Different Flotation Performance of Ultrafine Scheelite under Two Hydrodynamic Cavitation Modes

Industrial application of microbubble generation methods for recovering fine particles through froth flotation: A review of the state-of-the-art and perspectives

The depletion of high-grade and coarse-grain ores has led to an increasing demand for the development of efficient separation technologies for low-grade and fine-grain ores. However, conventional froth flotation techniques are not adequate to efficiently recover fine and ultrafine particles (typically <10-15 μm) due to the low collision probability between these particles and the relatively large bubbles used in the process. The introduction of microbubbles has shown promise in enhancing particle recovery, making it a subject of significant interest. Thus, this review focuses on microbubble generation methods that have the potential to be scaled up for industrial applications, with a specific emphasis on their suitability for froth flotation. The methods are categorized based on their scalability: high-hydrodynamic cavitation, porous media/medium-dissolved air, electrolysis/low-microfluidics, and acoustic methods. The bubble generation mechanisms, characteristics, advantages and limitations of each method and its applications in froth flotation are discussed to provide suggestions for improvement. There is still no appropriate technology that can optimize bubble size distribution, production rate and cost together for industrial froth flotation application. Therefore, novel approaches of combining multiple methods are also explored to achieve the potential synergic effects. By addressing the limitations of current microbubble generation methods and proposing potential enhancements, this review aims to contribute to the development of efficient and cost-effective microbubble generation technologies for fine and ultrafine particles in the froth flotation industry.

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

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.

Determination and modulation of the typical interactions among dispersed phases relevant to flotation applications: A review

Flotation is a process involving multi-components, multi-scales, and gas-liquid-solid three phases, where the material separation is achieved based on the difference in surface hydrophobicity of various constituents. In a flotation system, fluids are usually regarded as the continuous phase, while the dispersed phases refer to scattered particles, bubbles, and droplets with low solubility as a dispersion that is surrounded by the aqueous environment. Fundamentally, the interactions among dispersed phases exist throughout the flotation process, and play distinct roles during different periods. For example, the liquid collector-solid, solid-solid, bubble-bubble and gas bubble-solid interactions are closely associated with the particle surface modification, particle behavior, bubble size evolution and separation in flotation, respectively. Therefore, the influences of each stage are all worthy of concern, and should be spared sufficient attention, which requires to formulate a horizontal writing structure. In this review, instead of summarizing all available characterization techniques or measurements, certain typical examples or methods were consciously chosen to perform analysis or comparison, aiming to summarize recent studies on the determination and modulation of dispersed phase interactions. The determination on the interactions among dispersed phases is helpful for fundamentally understanding the microcosmic process connotations, and their modulation contributes to firmly providing macroscopic optimization schemes for practical applications. By integrating some typically available theoretical calculations and experimental measurements related to the dispersed phase interactions, the present article is devoted to revealing the influential factors, finding out the current challenges or knowledge gaps, and affording certain references or suggestions for future investigations.

Electrokinetic potential reduction of fine particles induced by gas nucleation

Electrokinetic potential of particles has been extensively studied in colloidal systems over the past century, while up to date, the influence of gas on electrokinetic behaviors of particles has not been fully understood yet. In this study, the electrokinetic response of particles to gas nucleation was systematically investigated with coal as the object. The results showed that the nucleation of gas (both on particle surfaces and in water) significantly changed the particle' electrokinetic behaviors. Higher gas content and particle's surface hydrophobicity normally trigger more intensive gas nucleation, thus inducing more significant reduction of particle zeta potential. After gas nucleation, numerous nanobubbles (NBs) appear in the suspensions mainly in two forms: NBs adhering onto solid surfaces (ANBs) and NBs stagnating in bulk solutions (BNBs). ANBs not only enhance the surface heterogeneity, but also cause the "steric hindrance" effect, and electric double layer (EDL) overlapping and associated ions shielding towards charged particles, which significantly decrease their electrokinetic potentials. Although BNBs can also reduce the zeta potential of particles by EDL compressing, their functions are rather limited.

A novel flotation technique combining carrier flotation and cavitation bubbles to enhance separation efficiency of ultra-fine particles

In this paper, a novel flotation technique that combines nano-scale bubbles generated by hydrodynamic cavitation (HC) and carrier flotation is proposed to promote the flotation efficiency of a high-ash (43%) ultra-fine coal sample (<45 µm). We investigated the mechanism by which cavitation bubbles enhance the separation efficiency of carrier flotation using focused beam reflectance measurements, polarizing microscopy, and extended Derjaguin-Landau-Verwey-Overbeek theory. The carrier particles (polystyrene (PS)) and fine coal were pre-treated in a venturi tube and then floated in a laboratory mechanical flotation cell. The flotation results indicate that the presence of cavitation bubbles significantly improved the carrier flotation performance of high-ash ultra-fine coal. This improvement was attributed to the presence of highly hydrophobic PS, which creates additional gas nuclei in the flotation system. The nano-bubbles, which were produced by the venturi tube and adhered to the fine coal particle surfaces, were conducive to the agglomeration of fine coal particles into large aggregates. Moreover, the nano-bubbles functioned as "bridges" of interaction between the carrier particles and large aggregates of fine coal particles. This paper mainly focused on the effect of carrier (PS) and HC on high-ash fine coal. The influence of different HC intensities on carrier (PS) flotation was discussed. Two models for the interactions between the coal particles, nano-bubbles, and PS during cavitation were proposed and were proved using the E-DLVO theory.

