Microbubble Generator Flotation Cell Fine Particle Recovery
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional mechanical flotation cells struggle to efficiently recover fine mineral ore particles due to the use of relatively large flotation gas bubbles, which are not effective in trapping finer particles, leading to these particles being lost in the tailings.
Innovation Solution
The introduction of microbubbles into mechanical flotation cells, generated by a microbubble generator, allows for the efficient recovery of fine mineral ore particles by increasing the residence time of microbubble-fine particle agglomerates within the flotation line, without the need for additional pumping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional mechanical flotation cells use large flotation gas bubbles, then the structure is simple and easy to operate, but fine mineral ore particles are not effectively trapped and are lost in tailings
Solution Approach 1:
The flotation gas introduction system is segmented into two distinct components: a mechanical agitator for general mixing and a separate microbubble generator for producing fine bubbles. This segmentation allows each component to perform its specialized function optimally, resolving the contradiction between structural simplicity and fine particle recovery effectiveness.
Solution Approach 2:
A microbubble generator is introduced as an intermediary device between the mechanical agitator and the slurry. This intermediary component transforms the large bubbles from the mechanical agitator into microbubbles (1-100 μm) that are effective for trapping fine particles, while maintaining the overall simplicity of the flotation cell structure.
2Productivity
If microbubbles are introduced into mechanical flotation cells, then recovery of fine particles improves, but device complexity increases
Solution Approach 1:
The microbubble generator is merged with the existing mechanical agitation system, where the microbubble generator utilizes the mechanical energy from the agitator to drive bubble formation. This merging approach integrates the microbubble generation function into the existing structure, minimizing additional complexity while achieving fine particle recovery.
Solution Approach 2:
The mechanical agitator serves dual functions: traditional mixing and driving the microbubble generator. This multi-functionality reduces the need for separate dedicated microbubble generation equipment, thereby limiting the increase in device complexity while still achieving improved fine particle recovery.
3Productivity
If microbubble-fine particle agglomerates are introduced into flotation cells, then residence time increases and recovery improves, but additional pumping equipment is required
Solution Approach 1:
The flotation cell design allows microbubble-fine particle agglomerates to naturally rise to the surface and be collected in the overflow without requiring additional pumping equipment. The system uses the natural buoyancy of microbubbles and gravity-driven flow to achieve extended residence time and improved recovery, eliminating the need for extra pumping infrastructure.
Solution Approach 2:
The flotation cell is designed with optimized geometry and flow patterns that create equipotential conditions for bubble-particle agglomerates to rise naturally to the surface. This design eliminates the need for additional energy input from pumps by utilizing the existing gravitational and buoyant forces to achieve the desired residence time extension.
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 recovery of fine mineral ore particles, improving the overall efficiency of the flotation process by ensuring that valuable material is not lost in the tailings, even from ores of poor quality.
Implementation Method 1
at least one of the flotation cells comprising a mechanical agitator comprises, in addition to the mechanical agitator, a microbubble generator for introducing microbubbles into the slurry
Implementation Method 2
a flotation line for separating valuable metal containing ore particles from ore particles suspended in slurry
Implementation Method 3
a mechanical agitator comprising a rotor, a stator, and a system for introducing flotation gas into the flotation cell
Implementation Method 4
for the separation of slurry into underflow and overflow with the help of flotation gas
Implementation Method 5
underflow from a previous flotation cell is arranged to be led into a subsequent flotation cell by gravity
Data Source
Figure 1
Figure 2
Figure 3a~3b
AI summary
A flotation line (10) for treating mineral ore particles suspended in slurry is disclosed. The flotation line (10) comprises a rougher part (11) with at least one rougher flotation cell (111 a, 111 b) from which overflow is arranged to flow directly into a cleaner flotation line; and a scavenger part (12) with at least two scavenger flotation cells (112a, 112b) from which overflow is arranged to flow back into a rougher flotation cell (111 a, 111 b), or into a regrinding step (91) and then into a cleaner flotation line. Underflow from a last scavenger flotation cell is arranged to be removed from the flotation line (10) as tailings. At least 75 % of the flotation cells comprise a mechanical agitator (70) comprising a system for introducing flotation gas into the flotation cell. The flotation cells are connected in series and arranged in fluid communication. A subsequent flotation cell is arranged to receive underflow from a previous flotation cell. At least one of the flotation cells of the flotation line comprising a mechanical agitator (70) comprises a microbubble generator (60) for introducing microbubbles into the slurry.