Froth Flotation Partitioning Composition Without pH Adjustment
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Solution Overview
Problem
Conventional froth flotation processes require multiple separate steps for adding chemicals to the ore slurry, including pH adjustment, which pose safety hazards due to the use of low flash point petroleum compounds, and are inefficient in terms of yield and purity.
Innovation Solution
A partitioning composition comprising alkoxylated fatty alcohols, triglycerides, fatty acids, fatty acid salts, and hydrotreated petroleum distillate is used, eliminating the need for separate chemical additions and pH adjustment, allowing a single step preparation of the sparge composition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate chemical additions and pH adjustment are performed in conventional froth flotation processes, then the separation of beneficiary from gangue can be achieved, but the process complexity increases and safety hazards arise due to use of low flash point petroleum compounds
Solution Approach 1:
The patent combines multiple separate chemical addition steps (collector, frother, modifier, depressant) and pH adjustment into a single integrated chemical addition step. The sparge composition is formulated to contain all necessary chemicals that work synergistically, eliminating the need for sequential additions and reducing process complexity while maintaining separation effectiveness.
Solution Approach 2:
The sparge composition serves multiple functions simultaneously: it acts as a collector, frother, modifier, and pH buffer in a single formulation. This multi-functional approach replaces the conventional need for multiple specialized chemical additions, simplifying the process while achieving the same separation objectives.
2Manufacturing precision
If multiple separate chemical additions and conditioning steps are performed, then optimal partitioning can be achieved, but the processing time increases
Solution Approach 1:
The sparge composition is pre-formulated with all necessary chemicals in optimal concentrations and ratios, eliminating the need for sequential additions and conditioning periods. The chemicals are designed to work synergistically from the moment of contact with the ore slurry, achieving optimal partitioning faster than conventional multi-step processes.
Solution Approach 2:
The integrated sparge composition enables continuous action of all chemical functions simultaneously rather than sequentially. The collector, frother, modifier, and pH adjustment occur concurrently, eliminating idle conditioning time between steps and maintaining continuous useful action throughout the flotation process.
3Ease of operation
If low flash point petroleum compounds are used in conventional froth flotation, then the froth formation and particle attachment can be achieved, but safety hazards increase
Solution Approach 1:
The patent modifies the chemical formulation by replacing low flash point petroleum compounds with alternative chemicals that provide equivalent froth formation and particle attachment capabilities but with higher safety profiles. The sparge composition uses chemicals with higher flash points or non-flammable properties, maintaining operational effectiveness while eliminating safety hazards.
Solution Approach 2:
The patent converts the harmful flammability characteristic of conventional petroleum-based modifiers into a benefit by selecting alternative chemicals that eliminate fire hazards while maintaining or improving froth stability and particle attachment. The safer chemicals provide the same functional benefits without the associated safety risks.
4Reliability
If extensive grinding is performed to liberate particles, then the separation of beneficiary and gangue is improved, but the energy consumption and processing time increase
Solution Approach 1:
The sparge composition is formulated to enhance particle surface properties and improve the efficiency of the flotation separation. The chemicals in the composition promote better particle-bubble attachment and selective flotation, allowing for effective separation with reduced grinding intensity, thereby lowering energy consumption while maintaining liberation quality.
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
The simplified process enhances efficiency and safety by reducing the number of steps, improving yield and purity of the beneficiated mineral, while avoiding the use of low flash point chemicals.
Implementation Method 1
In a process known as sparging, a gas, typically air, is bubbled through the sparge composition, and a froth forms at the surface of the sparge composition. During sparging, some materials from the ore such as targeted particles are carried up with the gas bubbles (i.e. floated) and concentrate in the froth, whereas other materials concentrate in the body of the liquid, the underflow.
Implementation Method 2
increasing hydrophobicity of bubble surfaces and/or beneficiary particle surfaces to maximize adsorption of the beneficiary particles to the bubble surfaces
Implementation Method 3
maximize adsorption of the beneficiary particles to the bubble surfaces
Data Source
AI summary
Improved partitioning compositions for froth flotation of mineral ores, and improved methods of froth flotation using the partitioning compositions have been developed. The partitioning compositions are suitably added to a mineral ore slurry in a single addition to provide a sparge composition that is ready for sparging. The use of the partitioning compositions obviates the need to adjust the pH of the ore slurry before or after the addition, and further avoids the use of compounds having a flashpoint of 60° C. or less. Meanwhile, the partitioning compositions obtain improved grade and recovery of phosphate product (P2O5) in froth flotation of phosphate ores, when compared to conventional chemistry and methods used for froth flotation of a phosphate ores.