Flotation of fine kaolinite using dodecylamine chloride/fatty acids mixture as collector

Emerging Trends of Computational Chemistry and Molecular Modeling in Froth Flotation: A Review

Froth flotation is the most versatile process in mineral beneficiation, extensively used to concentrate a wide range of minerals. This process comprises mixtures of more or less liberated minerals, water, air, and various chemical reagents, involving a series of intermingled multiphase physical and chemical phenomena in the aqueous environment. Today's main challenge facing the froth flotation process is to gain atomic-level insights into the properties of its inherent phenomena governing the process performance. While it is often challenging to determine these phenomena via trial-and-error experimentations, molecular modeling approaches not only elicit a deeper understanding of froth flotation but can also assist experimental studies in saving time and budget. Thanks to the rapid development of computer science and advances in high-performance computing (HPC) infrastructures, theoretical/computational chemistry has now matured enough to successfully and gainfully apply to tackle the challenges of complex systems. In mineral processing, however, advanced applications of computational chemistry are increasingly gaining ground and demonstrating merit in addressing these challenges. Accordingly, this contribution aims to encourage mineral scientists, especially those interested in rational reagent design, to become familiarized with the necessary concepts of molecular modeling and to apply similar strategies when studying and tailoring properties at the molecular level. This review also strives to deliver the state-of-the-art integration and application of molecular modeling in froth flotation studies to assist either active researchers in this field to disclose new directions for future research or newcomers to the field to initiate innovative works.

Substituent Effects in Kaolinite Flotation Using Dodecylamine: Experiment and DFT Study

The molecular structure of cationic surfactants is closely related to their flotation performance. In this paper, three cationic surfactants with different head group structures were selected as collectors of kaolinite, and the substituent effects were studied by the DFT method. The DFT calculation results showed that increasing the number of substituents in the dodecylamine head group can significantly increase its surface and head group charge. Dodecylamine has the lowest LUMO orbital energy, so dodecylamine has the strongest electron attraction ability and the strongest interaction with kaolinite. Electron density differential showed that there was an area of electron aggregation between the collector and the surface of the kaolinite. The interaction energy of DDA on kaolinite surfaces was greater than that of the other two collectors, indicating that the adsorption of DDA on the surface of kaolinite was more stable. Flotation results showed that higher a kaolinite yield was obtained in the presence of dodecyl dihydroxyethyl methyl ammonium chloride. The calculated results of the solvent-accessible surfaces, the head group charge, and the number of bonds between the collector and the kaolinite show good consistency with the actual flotation results of the three collectors, which can be used as a screening index for kaolinite flotation collectors.

Associations of Gangue Minerals in Coal Flotation Tailing and Their Transportation Behaviors in the Flotation Process

The mass production of flotation tailings has become a serious risk to the environment. Re-concentration of tailings is one of the best ways to solve this problem, which requires a better understanding of flotation tailings. In the present work, flotation kinetics, timed-release flotation, X-ray diffraction (XRD), Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy-energy dispersive spectroscopy (SEM-EDS), and solid-state nuclear magnetic resonance (SSNMR) were used to analyze the properties of flotation tailings with different particle sizes and densities, the occurrence and binding state of gangue minerals in tailing, and the transportation behaviors in the re-flotation process. Flotation results showed that the flotation yield exhibited little change with the extension of flotation time, while the ash content of the froth concentrates increased. An increase of the flotation time could reduce the ash content of the obtained product. The characterization results confirmed that the main gangue minerals in the tailings were kaolinite and quartz. With the decrease of particle size or the increase of floating and sinking density, the contents of kaolinite and quartz increased. However, due to the different dissemination characteristics of kaolinite and quartz in the tailings, the distributions of kaolinite and quartz in the different particle sizes and densities of tailing had differences. Although both kaolinite and quartz could exist as monomers, kaolinite was more easily associated with coal. Based on the above cognition, a new flotation method is proposed for coal flotation tailing. A part of the concentrates in the early stage of flotation should be scraped out quickly. Then, the concentrates obtained in the later stage of flotation are collected and merged into the concentrates obtained during the early stage of flotation, while the secondary tailing is directly pumped into the raw feed system.

Iron ore production using a new Gemini surfactant at 273 K

Herein we present the use of a Gemini surfactant and reverse froth flotation to efficiently separate magnetite from quartz and produce iron ore at 273 K. This surfactant achieved an obviously superior flotation performance (TFe recovery increased by 48.18%), and the dosage of the Gemini surfactant was three times less than that of a conventional monomeric surfactant. Our findings are expected to serve as a general guide to design a new and excellent collector for high-efficiency mineral flotation and to lead to an efficient and clean development of mineral resources.

