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Hydrodynamics and Gas Dispersion in Flotation

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A special issue of Minerals (ISSN 2075-163X). This special issue belongs to the section "Mineral Processing and Extractive Metallurgy".

Deadline for manuscript submissions: closed (26 August 2022) | Viewed by 22694

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Special Issue Editors

Dr. Luis Vinnett

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Department of Chemical and Environmental Engineering, Universidad Técnica Federico Santa María, Av. España 1680, Valparaíso, Chile
Interests: flotation; modelling and simulation; optimization; hydrodynamics and gas dispersion; process control
Special Issues, Collections and Topics in MDPI journals

Dr. Cesar O. Gomez

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Guest Editor

COG Technologies Inc., Montréal, QC H3C 4L3, Canada
Interests: characterization and optimization of flotation machines; gas dispersion, measurements; single bubble and bubble swarm hydrodynamics; frother analysis and characterization; effects on metallurgical performance

Special Issue Information

Dear Colleagues,

Flotation is a complex process for mineral beneficiation that involves the formation of particle–bubble aggregates in a liquid medium. These aggregates are the result of collisions between rising bubbles and suspended particles, and the respective attachment of hydrophobic or hydrophobized mineral particles. Satisfactory flotation performances are strongly dependent on the generation of large interfacial areas in the pulp zone by dispersing gas into a population of small bubbles. Machine hydrodynamics are also crucial to favor particle–bubble collisions and aggregate stabilities. Bubble size and gas holdup measurements have allowed the effects of gas flowrate on flotation kinetics and metallurgical performance to be better understood. Thus, the adequate selection of frothers and the presence of inorganic salts have proved to have significant effects on flotation responses. Machine designs and their impacts on cell/column hydrodynamics have been critical for the beneficiation of difficult-to-float minerals. In this regard, continuous developments have been made to improve the trade-off between particle–bubble attachment and aggregate stability in flotation systems subject to a wide range of particle sizes and liberations.

Hydrodynamics and gas dispersion measurements have been successfully carried out to diagnose the operation and assess the performance of laboratory and industrial flotation units. However, their use for improving metallurgical indexes and machine operations have not been routinely applied in flotation practice.

The aim of this Special Issue is to invite contributions from a group of experts to present the latest results and recent advancements in the following areas:

Gas dispersion characterization, including bubble size, superficial gas rate and gas holdup measurements, and the interactions between these variables.
Every relevant topic on the formation and break-up of particle–bubble aggregates, such as single bubble and bubble swarm hydrodynamics, collection efficiencies, and mixing.
Effects of frothers and inorganic salts on flotation hydrodynamics and gas dispersion.
Effect of gas dispersion and machine hydrodynamics on metallurgical performances in laboratory and industrial flotation systems.

Dr. Luis Vinnett
Dr. Cesar O. Gomez
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Minerals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

flotation
gas dispersion
bubble size estimation
frother characterization
critical coalescence concentration
superficial gas rate
gas hold-up
residence time distribution
mixing
computational fluid dynamics
particle–bubble interactions

Published Papers (12 papers)

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Editorial

Jump to: Research, Review

2 pages, 188 KiB

Open AccessEditorial

Editorial for Special Issue “Hydrodynamics and Gas Dispersion in Flotation”

by Luis Vinnett and César O. Gómez

Minerals 2023, 13(9), 1219; https://doi.org/10.3390/min13091219 - 17 Sep 2023

Viewed by 599

Abstract

Gas dispersion, the breakage of a mass of gas into a population of small bubbles, is one of the most important subprocesses occurring in flotation machines [...] Full article

(This article belongs to the Special Issue Hydrodynamics and Gas Dispersion in Flotation)

