Numerical Simulations of Two-Phase Flow in a Dorr-Oliver Flotation Cell Model
Abstract: Two-phase (water and air) flow in the forced-air mechanically-stirred Dorr-Oliver machine has been investigated using computational fluid dynamics (CFD). A 6 m 3 model is considered. The flow is modeled by the Euler-Euler approach, and transport equations are solved using software ANSYS-CFX5. Unsteady simulations are conducted in a 180-degree sector with periodic boundary conditions. Air is injected into the rotor at the rate of 2.63 m 3 /min, and a uniform bubble diameter is specified. The effects of bubble diameter on velocity field and air volume fraction are determined by conducting simulations for three diameters of 0.5, 1.0, and 2.0 mm. Air volume fraction contours, velocity profiles, and turbulent kinetic energy profiles in different parts of the machine are presented and discussed. Results have been compared to experimental data, and good agreement is obtained for the mean velocity and turbulent kinetic energy profiles in the rotor-stator gap and in the jet region outside stator blades.
Hydrodynamic and Flotation Kinetic Analysis of a Large Scale Mechanical Agitated Flotation Cell with the Typical Impeller and the Arc Impeller
The processing of low grade mineral ores using large scale flotation cells is obviously more advantageous than smaller-scale processing. Large-scale flotation cells have become increasingly important for effective volume scale-up. In this study, the latest and largest flotation cell in China, with an effective volume of 680 m3, is considered. Hydrodynamics and flotation kinetics analyses are conducted using computational fluid dynamics (CFD) simulation. It is demonstrated that the flotation cell with a typical impeller produces suitable hydrodynamics for mineral particles based on analysis of the flow pattern, gas dispersion and solid suspension. The performance of the large-scale flotation cell is studied using hydrodynamic performance parameters. The variation of the performance parameters, such as the power number (Np), the Froude number (Fr), the air flow number (Na), and so on, with the flotation cell volumes, followed trends similar to that of previous cells of a different size, which were proven to be effective for engineering applications. To decrease the detachment of mineral particles, a new type of impeller, for which the impeller plate is a hyperbolic curve, viz. an arc impeller, was developed. Compared with the typical impeller, the arc impeller expands and lifts the low circulating flow, thereby shortening the transportation distance of the mineral particles. The data indicates that kinetic eddy dissipation plays a key role in determining the collision kernel and collision probability profile. The newly designed arc impeller leads to a higher collision probability than the typical impeller, resulting in better flotation performance. This research should aid in the optimization of the structure of the 680 m3 flotation cell.
Gas dispersion measurements in flotation cells
Abstract Progress in science and engineering relies on accurate and precise measurements. Flotation is no exception. It is arguable that progress in both fundamental understanding (modeling) and plant practice has been limited by the lack of instruments and sensors capable of functioning in operating flotation machines. The McGill Mineral Processing group has developed instruments and procedures to measure three variables in industrial cells: superficial gas velocity, gas-holdup and bubble size distribution. This communication describes advances on equipment and operating procedures, and introduces a protocol for sensor installation and documentation that makes possible the correction of measurements to bubble-collection-point conditions.