Molecular Dynamics Simulation Study on the Interactions of Mixed Cationic/Anionic Collectors on Muscovite (001) Surface in Aqueous Solution

In this study, the adsorption mechanisms of dodecylamine hydrochloride(DDAHC), sodium dodecyl sulfate (SDS), sodium dodecyl benzene sulfonate(SDBS), and their mixed anionic/cationic collectors at ten different molar ratios on a muscovite (Mcv) surface in neutral aqueous solution were assessed by molecular dynamics simulations (MDS). According to the snapshot, interaction energy, radial distribution function (RDF), and density profile between the Mcv surface and collector molecules, the individual DDAHC collector was an effective collector for the flotation of Mcv. The molar ratio of anionic/cationic collectors was determined to be an essential factor in the flotation recovery of Mcv. The DDAHC collector was involved in the adsorption of the mixed anionic/cationic collectors on the Mcv (001) surface, whereas SDS and SDBS collectors were co-adsorbed with DDAHC. The mixed cationic/anionic collector showed the best adsorption on the Mcv surface in a molar ratio of 2. Additionally, SDBS, which has one more benzene ring than SDS, was more likely to form spherical micelles with DDAHC, thus resulting in better adsorption on the Mcv surface. The results of micro-flotation experiments indicated that the DDAHC collector could improve the flotation recovery of Mcv in neutral aqueous solution, which was in agreement with MDS-derived findings. In conclusion, DDAHC alone is the optimum collector for Mcv flotation under the neutral aqueous conditions, while the mixture of DDAHC and SDBS collectors (molar ratio = 2:1) exhibits the similar flotation performance.

Flotation Separation of Diaspore and Kaolinite by Using a Mixed Collector of Sodium Oleate-Tert Dodecyl Mercaptan

Sodium oleate (NaOl), a collector in diaspore flotation, has been widely used for more than 30 years, while its low selectivity becomes an issue under today's process requirement. This study introduced tert dodecyl mercaptan (TDM) together with NaOl as a mixed collector to improve selectivity in diaspore flotation. We found that using the mixed collector of NaOl/TDM (total concentration 0.1 mM, the molar ratio 8:2 of NaOl: TDM) at pH = 9-10 significantly effectively separated diaspore and kaolinite. Comparing the recovery of Al₂O₃ and the ratio of Al₂O₃ to SiO₂ (A/S) treated by NaOl/TDM (pH = 9) and NaOl (pH = 10), the Al₂O₃ recovery and A/S in concentrate for NaOl/TDM are 7.5% and 2.2 higher than that for NaOl in mixed mineral flotation. Also, surface tension measurements, Zeta potential measurements and Fourier Transform Infrared (FTIR) spectra analysis were used to examine its selectivity from a flotation mechanical perspective. Surface tension measurements show that mixed collector NaOl/TDM has stronger surface activity and hydrophobic association than NaOl. The results of Zeta potential measurements and FTIR spectra analysis indicate that NaOl and TDM can selectively co-adsorb diaspore through physical adsorption. Moreover, the adsorption of TDM promotes the adsorption of NaOl on diaspore. However, when NaOl/TDM treats on kaolinite together, TDM can hardly adsorb on mineral surface, nor can it promote the adsorption of NaOl.

Morpholine-Based Gemini Surfactant: Synthesis and Its Application for Reverse Froth Flotation of Carnallite Ore in Potassium Fertilizer Production

Potassium fertilizer plays a critical role in increasing the food production. Carnallite is concentrated by reverse froth flotation and used as a raw material to produce potassium fertilizer (KCl) in agriculture. However, all the surfactants used in the carnallite reverse flotation process are conventional monomeric surfactants contain a single similar hydrophobic group in the molecule, which results in a low production efficiency. In this work, a new morpholine-based Gemini surfactant, 1,4-bis (morpholinododecylammonio) butane dibromide (BMBD), was prepared and originally recommended as a collector for reverse froth flotation separation of halite (NaCl) from carnallite ore. The flotation results indicated BMBD had higher flotation recovery and stronger affinity of halite against carnallite compared with conventional monomeric surfactant N-(n-Dodecyl) morpholine (DDM). Fourier transform infrared spectra suggested that BMBD molecules were adsorbed on halite surface rather than the carnallite surface. Additionally, BMBD molecules can strongly reduce the surface tension of NaCl saturated solution. Considering the BMBD's unique properties, such as double reactive centers to mineral surfaces, double hydrophobic groups, and stronger surface tension reducing ability, made it be a superior collector for reverse flotation desalination from carnallite ores than DDM.

