable oil-in-water type collector emulsion using an emulsifier and a thickener, where the emulsifier has a hydrophobic and hydrophilic portion, and the thickener increases the viscosity of the solution, allowing for effective dispersion of collectors in the slurry without completely surrounding them, thus maintaining sufficient hydrophobicity for interaction with concentrate particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If sufficient amounts of emulsifiers are used to disperse water-immiscible collectors in slurry, then the collectors disperse better in the aqueous medium, but the hydrophobicity of the collectors is reduced which defeats the purpose of being a collector
Solution Approach 1:
The patent applies partial action by using an insufficient amount of emulsifier that does not completely surround the collector droplets. This partial emulsification creates a stable dispersion while leaving portions of the collector surface exposed to maintain hydrophobicity. The emulsifier coverage is deliberately kept below complete coverage to balance dispersion stability with collector effectiveness.
Solution Approach 2:
The patent changes the physical parameter of viscosity by adding a thickening agent to the slurry. This viscosity increase stabilizes the partially emulsified collector dispersion without requiring complete emulsifier coverage. The thickener compensates for the reduced stability from partial emulsification, allowing the system to maintain both dispersion and hydrophobicity.
2Stability of the object's composition
If emulsifiers are used to disperse collectors in slurry, then the collectors can be dispersed in the aqueous medium, but the emulsifiers interfere with other additives like frothing agents
Solution Approach 1:
By using insufficient amounts of emulsifier that do not completely cover the collector droplets, the patent reduces the total emulsifier concentration in the system. This partial action minimizes the interference with frothing agents and other additives while still achieving adequate dispersion through the combined effect of partial emulsification and thickening.
3Reliability
If collectors adhere to the surfaces of concentrate particles, then the concentrate can be separated from slurry, but the hydrophobic collectors do not disperse well in water making interactions difficult
Solution Approach 1:
The patent uses partial emulsification with insufficient emulsifier amounts, creating a dispersion where collector droplets are partially stabilized in the aqueous phase. This partial action allows adequate dispersion for transport and mixing while maintaining sufficient hydrophobic surface area for effective concentrate particle interaction during flotation.
Solution Approach 2:
The thickening agent acts as an intermediary that stabilizes the collector dispersion without interfering with the collector-concentrate interaction. The increased viscosity provides mechanical stability to the dispersion while the collector surfaces remain sufficiently exposed to adhere to concentrate particles.
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 the efficiency of the froth separation process by improving the stability and performance of the collector emulsion, allowing for increased recovery of the valuable concentrate while reducing the required dosage of emulsifier, thereby overcoming the limitations of using emulsifiers alone.
Implementation Method 1
making stable oil-in-water type collector emulsion with emulsifier and thickener
Implementation Method 2
the thickener increases the viscosity of the solution
Implementation Method 3
The slurry is then sparged to form bubbles which rise up out of the slurry. The more hydrophobic material (the concentrate) adheres to and rises up with the bubbles
Data Source
AI summary
The invention provides methods and compositions for improving a froth flotation type separation. The method uses a thickener to improve the effectiveness of an emulsifier. The improvement allows for low dosages of emulsifier to work well so the emulsifier does not cancel out the effectiveness of other additives in the slurry such as collectors, frothing agents, regulators, depressors, deactivators, and/or activators.