Experimental Study and Analysis on Performance and Dedusting Efficiency of Frothing Generator

By simulating test and study in laboratory, the structure and performance offrothing generator were determined. The relative curves between the frothing volume and gas velocityof foaming net, supplying liquid volume and the content of foaming agent were obtainedrespectively. There were an optimum gas-velocity of foaming net, an optimum supplying liquid volumeand an optimum content of foaming agent under the condition of the given material quality and shapeof foaming net and spraying form. The spraying froth is of a great assistance in collectingrespirable dust.

A froth velocity measurement method based on improved U-Net++semantic segmentation in flotation process

During flotation,the features of the froth image are highly correlated with the concentrate grade and the corresponding working conditions.The static features such as color and size of the bubbles and the dynamic features such as velocity have obvious differences between different working conditions.The extraction of these features is typically relied on the outcomes of image segmentation at the froth edge,making the segmentation of froth image the basis for studying its visual information.Meanwhile,the absence of scientifically reliable training data with label and the necessity to manually construct dataset and label make the study difficult in the mineral flotation.To solve this problem,this paper constructs a tungsten concentrate froth image dataset,and proposes a data augmentation network based on Conditional Generative Adversarial Nets(cGAN)and a U-Net++-based edge segmentation network.The performance of this algorithm is also evaluated and contrasted with other algorithms in this paper.On the results of semantic segmentation,a phase-correlationbased velocity extraction method is finally suggested.

Nanobubble generation and its applications in froth flotation(part Ⅱ):fundamental study and theoretical analysis

Froth flotation is a commonly employed technology to improve the quality of raw coal and minerals.Coal and minerals particle size and surface hydrophobicity are two main parameters that affect three key steps in froth flotation process:particle-bubble collision,adhesion,and detachment.This paper fundamentally investigated the effects of nanobubble on coal and phosphate flotation.It has been found that the presence of nanobubble in flotation pulp could widen the coal and phosphate flotation particle size range,increase the particle surface hydrophobicity,and thus improve the coal and phosphate froth flotation recovery.

Flotation of indium-beard marmatite from multi-metallic ore

Flotation of indium-beard marmatite from Dulong multi-metallic ore in Yunnan Province of China was studied to improve the grades and recoveries of zinc and indium of the zinc concentrate in Dulong concentration plant. The experimental results indicated that copper sulfate mixed with a chemical reagent X- 1 as the activator in the marmatite flotation produced a much better beneficiation than copper sulfate alone, increasing the zinc and indium recoveries of 10% and 6%, respectively, while the concentrate grades remained unchanged. Also, the new activator acted well around pH 10, allowing large savings on lime consumption in the marmatite flotation. In addition, it has been found that a sufficient activated time of activator with ore slurry in the flotation is needed to achieve good beneficiation of the marmatite ore.

CFD model simulation of bubble surface area flux in flotation column reactor in presence of minerals

Bubble surface area flux(S_b) is one of the main design parameter in flotation column that typically employed to describe the gas dispersion properties, and it has a strong correlation with the flotation rate constant. There is a limited information available in the literature regarding the effect of particle type,density, wettability and concentration on Sb. In this paper, computational fluid dynamics(CFD) simulations are performed to study the gas–liquid–solid three-phase flow dynamics in flotation column by employing the Eulerian–Eulerian formulation with k-e turbulence model. The model is developed by writing Fortran subroutine and incorporating then into the commercial CFD code AVL FIRE, v.2014.This paper studies the effects of superficial gas velocities and particle type, density, wettability and concentration on Sband bubble concentration in the flotation column. The model has been validated against published experimental data. It was found that the CFD model was able to predict, where the response variable as indicated by R-Square value of 0.98. These results suggest that the developed CFD model is reasonable to describe the flotation column reactor. From the CFD results, it is also found that Sb decreased with increasing solid concentration and hydrophobicity, but increased with increasing superficial gas velocity. For example, approximately 28% reduction in the surface area flux is observed when coal concentration is increased from 0 to 10%, by volume. While for the same solid concentration and gas flow rate, the bubble surface area flux is approximately increased by 7% in the presences of sphalerite.A possible explanation for this might be that increasing solid concentration and hydrophobicity promotes the bubble coalescence rate leading to the increase in bubble size. Also, it was found that the bubble concentration would decrease with addition of hydrophobic particle(i.e., coal). For instance, under the same operating conditions, approximately 23% reduction in the bubble concentration is predicted when the system was working with hydrophobic particles. The results presented are useful for understanding flow dynamics of three-phase system and provide a basis for further development of CFD model for flotation column.

