Process Water Treatment With Microbubble Cleaning Flotation
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Solution Overview
Problem
Conventional process water treatment methods for flotation processes result in contaminated recirculation due to residual flotation chemicals, fine particles, and microbiological contaminants, leading to disrupted flotation processes and reduced recovery efficiency in closed-loop systems.
Innovation Solution
A method involving dewatering underflow in a gravitational solid-liquid separator followed by cleaning flotation using microbubbles to separate fine particles and residual chemicals, forming purified process water that is recirculated back into the flotation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional tailings dam treatment with long retention time (20-40 days) is used, then residual flotation chemicals are decomposed and water quality is acceptable for reuse, but the treatment process is time-consuming and requires significant space
Solution Approach 1:
The patent replaces the conventional passive sedimentation system (tailings dam relying on gravity and long retention time) with an active flotation system using microbubbles. The microbubble flotation unit actively separates fine particles and chemicals from water through buoyancy forces generated by gas bubbles, achieving rapid clarification without requiring 20-40 day retention periods.
Solution Approach 2:
The patent utilizes phase transition by introducing gas phase microbubbles into the liquid phase supernatant. The microbubbles attach to fine particles and residual chemicals, causing them to float to the surface where they can be removed. This phase transition mechanism enables rapid separation that replaces the slow gravitational sedimentation process.
2Reliability
If conventional tailings dam treatment is used, then residual chemicals are decomposed, but separated water still contains undesired material in soluble form and fines do not have enough time to settle
Solution Approach 1:
The patent extracts fine particles and residual flotation chemicals from the supernatant using microbubble flotation. The microbubbles selectively attach to and carry these contaminants to the surface, where they form a removable froth layer. This extraction process removes both suspended fines and chemically-bound contaminants that would otherwise remain in the recirculated water.
Solution Approach 2:
The microbubbles serve as an intermediary medium between the liquid supernatant and the contaminants. The bubbles attach to fine particles and chemical residues, acting as carriers that transfer these contaminants from the water phase to the gas phase, enabling their removal without requiring long retention times for natural decomposition or settling.
3Productivity
If process water is recirculated in closed-loop systems, then water usage efficiency is improved, but flotation chemicals accumulate and disrupt the flotation process
Solution Approach 1:
The patent enables continuous operation of the closed-loop water system by continuously removing accumulated contaminants. The microbubble flotation unit operates continuously to separate fine particles and residual chemicals from the recirculated water, preventing the accumulation that would otherwise disrupt flotation processes. This continuous cleaning action maintains water quality throughout the closed-loop system.
Solution Approach 2:
The patent converts the harmful effect of accumulated flotation chemicals and fine particles into a beneficial separation process. By introducing microbubbles that selectively attach to these contaminants, the system transforms the problematic accumulation into an easily removable froth phase, turning a harmful buildup into a convenient separation opportunity.
4Adaptability or versatility
If recirculated process water contains residual flotation chemicals, then closed-loop operation is maintained, but flotation process control becomes more challenging and recovery efficiency decreases
Solution Approach 1:
The patent implements a feedback mechanism where the microbubble flotation unit continuously monitors and removes contaminants from the recirculated water. By maintaining water quality through active removal of fine particles and residual chemicals, the system provides feedback control that prevents accumulation disruptions, thereby maintaining both closed-loop operation and ease of process control.
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 method effectively removes residual flotation chemicals and fine particles, improving flotation process control and recovery efficiency by preventing chemical interference and maintaining water quality, thus enhancing the overall operation of closed-loop systems.
Implementation Method 1
dewatering underflow in a gravitational solid-liquid separator to separate a sediment from a supernatant
Implementation Method 2
subjecting the supernatant to cleaning flotation, in which at least 90 % of the flotation gas bubbles have a size from 0,2 to 250 μm, in a cleaning flotation unit for collecting at least fine particles and residual flotation chemicals
Data Source
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AI summary
A method for treating process water of a flotation arrangement (1) is disclosed, the flotation arrangement comprising flotation arrangement (1) comprising a mineral flotation line (10) and a process water treatment arrangement (20) for treating underflow of the mineral flotation line. The method comprises the steps of a) dewatering underflow from the flotation in a gravitational solid-liquid separator (21); b) subjecting supernatant (221) from step a) to cleaning flotation for collecting at least fine particles and residual flotation chemicals, for separating at least fine particles and residual flotation chemicals from the supernatant into cleaning flotation overflow (232), and for forming purified process water (231) as cleaning flotation underflow; c) removing cleaning flotation overflow (232) as tailings, and d) recirculating purified process water (231) into the mineral flotation line (10).