微细粒矿物广义限域湍涡矿化过程强化及新型浮选模式

Process intensification of general confined turbulent-eddy mineralization for microfine mineral flotation and novel flotation mode

  • 摘要: 颗粒−气泡矿化过程是浮选过程的核心环节,微细粒矿物由于动量低、惯性弱,易随流体绕流,难以与气泡发生有效碰撞,并缺乏足够能量克服气固相间液膜微流体阻力制约,排液破膜效率低,黏附难,导致其矿化回收难,直接影响浮选过程效率与能力。以浮选黏附过程“相间微流体阻力效应”为切入点,结合碰撞过程湍涡强化原理,将广义限域空间概念引入浮选矿化过程,构建了高能量耗散限域湍涡矿化过程,提出了“限域矿化−阔域分离”新型浮选模式,并搭建中试试验系统,以煤气化细渣为试验对象,利用计算流体力学数值仿真解析中试系统中限域湍涡矿化体系流体动力学特性,通过碳灰浮选分离试验验证其可行性。结果表明:构建的高能量耗散限域湍涡矿化体系内管流、对撞流、搅拌流等流态协同诱导高能量耗散湍流场,产生小尺度微涡,而有压受限空间的设计增强了矿化体系压力,形成高压力场矿化环境。限域湍涡矿化体系中叶轮转速是影响流场结构与湍动能耗散的关键因素,随转速增加,Kolmogorov涡尺度由35.19 μm降至19.37 μm,而限域压力对矿化体系流速及湍流耗散分布影响较小,但可显著提升体系压力。在研究范围内,提高叶轮转速能有效提高煤气化细渣碳灰浮选分离效果,当叶轮转速升至432 r/min时,残碳回收率基本达到最大并趋于稳定;限域压力的增大有利于强化微细碳颗粒与气泡的矿化过程,提高残碳回收率,在高限域压力条件下,适当减少起泡剂用量,可进一步强化微细碳粒矿化捕集过程,提高残碳回收率,在叶轮转速432 r/min、限域压力0.06 MPa、起泡剂用量2.5 kg/t的工况条件下,碳灰浮选分离效果最佳,残碳回收率达90.55%,尾灰灰分98.91%。

     

    Abstract: Particle-bubble mineralization is the core step of the flotation process. Due to their low momentum and weak inertia, microfine mineral particles tend to follow streamlines and flow around bubbles, making effective particle-bubble collision difficult. In addition, micro-fine particles lack sufficient energy to overcome the micro-hydrodynamic resistance of the liquid film at the gas-solid interface. This results in poor drainage and rupture efficiency, weak particle-bubble attachment, and consequently low mineralization recovery, directly limiting flotation efficiency and performance. Focusing on the “interfacial micro-hydrodynamic resistance effect” in the particle-bubble attachment and incorporating the turbulent vortex intensification mechanism during particle-bubble collision, the concept of generalized confined space was introduced into the flotation mineralization process. A high-energy-dissipation confined turbulent-vortex mineralization process was developed, together with a novel flotation mode integrating “confined mineralization and unconfined separation”. A pilot-scale experimental system was subsequently constructed using coal gasification fine slag as the test material. Computational fluid dynamics (CFD) simulations were employed to analyze the hydrodynamic characteristics of the confined turbulent-vortex mineralization system, while carbon-ash flotation separation experiments were conducted to verify its feasibility. The results indicated that the synergistic interaction of pipe flow, impinging flow, and stirring flow within the proposed confined turbulent-vortex mineralization system induced a high-energy-dissipation turbulent flow field and generated small-scale turbulent vortices. Meanwhile, the pressurized confined-space design increased the system pressure and established a high-pressure mineralization environment. Impeller rotational speed was identified as the dominant factor affecting flow structure and turbulent energy dissipation within the confined turbulent-vortex mineralization system. As rotational speed increased, the Kolmogorov vortex scale decreased from 35.19 μm to 19.37 μm. In contrast, confined pressure had little influence on flow velocity and turbulent dissipation distributions but significantly increased the system pressure. Within the investigated range, increasing impeller rotational speed effectively improved the carbon-ash flotation separation performance of coal gasification fine slag. When the impeller speed reached 432 r/min, carbon recovery approached a plateau. Increasing confined pressure promoted the mineralization process between micro-fine carbon particles and bubbles, thus improving carbon recovery. Under high confined-pressure conditions, appropriately reducing frother dosage further enhanced the mineralization of micro-fine carbon particles and improved carbon recovery. The optimal separation performance was obtained at an impeller rotational speed of 432 r/min, a confined pressure of 0.06 MPa, and a frother dosage of 2.5 kg/t, corresponding to a carbon recovery of 90.55% and a tailing ash content of 98.91%.

     

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