Surface chemical study of the selective separation of chalcopyrite and marmatite

FCLS (Ferric Chromium Lignin Sulfonate) was used to aid the separation of chalcopyrite from marmatite. Flotation, adsorption and zeta-potential tests of treated marmatite and chalcopyrite were performed. The flotation of marmatite was strongly depressed, while that of chalcopyrite was only slightly depressed, over a wide range of pH values when FCLS was used as depressant in the presence of Butyl Xanthate (BX). The adsorption of BX onto chalcopyrite or marmatite takes place over a wide pH range. The adsorption density of BX on chalcopyrite and marmatite decreases as the pH increases. The adsorption density of FCLS onto marmatite is greater than the adsorption density onto chalcopyrite. The zeta potentials of chalcopyrite and marmatite become more negative due to the addition of xanthate and FCLS.

Effect of pyrite content of feed and configuration of locked particles on rougher flotation of copper in low and high pyritic ore types

Misreported pyrite into copper concentrates dramatically declines copper grade and recovery. Copper flotation can be also more complicated if flotation feed comes from an elevated-pyritic copper ore. In this investigation, the effect of two different ore types(high pyritic and low pyritic feeds) was studied on rougher stage of industrial copper flotation circuit. Samples were taken from different streams and the structure of chalcopyrite within the pyrite and non-sulfide gangue minerals was examined in various size fractions for mentioned ore types. Results indicated that 72% and 56% of the total floated pyrite was transferred to concentrate in first four cells in the low and high pyritic feeds, respectively. Whereas, this proportion for floated SiO_2 in last ten cells was detected as 72% and 71%, respectively. A detailed interpretation of the effect of locked particles in different size fractions on rougher flotation cells is studied from industrial point of view.

Froth flotation of refuse coal fines and process optimization using 2D surface plots

Refuse coal fines of size <500 μm was collected from a metallurgical coal preparation plant located in the eastern coalfield region of India. The coal was beneficiated using froth flotation technique to recover clean coal with ash content of about 20% with the highest possible yield. Diesel oil as collector and pine oil as frother were used. Box-Behnken statistical design was followed for analyzing the performance at varying pulp density, collector and frother dosage. Results were discussed using 2D surface plots. Response function predictions determined by the regression analysis show coefficient of correlation(R^2) for yield and the ash content as 0.72 and 0.86, respectively. The highest yield of 45.79% is obtained at pulp density 10%, collector dose 2 kg/t and frother dose 1.5 kg/t. The lowest ash content of 18.9% is obtained at pulp density 10%, collector dose 1 kg/t and frother dose 1 kg/t.

Flotation Control System Based on Recognition of Froth Image

In industrial flotation, froth layer plays an important role and reflects directly whether coal, air, water and reagents match each other properly or not and whether the quality of flotation is good or not. So the supervision and recognition of the state of froth layer is very important in the flotation process. The ash content of clean coal froth was predicted through extracting the features of images of flotation froth. The froth images were classified according to their structure. A control system of adding flotation reagents was established based on the LVQ neural net.

Kinetic approach to the study of froth flotation applied to a lepidolite ore

The number of published studies related to the optimization of lithium extraction from low-grade ores has increased as the demand for lithium has grown. However, no study related to the kinetics of the concentration stage of lithium-containing minerals by froth flotation has yet been reported. To establish a factorial design of batch flotation experiments, we conducted a set of kinetic tests to determine the most selective alternative collector, define a range of pulp p H values, and estimate a near-optimum flotation time. Both collectors（Aeromine 3000 C and Armeen 12D） provided the required flotation selectivity, although this selectivity was lost in the case of pulp p H values outside the range between 2 and 4. Cumulative mineral recovery curves were used to adjust a classical kinetic model that was modified with a non-negative parameter representing a delay time. The computation of the near-optimum flotation time as the maximizer of a separation efficiency（SE） function must be performed with caution. We instead propose to define the near-optimum flotation time as the time interval required to achieve 95%–99% of the maximum value of the SE function.

