Structural properties of residual carbon in coal gasification fine slag and their influence on flotation separation and resource utilization:A review

Coal gasification fine slag(FS)is a typical solid waste generated in coal gasification.Its current disposal methods of stockpil-ing and landfilling have caused serious soil and ecological hazards.Separation recovery and the high-value utilization of residual carbon(RC)in FS are the keys to realizing the win-win situation of the coal chemical industry in terms of economic and environmental benefits.The structural properties,such as pore,surface functional group,and microcrystalline structures,of RC in FS(FS-RC)not only affect the flotation recovery efficiency of FS-RC but also form the basis for the high-value utilization of FS-RC.In this paper,the characteristics of FS-RC in terms of pore structure,surface functional groups,and microcrystalline structure are sorted out in accordance with gasification type and FS particle size.The reasons for the formation of the special structural properties of FS-RC are analyzed,and their influence on the flotation separation and high-value utilization of FS-RC is summarized.Separation methods based on the pore structural characterist-ics of FS-RC,such as ultrasonic pretreatment-pore-blocking flotation and pore breaking-flocculation flotation,are proposed to be the key development technologies for improving FS-RC recovery in the future.The design of low-cost,low-dose collectors containing polar bonds based on the surface and microcrystalline structures of FS-RC is proposed to be an important breakthrough point for strengthening the flotation efficiency of FS-RC in the future.The high-value utilization of FS should be based on the physicochemical structural proper-ties of FS-RC and should focus on the environmental impact of hazardous elements and the recyclability of chemical waste liquid to es-tablish an environmentally friendly utilization method.This review is of great theoretical importance for the comprehensive understand-ing of the unique structural properties of FS-RC,the breakthrough of the technological bottleneck in the efficient flotation separation of FS,and the expansion of the field of the high value-added utilization of FS-RC.

Effective separation of coal gasification fine slag: Role of classification and ultrasonication in enhancing flotation

Effective separation of residual carbon and ash is the basis for the resource utilization of coal gasification fine slag(CGFS).The conventional flotation process of CGFS has the bottlenecks of low carbon recovery and high collector dosage.In order to address these issues,CGFS sample taken from Shaanxi,China was used as the study object in this paper.A new process of size classification-fine grain ultrasonic pretreatment flotation(SC-FGUF)was proposed and its separation effect was compared with that of wholegrain flotation(WGF)as well as size classification-fine grain flotation(SC-FGF).The mechanism of its enhanced separation effect was revealed through flotation kinetic fitting,flotation flow foam layer stability,particle size composition,surface morphology,pore structure,and surface chemical property analysis.The results showed that compared with WGF,pre-classification could reduce the collector dosage by 84.09%and the combination of pre-classification and ultrasonic pretreatment could increase the combustible recovery by 17.29%and up to 93.46%.The SC-FGUF process allows the ineffective adsorption of coarse residual carbon to collector during flotation stage to be reduced by pre-classification,and the tightly embedded state of fine CGFS particles is disrupted and surface oxidizing functional group occupancy was reduced by ultrasonic pretreatment,thus carbon and ash is easier to be separated in the flotation process.In addition,some of the residual carbon particles were broken down to smaller sizes in the ultrasonic pretreatment,which led to an increase in the stability of flotation flow foam layer and a decrease in the probability of detachment of residual carbon particles from the bubbles.Therefore,SCFGUF could increase the residual carbon recovery and reduce the flotation collector dosage,which is an innovative method for carbon-ash separation of CGFS with good application prospect.

Latest advances and progress in the microbubble flotation of fine minerals:Microbubble preparation,equipment,and applications

In the past few decades,microbubble flotation has been widely studied in the separation and beneficiation of fine minerals.Compared with conventional flotation,microbubble flotation has obvious advantages,such as high grade and recovery and low consumption of flotation reagents.This work systematically reviews the latest advances and research progress in the flotation of fine mineral particles by microbubbles.In general,microbubbles have small bubble size,large specific surface area,high surface energy,and good selectivity and can also easily be attached to the surface of hydrophobic particles or large bubbles,greatly reducing the detaching probability of particles from bubbles.Microbubbles can be prepared by pressurized aeration and dissolved air,electrolysis,ultrasonic cavitation,photocatalysis,solvent exchange,temperature difference method(TDM),and Venturi tube and membrane method.Correspondingly,equipment for fine-particle flotation is categorized as microbubble release flotation machine,centrifugal flotation column,packed flotation column,and magnetic flotation machine.In practice,microbubble flotation has been widely studied in the beneficiation of ultrafine coals,metallic minerals,and nonmetallic minerals and exhibited superiority over conventional flotation machines.Mechanisms underpinning the promotion of fine-particle flotation by nanobubbles include the agglomeration of fine particles,high stability of nanobubbles in aqueous solutions,and enhancement of particle hydrophobicity and flotation dynamics.

