Hybrid CFD-experimental investigation into the effect of sparger orifice size on the metallurgical response of coal in a pilot-scale flotation column

Although column flotation cells have been extensively studied in the literature, the hydrodynamic impact of orifice properties has not been adequately addressed yet. This paper initially investigates the effect of sparger orifice diameter on hydrodynamic behavior of coal particles in a pilot-scale column flotation. The metallurgical responses (i.e., ash, yield and recovery contents) were evaluated for four different sparger orifice sizes including 1, 3, 5, and 7 mm under constant operating conditions by experimental measurements associated with computational fluid dynamics (CFD) simulations. A numerical model of a two-phase air-water flow in the column (3 m x 0.5 m) was chosen and the turbulence patterns inside the collection zone and at the pulp-froth interface were simulated by employing the Volume-Of-Fluid (VOF) model. The experimental results indicated that desiring concentrated product i.e., ash content of 8.8% and yield of 57.2% could be obtained using the 3 mm orifice size. Simulation results revealed that as the sparger orifice size decreased to 1 mm, the reduced carrying capacity of the bubbly regime led to the poor flotation performance. In contrast, the turbulence condition intensified as the sparger orifice size was increased to 7 mm. Another negative consequence of the 7 mm orifice was attributed to the exceeded entrainment of high ash fines due to a bubble swarm mechanism. The 7 mm sparger orifice diameter showed a concentrate of 17.1% ash and 12.5% yield. Finally, according to the obtained results in this work and literature studies, several necessary highlights were suggested for future works in this scope.

Automated summary

Although extensively studied in the literature, this paper highlights the inadequate consideration of the hydrodynamic impact of orifice properties in column flotation cells. It demonstrates the influence of different sparger orifice sizes on metallurgical responses and fluid dynamics, indicating optimal performance with a 3 mm orifice size. Decreasing to 1 mm reduces carrying capacity while increasing to 7 mm intensifies turbulence but also leads to excessive entrainment of high ash fines.