Research

Jump to: Editorial, Review

10 pages, 1091 KiB

Open AccessCommunication

The Role of Stereological Assumptions in Bubble Size Estimations and Their Implications for Assessing Critical Coalescence Concentrations

by Luis Vinnett and Diego Mesa

Minerals 2023, 13(6), 803; https://doi.org/10.3390/min13060803 - 13 Jun 2023

Cited by 1 | Viewed by 766

Abstract

Accurate measurement of bubble size is critical for assessing flotation performance. However, the 3D nature of bubbles, in contrast to the 2D nature of photographs obtained using a bubble viewer apparatus, may lead to distortions related to stereological assumptions. This study aimed to quantify the impact of these stereological effects on bubble size measurements in frother characterisations. Our results showed that different assumptions regarding bubble shape and volume resulted in variations in bubble size calculations of up to 10%. Furthermore, these stereological effects were propagated to the calculation of the critical coalescence concentration, leading to uncertainties of up to 14% depending on the type of frother. These findings emphasise the importance of considering stereological effects and selecting an appropriate calculation method when measuring bubble size for flotation and reagent assessments. Full article

(This article belongs to the Special Issue Hydrodynamics and Gas Dispersion in Flotation)

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13 pages, 2603 KiB

Open AccessArticle

Alkali Halide and MIBC Interaction at Typical Flotation Interfaces in Saline Water as Determined by Molecular Dynamics Simulations

by Omar Alvarado, Gonzalo R. Quezada, Jorge H. Saavedra, Roberto E. Rozas, Leopoldo Gutiérrez and Pedro G. Toledo

Minerals 2023, 13(5), 665; https://doi.org/10.3390/min13050665 - 12 May 2023

Cited by 1 | Viewed by 918

Abstract

The molecular structure of the liquid–vapor interfaces of aqueous solutions of alkali metal halides and methyl isobutyl carbinol (MIBC, (CH₃)₂CHCH₂COCH₃) is determined by using molecular dynamics simulations with polarizable force fields for the first time. The salts are chlorides, and iodides, some of which are found in raw and partially desalinated seawater increasingly used in flotation operations in regions affected by severe and prolonged drought. The density profiles at the interfaces show that all ions prefer the interface; however, with MIBC, non-polarizable ions, generally small ones, are increasingly pushed into the liquid bulk. A few ions of comparatively less ionic NaCl than KCl and CsCl, persist at the interface, consistent with spectroscopy observations. On the other hand, strongly polarizable ions such as I⁻ always share the interface with MIBC. In the presence of chlorides, the frother chains at the interface stretch slightly more toward vapor than in freshwater; however, in the presence of iodides, the chains stretch so much that they become orthogonal to the interface, giving rise to a well-packed monolayer, which is the most effective configuration. The dominant water configurations at the interface are double donor and single donor, with hydrogen atoms pointing toward the liquid, consistent with studies with sum-frequency generation experiments and extensive ab initio simulations. This picture changes radically in the presence of MIBC and salts. Depending on the halide and MIBC concentration, the different molecular configurations at the interface lead to very different surface tensions. The structure and properties of these new salt-rich interfaces and their impact on the location and arrangement of frother molecules should serve the flotation practitioner, especially in the search for the best frother and dosing in poor-quality water. Full article

(This article belongs to the Special Issue Hydrodynamics and Gas Dispersion in Flotation)

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15 pages, 3501 KiB

Open AccessArticle

The Impact of Froth Launders Design in an Industrial Flotation Bank Using Novel Metallurgical and Hydrodynamic Models