Minimalization of Ash from Iranian Gilsonite by Froth Flotation

Gilsonite is a natural, brittle, and glisten tar hydrocarbon, which widely uses in the chemical, paint, and oil industry, besides asphalt production and thermal insulation. Major gangues of Gilsonite are gypsum, pyrite, silica, dolomite, calcite, and shale which are known as ash. Due to the fine liberation degree of gangue minerals from Gilsonite, most of the physical mineral processing methods are not applicable. Gilsonite has partially a behavior like coal in flotation due to its high carbon content and the similar composition of ash. As a result, flotation is one of the best methods to decrease the ash content of Gilsonite. In this study, four factors i.e. the dosage of collector, frother, and depressant, and solid to liquid ratio in three levels were examined in flotation to reduce the ash content and increase the recovery of Gilsonite. These tests were designed with the Taguchi method by Design-Expert software. Our results showed the lowest ash content of 5.2% was obtained in the condition which 200 g/t Gasoil as collector, 100 g/t MIBC as a frother, 300 g/t sodium silicate as a depressant, and pulp density was 5% solid to liquid weight ratio.

Destabilising persistent coal froth using silicone oil

Persistent froth is becoming more and more common in coal and mineral flotation plants and presents safety and operational challenges.No effective method has been developed to destabilise persistent froth.As a new initiative,this study examined the structural difference between persistent foam and coal froth,based on which a solution was developed to maximumly destabilise coal froth.Destabilisation test,oscillatory rheology measurement and scanning electron microscopy(SEM) analysis indicated that the coal froth was more stable than the foam due to the formation of thin capillaries and tightly arranged coal particles on bubble surfaces.Although 107 μm silicone oil droplet could completely destabilise the foam at 2 mmol/L concentration,it only destabilised less than 50% coal froth even at 6 mmol/L concentration.To maximumly destabilise the coal froth formed by-38 and-20 μm particles,24 and 18 μm silicone oil droplets were required to pass through the thin capillaries and enter the bubble films,respectively.However,smaller silicone oil droplets could not bridge the bubble films to destabilise coal froth and therefore a critical droplet size occurred depending on the size of particles stabilising the froth.

First-principle study on the surface atomic relaxation properties of sphalerite

The surface properties of sphalerite （ZnS） were theoretically investigated using first principle calculations based on the density functional theory （DFT）. DFT results indicate that both the （110） and the （220） surfaces of sphalerite undergo surface atom relaxation after geometry optimization, which results in a considerable distortion of the surface region. In the normal direction, i.e., perpendicular to the sur- face, S atoms in the first surface layer move outward from the bulk （dl）, whereas Zn atoms move toward the bulk （d2）, forming an S-enriched surface. The values of these displacements are 0.003 nm for dl and 0.021 nm for d2 on the （110） surface, and 0.002 nm for dl and 0.011 nm for d2 on the （220） surface. Such a relaxation process is visually interpreted through the qualitative analysis of molecular mechanics. X-ray photoelectron spectroscopic （XPS） analysis provides the evidence for the S-enriched surface. A polysulphide （S n^2- ） surface layer with a bind- ing energy of 163.21 eV is formed on the surface of sphalerite after its grinding under ambient atmosphere. This S-enriched surface and the S 2- surface layer have important influence on the flotation properties ofsphalerite. Keywords：

Flow field in air-sparged hydrocyclone

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STUDIES ON THE FROTH CHARACTERISTICS OF COMPOSITE COLLECTORS IN NONMETALLIC MINERAL FLOTATION

The flotation results of a phosphate ore are improved by replacing the conventional collectors of fatty acids with composite collectors. The synergistic effect on the froth characteristics in systems using composite collectors has then been studied, and the concept of 'mixed hemimicellae' has been proposed in the adsorption of composite collectors at the air/solution interfaces.

PRESSURE DISTRIBUTION IN THE AIR-SPARGED HYDROCYCLONE

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2^kFactorial Experiments on Factors that Influence the Recovery of Gold during the Upgrade of Ilesha-Itagunmodi Gold Ore through Froth Flotation