Electro-flotation and collision-attachment mechanism of fine cassiterite

In order to discuss the particle-bubble interaction during the electro-flotation of cassiterite,the recovery of cassiterite with different particle sizes was investigated,and the collision mechanism between the cassiterite particles and H2 bubbles was explored.The flotation tests were carried out in a single bubble flotation cell.The results show that cassiterite particles 10 μm,10-20 μm,20？38 μm and 38-74 μm match with bubbles with size of 50-150 μm,about 250 μm,74 μm and 74 μm,respectively,and a better recovery can be obtained.It is demonstrated that the recovery of cassiterite is influenced by the size of cassiterite particles and bubbles.Furthermore,the probabilities of collision,adhesion,detachment and collection were calculated using the collision,attachment and collection models.Theoretical calculation results show that the collision probability decreases sharply with decreasing particle size and increasing bubble size（below 150 μm）.The attachment probability would increase from the effective collision,leading to the increase of recovery.

Effect of magnetic seeding agglomeration on flotation of fine minerals

Magnetic seeding agglomeration(MSA),i.e.,adding magnetic seeds and a low intensity pre-magnetization for fine agglomeration,was applied to the flotation of coal,pyrite and hematite ore slimes.Size analysis and flotation tests highlight that the MSA improved flotation recovery and kinetics of pyrite ore while causing some loss in selectivity,and in the presences of the polyacrylamide for coal and starch for hematite the agglomeration flotation was further strengthened due to the synergetic effect between the flocculants and magnetic seeds.Magnetism analyses and calculation confirmed the adsorption of magnetic seeds onto minerals,resulting in a decreased threshold magnetic field intensity for the MSA to happen.Then atomic force microscope(AFM)study found that there exists a long range force between magnetic seeds and minerals,which facilitates the adsorption of magnetic seeds on minerals.FTIR shows both the polyacrylamide and starch adsorbed onto minerals and magnetic seeds,thus acting as the bridging media between minerals and magnetic seeds,intensifying the agglomeration in flotation.Surface characterization of the MSA was understood by SEM imaging,and models of the MSA were proposed.

Hydrophobic flocculation flotation of rutile fines in presence of styryl phosphonic acid

The hydrophobic flocculation flotation of rutile fines in the presence of styryl phosphonic acid（SPA） was investigated by flotation tests, zeta-potential measurement, optical microscope observation, laser-based particle size analysis, adsorption measurements and DLVO theory. The flotation tests indicated that rutile fines could be flocculated by SPA, and pH, shear force（stirring speed） and stirring time played significant roles in flocculation. The isoelectric point（IEP） and zeta-potential in whole range all moved to negative values as SPA was added according to the results from zeta-potential measurement. It was demonstrated that the primary reason for above was chemical adsorption. The laser-based particle size results showed the particle size at a stirring speed of 1800 r/min and 1000 mg/L SPA was the largest in all experiments. Furthermore, using the optical microscope observation and flotation tests, it was important for flotation of rutile fines to produce the flocculant. In the light of above-mentioned facts, floc flotation of rutile fines could be induced in the form of chemical adsorption by SPA to increase particle size. The data calculated from DLVO theory also indicated that chemical adsorption was the main reason for the formation of flocculant.

Flotation mechanisms of molybdenite fines by neutral oils

The flotation mechanisms of molybdenite fines by neutral oils were investigated through microflotation test, turbidity measure- ments, infrared spectroscopy, and interracial interaction calculations. The results of the flotation test show that at pH 2-11, the floatability of molybdenite fines in the presence of transformer oil is markedly better than that in the presence of kerosene and diesel oil. The addition of transformer oil, which enhances the floatability of molybdenite fines, promotes the aggregation of molybdenite particles. Fourier transform infrared measurements illustrate that physical interaction dominates the adsorption mechanism of neutral oil on molybdenite. Interracial inte- raction calculations indicate that hydrophobic attraction is the crucial force that acts among the oil collector, water, and molybdenite. Strong hydrophobic attraction between the oily collector and water provides the strong dispersion capability of the collector in water. Furthermore, the dispersion capability of the collector, not the interaction strength role in the flotation system of molybdenite fines. Our findings provide between the oily collectors and molybdenite, has a highly significant insights into the mechanism ofmolybdenite flotation.