by Paulina Vallejos, Juan Yianatos, Rodrigo Grau and Alejandro Yáñez

Minerals 2023, 13(2), 169; https://doi.org/10.3390/min13020169 - 24 Jan 2023

Cited by 2 | Viewed by 1440

Abstract

In flotation cells, especially in large flotation units, froth management is a crucial variable that should be considered during the design phase or optimized to improve the performance of existing flotation circuits. This paper presents a simulation evaluation of the effect of launder design on the metallurgical performance of an industrial flotation circuit consisting of five TankCell^® e630 (630 m³) cells in a Cu rougher duty. This analysis was carried out using a new industrial simulator that includes novel metallurgical and hydrodynamic models, developed from a wide database collected from many industrial concentrators. This tool is currently incorporated into HSC Chemistry^® software and allows evaluating the effect of launder design on mineral froth recovery, water recovery, entrainment, and other variables. The industrial flotation circuit was evaluated under different launder design scenarios, considering an actual flotation circuit that includes TankCell^® e630 cells for calibration and as a reference (baseline). Firstly, two different designs were evaluated in the full circuit: a standard launder design and a new launder technology. It was found that the new launder technology enabled improvement of the mineral recovery along the circuit, mainly for coarse particles, due to the improvement in froth mineral recovery. Next, a partial upgrade of the launder design along the circuit was analysed. Thus, the new launder technology was evaluated in the first and the last two cells of the bank. The results showed that upgrading the launders in different cells along the circuit delivered an increase in the final recovery with respect to the baseline, with a partial impact on the concentrate grade. However, these changes are less than those when evaluating the full upgrade scenario. A partial launder upgrade either in the first or last two cells of the bank showed similar final recoveries, but the latter enabled a slightly higher concentrate grade (about 1% higher) to be achieved. Finally, the evaluation of launder design using the industrial simulator made it possible to estimate its effect on variables that are not commonly obtained from plant surveys, including superficial gas rates at the froth surface level, froth recovery per particle size, collection recovery per particle size and liberation, gangue entrainment, and bubble loading grade. Full article

(This article belongs to the Special Issue Hydrodynamics and Gas Dispersion in Flotation)

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17 pages, 3927 KiB

Open AccessArticle

Modelling Bubble Flow Hydrodynamics: Drift-Flux and Molerus Models

by Cesar O. Gomez and Miguel Maldonado

Minerals 2022, 12(12), 1502; https://doi.org/10.3390/min12121502 - 24 Nov 2022

Cited by 3 | Viewed by 1102

Abstract

Minerals flotation is a widely used process to produce base metal concentrates through the selective capture of particles on the surface of bubbles. The process performance depends on the size distribution of the bubble population generated by gas dispersion, which is characterized by three variables: superficial gas velocity, gas holdup, and bubble size. A literature review revealed that current instrumentation cannot provide reliable on-line measurement of these variables except for gas velocity. There are some promising alternatives for gas holdup, but bubble size measurement will continue to be unavailable. The use of a model that integrates the three gas dispersion variables makes possible the calculation of one of the variables when knowing the values of the other two. Modelling bubble flow has been pursued using two approaches: determining the bubble terminal velocity reduction by the presence of other bubbles and regarding the bubble swarm as a packed bed through which a fluid is allowed to flow. Models based on these approaches (drift-flux and Molerus, respectively) were found in the literature and used to assess their prediction ability. Gas holdup predictions for known values of gas velocity and bubble size showed similar trends for both models; Molerus results were always higher than those obtained with the drift-flux model, and the difference between both predictions increased with bubble size and gas velocity. A relationship between bubble surface area flux and gas holdup was explored (a single line was expected); Molerus values showed a noticeable effect of bubble size, while drift-flux results showed a minor effect of bubble size only for gas holdups below 10%. Model accuracy was established using a data set collected to characterize frother roles in flotation for six commercial frothers, which included values of the three gas dispersion variables measured simultaneously and reported at the same conditions. The results indicate that bubble size predictions obtained from Molerus model are closer to the measured values than those obtained from the drift-flux model. Drift-flux predictions systematically underestimated the measured bubble size, with relative errors between 10 and 30%, while Molerus predictions showed values around the measured size with relative errors not larger than 15% (and in most cases below 10%). The accuracy of the Molerus predictions is acceptable for applications in the control of individual cells and flotation circuits operation. Further testing to assess the performance of Molerus model with data collected in lab and industrial mechanical cells and columns, where conditions in the test volume may not be stable or homogeneous, is recommended. Full article

(This article belongs to the Special Issue Hydrodynamics and Gas Dispersion in Flotation)