Study on the aggregation behavior of kaolinite particles in the presence of cationic, anionic and non-ionic surfactants

Aggregation behaviors of kaolinite particles with different surfactants were studied in this paper. Aggregation settling yield and fractal dimension analysis were used to determine the aggregation results. Zeta potential measurements, adsorption tests, Infrared spectroscopy analysis and scanning electron microscope measurements were conducted for further investigation into the mechanism. Experimental results showed that much better aggregation results was obtained in the presence of cationic surfactant than that in the presence of anionic and non-ionic surfactants. 98% aggregation setting yield was obtained in the presence of dodecylamine. Adsorption tests indicated that the adsorption capacity of dodecylamine on kaolinite surface was larger than that of sodium oleate and Tween80. Zeta potential measurements confirmed that dodecylamine was more beneficial to the aggregation of kaolinite particles. Infrared spectroscopy analysis revealed that the adsorption of dodecylamine on kaolinite surface was attributed to electrostatic and hydrogen-bonding interactions. Sodium oleate was adsorbed by chemical adsorption. However, Tween80 can hardly be adsorbed by kaolinite surface.

A review of the surface features and properties, surfactant adsorption and floatability of four key minerals of diasporic bauxite resources

Diasporic bauxite represents one of the major aluminum resources. Its upgrading for further processing involves a separation of diaspore (the valuable mineral) from aluminosilicates (the gangue minerals) such as kaolinite, illite, and pyrophyllite. Flotation is one of the most effective ways to realize the upgrading. Since flotation is a physicochemical process based on the difference in the surface hydrophobicity of different components, determining the adsorption characteristics of various flotation surfactants on the mineral surfaces is critical. The surfactant adsorption properties of the minerals, in turn, are controlled by the surface chemistry of the minerals, while the latter is related to the mineral crystal structures. In this paper, we first discuss the crystal structures of the four key minerals of diaspore, kaolinite, illite, and pyrophyllite as well as the broken bonds on their exposed surfaces after grinding. Next, we summarize the surface chemistry properties such as surface wettability and surface electrical properties of the four minerals, and the differences in these properties are explained from the perspective of mineral crystal structures. Then we review the adsorption mechanism and adsorption characteristics of surfactants such as collectors (cationic, anionic, and mixed surfactants), depressants (inorganic and organic), dispersants, and flocculants on these mineral surfaces. The separation of diaspore and aluminosilicates by direct flotation and reverse flotation are reviewed, and the collecting properties of different types of collectors are compared. Furthermore, the abnormal behavior of the cationic flotation of kaolinite is also explained in this section. This review provides a strong theoretical support for the optimization of the upgrading of diaspore bauxite ore by flotation and the early industrialization of the reverse flotation process.

The flotation and adsorption of mixed collectors on oxide and silicate minerals

The analysis of flotation and adsorption of mixed collectors on oxide and silicate minerals is of great importance for both industrial applications and theoretical research. Over the past years, significant progress has been achieved in understanding the adsorption of single collectors in micelles as well as at interfaces. By contrast, the self-assembly of mixed collectors at liquid/air and solid/liquid interfaces remains a developing area as a result of the complexity of the mixed systems involved and the limited availability of suitable analytical techniques. In this work, we systematically review the processes involved in the adsorption of mixed collectors onto micelles and at interface by examining four specific points, namely, theoretical background, factors that affect adsorption, analytical techniques, and self-assembly of mixed surfactants at the mineral/liquid interface. In the first part, the theoretical background of collector mixtures is introduced, together with several core solution theories, which are classified according to their application in the analysis of physicochemical properties of mixed collector systems. In the second part, we discuss the factors that can influence adsorption, including factors related to the structure of collectors and environmental conditions. We summarize their influence on the adsorption of mixed systems, with the objective to provide guidance on the progress achieved in this field to date. Advances in measurement techniques can greatly promote our understanding of adsorption processes. In the third part, therefore, modern techniques such as optical reflectometry, neutron scattering, neutron reflectometry, thermogravimetric analysis, fluorescence spectroscopy, ultrafiltration, atomic force microscopy, analytical ultracentrifugation, X-ray photoelectron spectroscopy, Vibrational Sum Frequency Generation Spectroscopy and molecular dynamics simulations are introduced in virtue of their application. Finally, focusing on oxide and silicate minerals, we review and summarize the flotation and adsorption of three most widely used mixed surfactant systems (anionic-cationic, anionic-nonionic, and cationic-nonionic) at the liquid/mineral interface in order to fully understand the self-assembly progress. In the end, the paper gives a brief future outlook of the possible development in the mixed surfactants.