A low-grade gold ore from Ilesha-Itagunmodi, south western Nigeria was panned, dried and ball-milled before sieving into fractions. The morphological, mineralogical and chemical composition was studied by optical micro-scopy (Reflected and Transmission), X-ray diffraction (XRD) and Energy Dispersive X-ray fluorescence (XRF), respectively. The sieved fractions were subjected to chemical analysis (AAS). The +106 μm sieve had the highest concentration of the mineral and was then selected for the upgrade through froth flotation using standard reagents. In this paper a report on a 2k factorial experiment that provides an understanding of the impact of operational variables on the quantity of gold mineral obtained from the ore during froth flotation is presented. Analysis results showed that Ilesha-Itagunmodi gold ore is non-refractory with fine grain particles, amenable to froth flotation and contained about 20 other associated minerals, gold had a concentration of about 0.0024%. A com-bination of P-Xanthate and amine glycol collectors at a pH of 9.2 only produced a considerable increase in gold yield. This translated to about 87.13% increase in recovery of gold from the ore. Analysis of variance (ANOVA) was carried out and the model equation obtained was subsequently optimised to obtain a model equation that could be used in predicting the recoverable quantity of gold, indicating that F11,1-values for Collector concentration, Frother concentration, pH and Conditioning time were 156.86, 6.96, 43.81, and 56.77 respectively. A model with an F value of 88.41 was obtained which indicated that the model was significant. The model equation obtained was subsequently optimised to be able to predict the recoverable quantity of gold. A “Pred R-Squared” value of 0.9365 (93.65%) was also obtained and is in reasonable agreement with the “Adj R-Squared” value of 0.9534 (95.34%). It was established that Ilesha placer gold ore is amenable to froth flotation using standard reagents.

Surface Characterization of Metallic Particles in Printed Circuit Board Comminution Fines and the Processing Implication

From the background of poor responses of metallic particles in printed circuit board comminution fines to chemical conditioning froth flotation schemes, contrary to expectations based on native metal flotation, surface studies were carried out on samples of these metallic particles in quest for the probable causatives. Auger electron spectroscopy combined with argon beam depth profiling was employed in studying the surface make-up of the metal particles. The composition profiles down to 340 nm surface depth obtained showed that the supposed metallic particles consist of organics, oxides, and various trace alloys different from the bulk material of the particles. The profiles reveal the peculiar surfaces of the particles and the matrix from which the particles were liberated. The study provides insight for better appraisal of the flotation system the sample presents. Implementing chemical conditioning flotation scheme on this sample must carefully consider the peculiar surface make up in contrast to native metal occurrences.

The Method of Flotation Froth Image Segmentation Based on Threshold Level Set

A novel flotation froth image segmentation based on threshold level set method is put forward in view of the problem of over-segmentation and under-segmentation which occurs when the existing method segmented the flotation froth images. Firstly, the proposed method adopts histogram equalization to improve the contrast of the image, and then chooses the upper threshold and lower threshold from grey value of histogram of the image equalization, and complete image segmentation using the level set method. In this paper, the model which integrates edge with region level set model is utilized, and the speed energy term is introduced to segment the target. Experimental results show that the proposed method has better segmentation results and higher segmentation efficiency on the images with under-segmentation and incorrect segmentation, and it is meaningful for ore dressing industrial.

Effects of particle size and concentration on bubble coalescence and froth formation in a slurry bubble column

A new approach for simulating the formation of a froth layer in a slurry bubble column is proposed. Froth is considered a separate phase, comprised of a mixture of gas, liquid, and solid. The simulation was carried out using commercial flow simulation software （FIRE v2014） for particle sizes of 60-150 μm at solid concentrations of 0-40vol%, and superficial gas velocities of 0.02-0.034m/s in a slurry bubble column with a hydraulic diameter of 0.2 m and height of 1.2 m. Modelling calculations were conducted using a Eulerian-Eulerian multiphase approach with k-ε turbulence. The population balance equations for bubble breakup, bubble coalescence rate, and the interfacial exchange of mass and momentum were included in the computational fluid dynamics code by writing subroutines in Fortran to track the number density of different bubble sizes. Flow structure, radial gas holdup, and Sauter mean bubble diameter distributions at different column heights were predicted in the pulp zone, while froth volume fraction and density were predicted in the froth zone. The model was validated using available experimental data, and the predicted and experimental results showed reasonable agreement. To demonstrate the effect of increasing solid concentration on the coalescence rate, a solid-effect multiplier in the coalescence effi- ciency equation was used. The solid-effect multiplier decreased with increasing slurry concentration, causing an increase in bubble coalescence efficiency. A slight decrease in the coalescence efficiency was also observed owing to increasing particle size, which led to a decrease in Sauter mean bubble diam- eter. The froth volume fraction increased with solid concentration. These results provide an improved understanding of the dynamics of slurry bubble reactors in the presence of hydrophilic particles.