Froth Modifier Composition for High-Grade Flotation Without Excess Foam
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Solution Overview
Problem
Existing froth flotation processes face challenges in achieving high purity and yield of beneficiated minerals while minimizing excessive frothing and froth handling issues, particularly in large-scale flotation cells.
Innovation Solution
The use of modifier compositions comprising fatty acid triglycerides and alkoxylated fatty alcohols, along with other components like collectors and pH adjusters, in sparge compositions to optimize froth flotation processes, enhancing the separation of minerals such as phosphate, lithium, and iron ores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extensive grinding or comminution is performed to liberate particles for better separation, then the liberation of particles is improved, but the energy consumption and processing time increase
Solution Approach 1:
The patent changes the chemical parameters of the flotation system by introducing specific modifiers (fatty acid triglycerides and alkoxylated fatty alcohols) that alter the surface properties of particles. This allows for effective separation without requiring extensive mechanical comminution, thereby reducing processing time while maintaining particle liberation quality.
2Manufacturing precision
If changes are made to chemistry or cell size to improve separation, then the purity of concentrate is improved, but excessive frothing occurs which reduces yield and causes handling issues
Solution Approach 1:
The patent introduces specific chemical modifiers (fatty acid triglycerides and alkoxylated fatty alcohols) as intermediaries that mediate between the collector and the mineral particles. These modifiers control the froth formation process, allowing high concentrate purity to be achieved without generating excessive froth that would reduce yield or cause handling problems.
Solution Approach 2:
The patent modifies the chemical composition parameters of the flotation system by adding specific ratios of fatty acid triglycerides (0.01-5% by weight) and alkoxylated fatty alcohols (0.01-5% by weight). This controlled parameter change optimizes froth stability to achieve pure concentrate while preventing excessive frothing.
3Productivity
If the size of flotation cells is increased to process more minerals, then productivity is improved, but froth removal becomes more difficult and recovery decreases
Solution Approach 1:
The patent changes the chemical parameters within the flotation cell by introducing specific modifiers that control froth properties. The fatty acid triglycerides and alkoxylated fatty alcohols adjust the froth stability and flow characteristics, making froth removal easier in large-scale cells while maintaining high processing capacity and recovery rates.
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
Improves the purity and yield of beneficiated minerals by stabilizing froth formation, reducing excessive frothing, and addressing froth handling issues in large-scale flotation cells.
Implementation Method 1
In froth flotation separation of a mineral ore, the ore is finely ground (comminuted) to form a comminuted ore in the form of a particulate. The comminuted ore is slurried in a liquid medium, typically water, to make a slurry that is a sparge composition.
Implementation Method 2
When the sparge composition is sparged, bubbles associate with the more hydrophobic particles present in the ore, and rise up out of the slurry; and the associated bubble-particle composite forms a layer, referred to as a 'froth' or 'overflow'.
Implementation Method 3
The role of a collector is to assist the flotation of targeted particles in the sparge composition. When the sparge composition is sparged, bubbles associate with the more hydrophobic particles present in the ore, and rise up out of the slurry.
Implementation Method 4
The role of a depressant is to hinder or prevent the flotation of untargeted particles in the sparge composition.
Data Source
AI summary
Modifier compositions, improved sparge compositions for froth flotation separation containing the modifier compositions, and improved methods of froth flotation using the modifier compositions have been developed, as well as kits including the modifier composition for industrial use. The modifier compositions obtain both improved yield and a higher grade of a targeted mineral product in froth flotation of one or more phosphate, lithium, and/or iron ores, while avoiding excess foam formation during the flotation.