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13 pages, 9841 KiB

Open AccessArticle

Flotation Performance and Gas Dispersion Properties in a Laboratory Flotation Cell

by Francisco Femenias, Miguel Maldonado, Nicolas Miranda and Leopoldo Gutierrez

Minerals 2022, 12(11), 1351; https://doi.org/10.3390/min12111351 - 25 Oct 2022

Cited by 1 | Viewed by 1549

Abstract

Flotation is a complex process that exhibits high dimensionality which makes modeling and optimization very challenging. One technique to alleviate the dimensionality problem is to combine variables together into more informative ones. Bubble surface area flux and air recovery are examples of dimensionality reduction. Gas holdup also captures the effect of a plurality of variables including gas rate, bubble size, surfactant type, and concentration. This work makes use of a dual flotation–conductivity cell to explore the relationship between gas dispersion properties, including frother concentration and flotation performance. Results demonstrate that gas holdup effectively captured the effect of gas rate and frother concentration and better correlates to flotation performance. Full article

(This article belongs to the Special Issue Hydrodynamics and Gas Dispersion in Flotation)

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10 pages, 2235 KiB

Open AccessCommunication

Reducing the Presence of Clusters in Bubble Size Measurements for Gas Dispersion Characterizations

by Luis Vinnett, Benjamín Urriola, Francisca Orellana, Camila Guajardo and Alex Esteban

Minerals 2022, 12(9), 1148; https://doi.org/10.3390/min12091148 - 10 Sep 2022

Cited by 5 | Viewed by 1609

Abstract

This short communication evaluates a new strategy to sample bubbles in gas dispersion characterizations. Bubble size is measured in a bidimensional flotation cell using the McGill bubble size analyzer under different types of frothers, frother concentrations and superficial gas rates. The original design of this bubble viewer is modified, changing the deflecting system to photograph only a fraction of the bubbles entering the device. As a result, the new design increases the ability to successfully identify bubbles by a maximum of 20% using an automated algorithm. This increase is caused by a reduction in the formation of clusters in the visual field. The improvement, which is a function of the operating conditions, is most significant in the transition from ellipsoidal/ellipsoidal–turbulent regimes (no frother or low frother concentrations) to conditions with an over-agglomeration of bubbles in the visual field (high superficial gas rates and high frother concentrations). A comparison of the bubble size parameters obtained from the original and proposed deflecting systems shows that the new design does not distort the estimated bubble size distributions. To complement the research findings, alternative sampling designs, using new or existing segmentation algorithms, are then proposed to improve gas dispersion characterizations at different scales. Full article

(This article belongs to the Special Issue Hydrodynamics and Gas Dispersion in Flotation)

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16 pages, 2875 KiB

Open AccessFeature PaperArticle

Investigation of the Effect of Electrolytes on the Breakaway of Air Bubbles at an Underwater Capillary Using High-Speed Cinematography and Passive Acoustic Techniques

by Pengbo Chu, Ronghao Li, Mark Lepage and Kristian Waters

Minerals 2022, 12(8), 972; https://doi.org/10.3390/min12080972 - 30 Jul 2022

Cited by 3 | Viewed by 1304

Abstract

Saline water froth flotation has received increasing attention in recent years due to sustainability-related concerns. Although the presence of electrolytes in these flotation systems is known to produce the desired bubble swarms, i.e., a macroscopic observation, the fundamental mechanism through which the solutes produce such an effect at the microscopic level remains obscure. For example, there is no agreed mechanism (i.e., break-up or coalescence—two major bubble formation mechanisms) of how the effect is achieved. Not only is understanding the impact of electrolytes on the bubble formation mechanisms a fundamental question, but it can also provide insight into the design of more efficient air dispersing mechanisms for saline flotation systems. Previous studies have demonstrated that electrolytes can inhibit coalescence, but their potential impact on break-up remains vague, which is the focus of this study. It is hypothesized that electrolytes have an impact on break-up, and by isolating break-up from coalescence, the effects of electrolytes on break-up can be revealed. A break-up-only bubble formation system was built. Under this condition, any impact from the electrolytes on the produced bubble can be attributed to an impact on break-up. High-speed cinematography and a passive acoustic technique were employed to capture the bubble size, acoustic frequency, and damping ratio during the break-up process. Under the quasi-static condition, an increase in the electrolyte concentration increased the bubble size produced via break-up, contradicting the common observations made for bubble swarms. The break-up imparted an initial capillary wave to the bubble surface, which is correlated with the bending modulus of the air/water interface affected by the electrolytes. No direct correlation was observed between the acoustic damping ratio and that of the capillary wave, suggesting that the electrolytes affect the break-up via a different mechanism from that by surfactants. Full article