Improving the sulfidation-flotation of fine cuprite by hydrophobic flocculation pretreatment

Hydrophobic flocculation pretreatment was performed to assess its effect on the recovery of fine cuprite in sulfidation-flotation. The results of the micro-flotation experiment showed that cuprite recovery is related to the particle size, and that an excessive content of fine particles(<18 μm) impacted the recovery of coarse particles. When hydrophobic flocculation pretreatment was used, the recovery of fine cuprite in sulfidation-flotation increased from 60.3% to 86.3% under optimum conditions(pH 9.5; sodium oleate concentration, 2 × 10^(-4) mol×L^(-1); stirring time, 6 min; stirring speed, 1600 r×min^(-1)). The laser particle size analysis and optical microscopy results indicate that hydrophobic flocculation pretreatment effectively reduces the content of fine cuprite, and augments the apparent particle size in the pulp. We performed the Derjaguin–Landau–Verwey–Overbeek(DLVO) theory and extended DLVO theory calculations to further support the interpretation of the results.

Nano-microbubble flotation of fine and ultrafine chalcopyrite particles

As is well known to mineral processing scientists and engineers, fine and ultrafine particles are difficult to float mainly due to the low bubble-particle collision efficiencies. Though many efforts have been made to improve flotation performance of fine and ultrafine particles, there is still much more to be done. In this paper, the effects of nano-microbubbles （nanobuhbles and microbubbles） on the flotation of fine （-38 ＋ 14.36 μm） and ultrafine （-14.36 ＋ 5μm） chalcopyrite particles were investigated in a laboratory scale Denver flotation cell. Nano-microbubbles were generated using a specially-designed nano- microbubble generator based on the cavitation phenomenon in Venturi tubes. In order to better under- stand the mechanisms of nano-microbubble enhanced froth flotation of fine and ultrafine chalcopyrite particles, the nano-microbubble size distribution, stability and the effect of frother concentration on nano- bubble size were also studied by a laser diffraction method. Comparative flotation tests were performed in the presence and absence of nano-microbubbles to evaluate their impact on the fine and ultrafine chalcopyrite particle flotation recovery. According to the results, the mean size of nano-microbubbles increased over time, and decreased with increase of frother concentration. The laboratory-scale flotation test results indicated that flotation recovery of chalcopyrite fine and ultrafine particles increased by approximately 16-21% in the presence of nano-microbubbles, depending on operating conditions of the process. The presence of nano-microbubbles increased the recovery of ultrafine particles （-14.36 ＋ 5 μm） more than that of fine particles （-38 ＋ 14.36 μm）. Another major advantage is that the use of nano-microbubbles reduced the collector and frother consumptions by up to 75% and 50%, respectively.

An effective approach for improving flotation recovery of molybdenite fines from a finely-disseminated molybdenum ore

An effective flotation approach is proposed for improving the recovery of molybdenite fines from a finely-disseminated molybdenum ore. To maximize the flotation recovery of molybdenum, process mineralogy of raw ore, contrast tests, optimization of operation conditions and particle size analysis were systematically investigated. Process mineralogy suggests that in the raw ore, 61.63% of molybdenite particles distribute in the 〈20 pm size fraction, and intergrow with muscovite and pyrite as the contained and disseminated type. Contrast tests indicate that conventional flotation responds to poor collection efficiency for particles less than 25 pm. Oil agglomerate flotation （OAF） process demonstrates an obvious superiority in improving the flotation recovery of molybdenite fines. Furthermore, the flotation results of OAF process reveal that the dosage of transformer oil plays a critical role on the average size of collected mineral particles （d（0）, agglomerates （d^0） and the molybdenum recovery. In addition, industrial tests illustrate that compared with the Mo-S bulk flotation approach, OAF process not only increases Mo recovery and grade of molybdenum concentrate by 22.75% and 17.47% respectively, but also achieves a sulfur concentrate with a superior grade of 38.92%.

