Magnetically Steerable Froth for Flotation Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current flotation processes for separating valuable materials like minerals and bitumen from unwanted materials face inefficiencies due to issues with air bubble usage, such as incomplete separation and residual material in tailings, which affects recovery rates and processing throughput.
Innovation Solution
The introduction of magnetically controllable and steerable froth using magnetic surfactants and synthetic beads or bubbles, which allows for non-mechanical mixing and steering of the froth layer, enhancing separation efficiency by controlling froth transport and residence time within the flotation cell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If air bubbles are used for flotation separation, then valuable material can be carried to the surface, but incomplete separation and residual material in tailings occur reducing recovery rates
Solution Approach 1:
Magnetic particles are introduced as an intermediary substance that mediates between the air bubbles and valuable material. The magnetic particles attach to hydrophobic valuable material particles, providing a magnetic component that enables controlled interaction with magnetic fields for improved separation and reduced residual material in tailings
Solution Approach 2:
The invention changes the physical parameters of the flotation system by introducing magnetic properties through magnetic particles. This allows the froth layer to become magnetically responsive, enabling new control mechanisms that improve separation completeness and recovery rates by preventing incomplete separation
2Productivity
If traditional flotation cells are used, then processing can be performed, but froth residence time is uncontrolled causing minerals to recycle back into the cell
Solution Approach 1:
A magnetic field application system provides feedback control of the froth layer by detecting froth position and applying magnetic forces to adjust residence time. The magnetic field strength and distribution can be dynamically controlled to optimize froth transport and prevent premature recycling of minerals back into the cell
Solution Approach 2:
The invention replaces traditional mechanical froth control mechanisms with magnetic field control. Instead of using mechanical agitators or physical barriers to control froth residence time, magnetic fields act on the magnetically responsive froth layer to precisely control transport and residence time, improving processing throughput while minimizing mineral recycling
3Ease of operation
If magnetic field control is implemented, then froth transport and residence time can be controlled, but device complexity increases
Solution Approach 1:
The magnetic field generation system is designed to perform multiple functions: controlling froth transport, adjusting residence time, and enhancing separation efficiency. By making the magnetic field system multi-functional, the patent reduces the need for separate control mechanisms, thereby managing device complexity while improving ease of operation
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 improves the separation efficiency by ensuring uniform froth transport and residence time, reducing recycling of minerals back into the cell and increasing the recovery of valuable materials, while also allowing for the reuse of synthetic beads or bubbles in a closed loop process.
Implementation Method 1
a surfactant with magnetic properties so as to cause the formation of a froth layer that contains at least some of the material-of-interest and is magnetically responsive
Implementation Method 2
a magnetic field generator configured to generate a magnetic field and provide non-mechanical mixing and steering/driving of the froth layer
Implementation Method 3
The magnetic field, together with the magnetically responsive surfactant, should produce more rapid separation dynamics as compared to gravity alone as the froth can be 'magnetically pulled' up out of the water layer
Data Source
AI summary
The present invention provides new techniques related to magnetically controllable and/or steerable froth for use in separation processes of mineral-bearing ore and bitumen. Apparatus is provided featuring a processor configured to contain a fluidic medium having a material-of-interest and also having a surfactant with magnetic properties so as to cause the formation of a froth layer that contains at least some of the material-of-interest and is magnetically responsive; and a magnetic field generator configured to generate a magnetic field and provide non-mechanical mixing and steering/driving of the froth layer in the processor. The material-of-interest may be mineral-bearing ore particles or bitumen. The processor includes a flotation tank, a primary separation vessel (PSV), or a pipe, including a tailings pipeline. The pipe has a non-magnetic pipe section, and the magnetic field generator includes a magnetic coil arranged in relation to non-magnetic pipe section to generate the magnetic field and provide the non-mechanical mixing and steering/driving of the froth layer in the pipe.