(This article belongs to the Special Issue Hydrodynamics and Gas Dispersion in Flotation)

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15 pages, 5399 KiB

Open AccessEditor’s ChoiceArticle

An Assessment of the Role of Combined Bulk Micro- and Nano-Bubbles in Quartz Flotation

by Shaoqi Zhou, Yang Li, Sabereh Nazari, Xiangning Bu, Ahmad Hassanzadeh, Chao Ni, Yaqun He and Guangyuan Xie

Minerals 2022, 12(8), 944; https://doi.org/10.3390/min12080944 - 27 Jul 2022

Cited by 10 | Viewed by 2177

Abstract

Bulk micro-nano-bubbles (BMNBs) have been proven to be effective at improving the flotation recovery and kinetics of fine-grained minerals. However, there is currently no research reported on the correlation between the properties of BMNBs and flotation performance. For this purpose, aqueous dispersions with diverse properties were created by altering preparation time (0, 1, 2, 3, 5, and 7 min), aeration rate (0, 0.5, 1, 1.5, and 2 L/min) and aging time (0, 0.5, 1, and >3 min). Micro- and nano-bubbles were characterized using focused beam reflection measurements (FBRM) and nanoparticle tracking analysis (NTA), respectively. The micro-flotation of quartz particles was performed using an XFG-cell in the presence and absence of BMNBs with Cetyltrimethylammonium bromide (CTAB) as a collector. The characterization of bubble sizes showed that the bulk micro-bubble (BMB) and bulk nanobubble (BNB) diameters ranged from 1–10 μm and 50–400 nm, respectively. It was found that the preparation parameters and aging time considerably affected the number of generated bubbles. When BNBs and BMBs coexisted, the recovery of fine quartz particles significantly improved (about 7%), while in the presence of only BNBs the promotion of flotation recovery was not significant (2%). This was mainly related to the aggregate via bridging, which was an advantage for quartz flotation. In comparison, no aggregates were detected when only nano-bubbles were present in the bulk solution. Full article

(This article belongs to the Special Issue Hydrodynamics and Gas Dispersion in Flotation)

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19 pages, 4980 KiB

Open AccessArticle

Using Top-of-Froth Conductivity to Infer Water Overflow Rate in a Two-Phase Lab-Scale Flotation Column

by Mark R. Lepage, Cesar O. Gomez and Kristian E. Waters

Minerals 2022, 12(4), 454; https://doi.org/10.3390/min12040454 - 07 Apr 2022

Cited by 1 | Viewed by 2080

Abstract

The metallurgical performance of a flotation machine is largely defined by phenomena occurring in the froth zone. The water content in the froth affects recovery by influencing froth stability and mobility and, at the same time, reduces grade by mechanical entrainment of gangue particles in the overflow water. Efficient operation requires a compromise between the water carried by bubbles from the collection zone and that which overflows. It is believed that the most suitable operating strategy could be based on the measurement of froth water content, as a strong correlation with water overflow is anticipated. This work reports the testing results of an in situ electrical conductivity sensor continuously measuring the froth zone water content in a laboratory-scale flotation column. The test program included simultaneous measurement of froth conductivity and water overflow rates for changes in gas flow rate and frother concentration. The results show a stronger dependence of the measured top-of-froth water content on frother concentration than on the gas flow rate. A relatively linear trend was shown between top-of-froth water content and water overflow rate for a given air rate and frother. Full article

(This article belongs to the Special Issue Hydrodynamics and Gas Dispersion in Flotation)

