Overflow Flotation Cell Upward Slurry Flow for Coarse Ore Recovery
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Solution Overview
Problem
Conventional froth flotation methods are inefficient in recovering coarse valuable ore particles due to their low contact angle with air bubbles, leading to particle dropback at the pulp/froth interface and increased energy consumption in grinding and classification processes.
Innovation Solution
The method involves grinding and classifying ore particles to create a slurry that is treated in overflow flotation cells with a continuous upwards flow, allowing coarse particles to be carried by the slurry flow and recovered without the need for buoyancy, thus eliminating the requirement for uniform particle size and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional froth flotation is used to separate valuable ore particles, then fine particles can be recovered, but coarse particles experience particle dropback at the pulp/froth interface due to low contact angle with air bubbles
Solution Approach 1:
Instead of relying on buoyancy force from air bubbles to lift coarse particles (conventional approach), the invention inverts the mechanism by using a continuous upwards slurry flow to carry particles upward. This flow-based transport eliminates the particle dropback problem at the pulp/froth interface that occurs with bubble-based flotation.
Solution Approach 2:
The invention transitions from pneumatic bubble-based flotation to hydraulic flow-based separation. A continuous upwards slurry flow is generated through the flotation cell, using fluid dynamics to transport both fine and coarse particles upward without relying on air bubble attachment, thereby eliminating the contact angle limitation.
2Manufacturing precision
If grinding and classification are performed to achieve uniform particle size for conventional flotation, then flotation efficiency improves, but energy consumption increases
Solution Approach 1:
The invention changes the operating parameters of the flotation cell to enable handling of varying particle sizes. By adjusting the continuous upwards slurry flow rate and other process parameters, the system achieves effective separation without requiring uniform particle size, thereby reducing grinding energy consumption while maintaining separation efficiency.
3Quantity of substance
If a deep froth layer is formed in conventional flotation cells, then fine particles are captured, but coarse particles detach from bubbles and fall back to the bottom
Solution Approach 1:
The invention extracts the harmful froth layer that causes coarse particle dropback. By operating without forming a deep froth layer and instead using a continuous upwards slurry flow, the system eliminates the interface where coarse particles detach and fall back, while still achieving effective separation through the flow mechanism.
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 enables efficient recovery of coarse valuable ore particles with increased mass pull and reduced energy consumption, allowing for larger flotation cells and varying particle size distributions, while minimizing water usage and maintaining high recovery rates.
Implementation Method 1
At least part of the valuable metal containing ore particles are adhered to the gas bubbles and rise upwards by buoyancy
Implementation Method 2
at least part of the valuable metal containing ore particles are adhered to the gas bubbles and rise upwards with the continuous upwards flow of slurry, and at least part of the valuable metal containing ore particles rise upwards with the continuous upwards flow of slurry
Data Source
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AI summary
A flotation method for recovering valuable metal containing ore particles from ore particles suspended in slurry is disclosed. In the method, the slurry is treated in an at least one overflow flotation cell (41) and the valuable metal containing ore particles are recovered by conducting the continuous upwards flow of slurry out of the at least one overflow flotation cell (41) as slurry overflow (412, 422, 432). At least part of the slurry overflow (412, 422, 432) is conducted to a further treatment step in a treatment system.