The role of bulk micro-nanobubbles in reagent desorption and potential implication in flotation separation of highly hydrophobized minerals

Micro-nanobubbles (MNBs) generated during hydrodynamic cavitation (HC) have been extensively studied in mineral processing field in the past two decades. Many researchers have claimed that MNBs can effectively promote the collection of fine particles in flotation, while studies on MNBs assisted mineral separation are rare. In this study, the role of bulk MNBs in desorbing flotation reagent was investigated, with the aim of illustrating the potential effects of MNBs on minerals separation. The results showed that bulk MNBs could efficiently remove the sodium oleate (NaOl) from diaspore surfaces, reducing the residual concentration of NaOl on solids, which was more significant when the amount of NaOl pre-adsorbed was relatively small. Furthermore, lower residual concentration of NaOl on solids caused by MNBs cleaning made the particles less hydrophobic and flocs more friable. Given that gangue entrapment in flocs was one of the main limits for high-selective flotation, the roles of MNBs in enhancing reagent desorption and associated flocs breakup and reorganization probably contribute to higher separation efficiency of different minerals, which was confirmed by the flotation results of diaspore/kaolinite mixture.

Effect of Hydrodynamic Cavitation Assistance on Different Stages of Coal Flotation

In this study, the effect of hydrodynamic cavitation (HC) on the conditioning stage (HCCS), separation stage (HCSS), and whole stage (HCWS) of coal flotation was investigated by flotation tests, laser granulometry, and contact angle measurements. The flotation results indicate that compared to conventional flotation, all HC-assisted flotation methods can improve concentrate combustible recovery and flotation constant rate. HCCS and HCSS show similar levels of improvement, while HCWS has a better flotation efficiency. The screening tests demonstrate that HC has the advantage of being able to liberate coarse coal particles (+0.25 mm) prior to being combined with gangues. On one hand, HC promotes the dispersion of both particles and agents, while longer cavitation time in HCCS does not lead to better flotation performance. On the other hand, enhancement of the adsorption of the collector on the surface of coal particles in HCCS is confirmed by flotation concentrate contact angle tests. However, HCSS leads to a decrease in concentrate hydrophobicity, compared to conventional flotation. The micro-nanobubbles generated by HC play an important role in improving flotation performance. HCWS offers the advantages of both HCCS and HCSS, and the cooperated mechanism of different HC modes enhances the recovery of coal particles in flotation.

Bulk nanobubbles in the mineral and environmental areas: Updating research and applications

In the last decade, the research with bulk nanobubbles (ultrafine bubbles with a diameter <1 μm, according to ISO 20480-1:2017) has been rapidly increasing in the academic and industrial environments. Nowadays, there are many applications reported in the literature, with several patents, procedures, and techniques on nanobubbles generation and an evergrowing research and many applications. Yet, most of those publications reporting bulk nanobubbles generation devices, do not bring information on measurements of size distribution or bubbles concentration (if nanobubbles). Further, there is a problem of scale and many of these products are small bench discontinuous rigs difficult to scale up, which might serve small scale purposes, but are not able for treating high flow-rate wastewaters or minerals pulps at industrial scale. These nanometric bubbles present interesting and peculiar properties such as high surface area per volume unit, high stability and longevity, surface charge in water and the ability to aggregate hydrophobic particles. These findings demonstrate their high potential for applications in many technological areas, which occur not only as isolated bubbles but also jointly with micro (~ 1-100 μm diameter) and/or macrobubbles (~100 μm - 2 mm diameter). This paper reviews the evolution of basic research on nanobubbles, the challenges concerning generation and stability and their applications in the mineral (flotation) and environmental areas (treatment of water and wastewaters or remediation of contaminated environments). Herein, because the importance in engineering, as a whole, most of the studies are based on the nanobubbles generated by depressurisation/hydrodynamic cavitation of the air-saturated water in flow constrictors (venturi, needle valves). In the mineral area, they appear to be responsible for increasing the recovery and flotation kinetics of fine (<74 μm) and ultrafine (<13 μm) particles at lower frother and collector dosages. In the environmental area, nanobubbles have been reported to enhance the removal of a variety of pollutants (emulsified oil, colloidal solids, organic/inorganic precipitates, ions) by flotation associated with bigger bubbles. More, the application of isolated nanobubbles on the removal of residual pollutants, such as amine and oil (both as flocs) were reported. Also, the use of ozone and oxygen nanobubbles has been studied for the remediation/decontamination of soil and aquatic ecosystems and for the oxidation of emerging pollutants in water and wastewater treatment. The future of nanobubbles in flotation separation research is highly promising; operating costs of the different forms of nanobubbles generation and bench studies should be validated through pilot and real scale with the continuous injection of these bubbles.

Adsorption of bulk nanobubbles on the chemically surface-modified muscovite minerals

Bulk nanobubbles (NBs) that are produced in the hydrodynamic cavitation (HC) process have been widely applied in mineral flotation for more than a decade, while how bulk NBs interact with minerals in the water-solid interface is still unclear. In this study, the adsorption behaviors of bulk NBs generated in the principle of HC on muscovite surfaces in the presence of dodecylamine (DDA) were investigated. The results show that NBs are likely coated with DDA in aqueous solutions. After attaching with muscovite, bulk NBs can adsorb on the mineral surfaces, probably following the three-contact line pinning theory. The adsorption of NBs increases the surface hydrophobicity of minerals, which can be inferred from the larger contact angles and the better flotation performances obtained in the presence of DDA/NBs. In addition, the adsorption of NBs is thought to be able to prevent the adsorption of DDA on the same space of the solid surfaces, which can be confirmed by the results of zeta potential measurements, contact angle measurements and AFM imaging results.