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7 pages, 976 KiB

Open AccessCommunication

A Method to Detect Abnormal Gas Dispersion Conditions in Flotation Machines

by Luis Vinnett, Juan Yianatos, Claudio Acuña and Iván Cornejo

Minerals 2022, 12(2), 125; https://doi.org/10.3390/min12020125 - 21 Jan 2022

Cited by 2 | Viewed by 2007

Abstract

This short communication presents a methodology to detect abnormal gas dispersion conditions in flotation machines. These abnormal conditions are characterized by the significant presence of cap-shaped bubbles. The approach considers the use of a bubble size analyzer to measure gas dispersion at industrial scale. The detection of abnormal conditions is critical when estimating bubble size by automated software. Otherwise, the estimates are significantly biased, since irregular bubbles are typically removed from the analysis. From the recorded images and the respective black and white representation, the variability of the shadow percentage caused by the bubbles in the vision field, abruptly increases in the presence of cap-shaped bubbles. Experimental conditions with coefficients of variation lower than 60–70% in the shadow percentage represent spherical and spherical-ellipsoidal regimes. In the former, automated bubble sizing software has proved to be sufficiently effective in obtaining reliable results. In the latter, different segmentation techniques have been proposed to obtain satisfactory results. Abnormal conditions are detected under coefficients of variation greater than 80% in the shadow percentage. The presence of cap-shaped bubbles causes inefficiencies in the collection of hydrophobic minerals in the pulp zone as well as disturbances in the separation stage (froth zone). Therefore, the detection of these irregular bubbles is suitable to provide feedback to flotation processes, allowing gas dispersion to be driven towards normal operating conditions. Full article

(This article belongs to the Special Issue Hydrodynamics and Gas Dispersion in Flotation)

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Review

Jump to: Editorial, Research

31 pages, 8386 KiB

Open AccessReview

Recent Developments in Generation, Detection and Application of Nanobubbles in Flotation

by Sabereh Nazari, Ahmad Hassanzadeh, Yaqun He, Hamid Khoshdast and Przemyslaw B. Kowalczuk

Minerals 2022, 12(4), 462; https://doi.org/10.3390/min12040462 - 10 Apr 2022

Cited by 20 | Viewed by 5704

Abstract

This paper reviews recent developments in the fundamental understating of ultrafine (nano) bubbles (NBs) and presents technological advances and reagent types used for their generation in flotation. The generation of NBs using various approaches including ultrasonication, solvent exchange, temperature change, hydrodynamic cavitation, and electrolysis was assessed. Most importantly, restrictions and opportunities with respect to the detection of NBs were comprehensively reviewed, focusing on various characterization techniques such as the laser particle size analyzer (LPSA), nanoparticle tracking (NTA), dynamic light scattering (DLS), zeta-phase light scattering (ZPALS), and zeta sizer. As a key feature, types and possible mechanisms of surfactants applied to stabilize NBs were also explored. Furthermore, flotation-assisted nano-bubbles was reported as an efficient method for recovering minerals, with a special focus on flotation kinetics. It was found that most researchers reported the existence and formation of NBs by different techniques, but there is not enough information on an accurate measurement of their size distribution and their commonly used reagents. It was also recognized that a suitable method for generating NBs, at a high rate and with a low cost, remains a technical challenge in flotation. The application of hydrodynamic cavitation based on a venturi tube and using the LPSA and NTA in laboratory scales were identified as the most predominant approaches for the generation and detection of NBs, respectively. In this regard, neither pilot- nor industrial-scale case studies were found in the literature; they were only highlighted as future works. Although the NB-stabilizing effects of electrolytes have been well-explored, the mechanisms related to surfactants remain the issue of further investigation. The effectiveness of the NB-assisted flotation processes has been mostly addressed for single minerals, and only a few works have been reported for bulk materials. Finally, we believe that the current review paves the way for an appropriate selection of generating and detecting ultrafine bubbles and shines the light on a profound understanding of its effectiveness. Full article

(This article belongs to the Special Issue Hydrodynamics and Gas Dispersion in Flotation)

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