An Entrapment Model of Water Flow on Fine Coal Flotation

Effect of entrapment of water flow on fine coal flotation was studied. The relation between constant of water flotation rate and flotation time was investigated and the water recycling model determined. The entrapment model of water flow about the relation between the recovery of fine particle and that of water in concentration was established. Finally, the equation about ash in fine clean coal at any time was derived by introducing a de-ashing coefficient.

Study of Cyclonic Microbubble FlotationColumn and Its Application to Fine Coal Processing

This paper deals with the operation principle of the cyclonic microbubble flotation column and its structure characterisics. The pilot test results and the commercial applied results of cyclonic microbubble flotation column for fine coal processing are also introduced. The test results proved that the cyclonic microbubble flotation column has many advantages suck as high selectivity, high efficiency in ash rejection from fine coals, low comsumption of energy, easy operation and maintenance, etc. It is a kind of equipment widely applied to fine coal processing.

Ash Depression in Fine Coal Flotation Using a Novel Polymer Aid

The current study investigated the effects of novel hybrid polyacrylamide polymers as ash (slime) depressants in fine coal flotation to enhance combustible recovery and ash rejection. Coal samples at P80 of approximately 45 um with ~25% ash content were floated in the presence of in-house synthesized hybrid aluminum hydroxide polyacrylamide polymers (Al(OH)3-PAM, or Al-PAM). All flotation experiments were carried out in a 5-L Denver flotation cell. Various influencing factors were examined to optimize the flotation process in the presence of the Al-PAM polymers, including the Al-PAM dosage, Al-PAM conditioning time, impeller rotation speed and pulp pH. Comparative and synergistic studies were also performed using organic polyacrylamide polymers (PAMs), commercial dispersants and Al-PAM/dispersant system. Results showed a significant improvement in both combustible recovery and ash rejection at an Al-PAM dosage of 0.25 mg/L. The maximum combustible recovery obtained, at natural pH, with Al-PAM and Al-PAM/dispersant system was determined to be 70% and 66% at ash content of 7.74% and 7.4%, respectively. Zeta potential values of both the raw coal and concentrate products showed a large shift toward more positive values (from ˉ50 mV to ˉ13 mV), indicating a significant decrease in ash-forming minerals (slimes) when Al-PAM polymers were applied.

Rheological investigations of the improved fine scheelite flotation spiked with agitation medium

The fine scheelite flotation using garnet and glass beads as agitation medium was investigated through slurry rheology and froth property analysis. The apparent viscosity of fine scheelite, calcite and quartz(-20 μm) slurry were measured and the corresponding scheelite flotation behaviours, froth water recovery and froth height were studied. It was found that calcite slurry could aggregate into network structures and exhibit much higher apparent viscosity at the vicinity of pH 8.5–9.0 than scheelite and quartz(scheelite, calcite, and quartz slurry at 20.34, 38.66, and 14.58 mPa·s, respectively). Agitation medium containing garnet and glass beads could reduce the slurry apparent viscosity by effectively dispersing the calcite network structures in flotation slurry, and improve the fine scheelite flotation selectivity. As the apparent viscosity was reduced, the froth water recovery decreased from 24.33% to 6.37% and initial froth height of the flotation froth decreased from 69.6 to 8.7 mm, and finally results in increase in separation efficiency from 23.10% to 31.96%. The results could be potentially used in flotation of fine minerals by applying agitation medium to improve the process selectivity.

Influence of Flotation Magnesia Particles and Al_(2)O_(3) Fines on Properties of Periclase-spinel Bricks

Periclase-spinel bricks were prepared using sintered magnesia,flotation magnesia,fused magnesium aluminate spinel and calcined Al_(2)O_(3)fines as the starting materials and calcium lignosulfonate as the binder,mixing,shaping and firing at 1650℃.Flotation magnesia particles were used to replace ordinary sintered magnesia particles and different amounts of calcined Al_(2)O_(3)fines were extra-added(0%,3%and 5%,by mass)to investigate their effects on the properties of periclase-spinel bricks.The results show that:the periclase-spinel bricks prepared with flotation magnesia particles have reduced apparent porosity and cold compressive strength,and enhanced bulk density,thermal shock resistance,hot strength and hot toughness.As the calcined Al_(2)O_(3)fines addition increases,the apparent porosity and the cold compressive strength decrease,and the bulk density,the thermal shock resistance,the hot strength and the hot toughness are improved.

FLOTATION RATE CONSTANT MODE FOR FINE COAL

The density of fine coal has a major effect on the value of its flotation rate constant. The collector dose can increase the flotation rate of fine coal, especially for low ash coal, but the effect for gangue is not notable. The flotation rate of gangue is mainly governed by the water entrainment. A coal flotation rate constant model has been developed.

Collision and attachment behavior between fine cassiterite particles and H_2 bubbles

Particle-bubble interaction during electro-flotation of cassiterite was investigated by determining the recovery of cassiterite and the collision mechanism of cassiterite particle and H2 bubble. Flotation tests at different conditions were conducted in a single bubble flotation cell. The recovery of cassiterite was found to be affected by cassiterite particle and bubble size. A matching range, in which the best recovery can be obtained, was found between particle and bubble size. Collision, attachment, and detachment of the particle-bubble were observed and captured by a high-speed camera. Particle-bubble collision and attachment were analyzed with the use of particle-bubble interaction theory to obtain the experimental results. An attachment model was introduced and verified through the photos captured by the high-speed camera. A bridge role was observed between the bubbles and particles. Particle-bubble interaction was found to be affected by bubble size and particle size, which significantly influenced not only the collision and attachment behavior of the particles and bubbles but also the flotation recovery of fine cassiterite particles.

Behaviors of fine bubbles in the shroud nozzle of ladle and tundish

Fine bubbles will create when the inert gas is introduced to the high rapidsteel stream within the shroud nozzle between ladle and tundish. The collision and attachment amongthe bubbles and fine inclusions will promote the floatation efficiency of inclusions in the tundish.The behaviors of the bubbles, such as the dispersion in shroud, coalescence and floatation intundish, are studied. The results show that the maximum sizes of the bubbles in the water and steelflow within the shroud in the length of 1.2 m are 0.70-1.44 mm and 1.53-3.16 mm respectively whenthe flow rates are 0.006-0.016 m^3/s; the terminal velocities of fine bubbles in the water andmolten steel within the tundish are 0.02-0.2 and 0.05-0.6 m/s.

Observation of fine particle aggregating behavior induced by high intensity conditioning using high speed CCD

The aggregating behavior between bubbles and particles induced by high intensity conditioning (HIC) was studied using high speed CCD technique. Bubble size measurement was conducted, and the attachment behavior between bubbles and particles in HIC cell and flotation cell were observed. The results show that in HIC cell, high intensity conditioning creates an advantage environment for the formation of small size bubble due to hydrodynamic cavitations, and these fine bubbles have high probability of bubble-particle collision, which will enhance fine particle flotation. The bubble-particle attachment experiments indicate that in high intensity conditioning cell, a lot of fine bubbles are produced in situ on the surface of fine particles, and most of fine particles are aggregated under the bridging action of fine bubbles. The observation of bubble-particle interaction in flotation cell illustrates that aggregates created by HIC can be loaded more easily by big air bubble in flotation cell than those created by normal conditioning.

Pico–nano bubble column flotation using static mixer-venturi tube for Pittsburgh No.8 coal seam

The flotation process is a particle-hydrophobic surface-based separation technique. To improve the essential flotation steps of collision and attachment probabilities, and reduce the step of detachment probabilities between air bubbles and hydrophobic particles, a selectively designed cavitation venturi tube combined with a static mixer can be used to generate very high numbers of pico and nano bubbles in a flotation column. Fully embraced by those high numbers of tiny bubbles, hydrophobic particles readily attract the tiny bubbles to their surfaces. The results of column flotation of Pittsburgh No. 8 seam coal are obtained in a 5.08 cm ID and 162 cm height flotation column equipped with a static mixer and cavitation venturi tube, using kerosene as collector and MIBC as frother. Design of the experimental procedure is combined with a statistical two-stepwise analysis to determine the optimal operating conditions for maximum recovery at a specified grade. The effect of independent variables on the responses has been explained. Combustible material recovery of 85–90% at clean coal product of 10–11% ash is obtained from feed of 29.6% ash, with a much-reduced amount of frother and collector than that used in conventional column flotation. The column flotation process utilizing pico and nano bubbles can also be extended to the lower limit and upper limit of particle size ranges, minus 75 lm and 300–600 lm, respectively, for better recovery.