Patent Application
20150151309
The present invention relates to devices and methods used to agitate slurry retained in flotation machines. One example of a flotation machine is a machine that utilizes one or more flotation cells that have tanks that retain a slurry, or pulp, to recover particles of material such as ore, minerals, metal, or other material that is within solid material suspended in a liquid of the slurry, or pulp.
Flotation machines often include a tank that retains a slurry, or pulp. Examples of such machines may be appreciated from U.S. Pat. Nos. 4,425,232, 4,800,017, and 5,205,926. The entirety of U.S. Pat. Nos. 4,425,232, 4,800,017, and 5,205,926 are incorporated by reference herein. The slurry retained by such tanks may include solid material such as ore or minerals that is mixed in a liquid such as water. For example, the material present in the slurry may include particles of copper bearing minerals, coal, iron minerals, phosphate rock, potash, silica, base metal sulfide or precious metal.
The slurry retained in the tank may be aerated to generate froth to suspend solid particles in the froth. The froth may be a large amount of bubbles formed at the top of the slurry in the tank. For instance, froth may be generated via a forced air technology to create bubbles and generate the froth. Alternatively, bubbles may be generated via a self-aspirated technology to create the froth. The tanks are designed so that the froth, which contains the solid particles, may be passed into one or more launders adjacent to the tank to separate the valuable minerals from the other liquid and other material. It should be understood that after the material is sent to the one or more launders, it may be further processed to recover the desired material.
Rotors may be included in each flotation cell of a flotation machine to agitate the slurry for purposes of forming air bubbles that capture particles and rise to the top of the slurry to form froth. Air may be forced through the rotor and expelled out adjacent blades located at the bottom of the rotor that is rotated so that air is mixed with the slurry to generate bubbles for forming the froth above the slurry retained in the tank. Such a froth so generated, however, may be difficult to maintain unless the rotor is rotated at relatively fast speed and may also require a rotor to be relatively large. Such size and speed constraints increase the cost of fabricating such flotation machines and operating such machines.
Further, such rotors typically include blades that generate a velocity spike in an exit stream of slurry that consumes a relatively significant amount of power used to rotate the rotor but fails to provide any meaningful improvement to froth formation performance. This design feature also increases the costs associated with operating the flotation machines.
A new rotor design is needed for flotation cells of flotation machines. The new rotor design preferably reduces the cost of manufacturing rotors and reduces the operating costs associated with moving of the rotors during operation of the flotation cells. Preferably, such a rotor design also improves the bubble generation performance of the rotors as compared to conventional rotors.
A flotation machine and flotation machine rotor are provided that can provide improved mineral recovery performance and reduced operating costs as compared to conventional designs.
In one embodiment, the flotation machine includes at least one flotation cell. Each flotation cell includes a tank that is sized to retain slurry comprised of a liquid mixed with at least one solid material and a rotor positioned in the tank that is rotated to agitate the slurry to facilitate formation of bubbles. The rotor includes a body that has outer blades that extend outwardly from the body, an inner channel, inner blades positioned adjacent the inner channel and a plurality of conduits in communication with the inner channel. Each of the conduits extends from the inner channel to an external surface of the body so that the slurry pulled into an opening of the body via rotation of the rotor passes through the inner channel and is ejected, or emitted, from the external surface of the body via the conduits.
In other embodiments, the rotor of the flotation machine includes a rotor positioned in the tank that is rotated to agitate the slurry to facilitate formation of a bubbly flow used to generate froth. The rotor is attached to a column and includes a body having a plurality of outer blades that extend outwardly from the body. Each of the outer blades has an outer edge that extends outwardly from an upper portion of the rotor to an outermost position located below the upper portion of the rotor. The outer edge extends inwardly from the outermost position to which the outer edge extends to a lower portion of the rotor. The lower portion of the rotor is located below the outermost position to which the outer edge extends and is positioned inward relative to the outermost position of the outer edge.
Embodiments of a rotor for flotation machines are also provided. One embodiment of the rotor includes a body that has outer blades that extend outwardly from the body, an inner channel, inner blades positioned adjacent the inner channel and a plurality of conduits in communication with the inner channel. Each of the conduits extends from the inner channel to an external surface of the body so that the slurry pulled into an opening of the body via rotation of the rotor subsequently passes through the inner channel and is then ejected, or emitted, from the external surface of the body via the conduits.
The body of the rotor may also include passageways for receiving at least one gas such as air. Each of the passageways may include an inlet to receive at least one gas and an outlet to emit the at least one gas received via the inlet. The outlet of each passageway is spaced apart from the outlets of other passageways. The outlet of each passageway may be positioned in the body between immediately adjacent outer blades. The outer blades may be spaced apart from one another along the external surface of the body of the rotor and the inner blades may be spaced apart from each other and may at least partially define the conduits.
The body of the rotor may be formed so that the inner blades and outer blades are integral with the body or are attached to the body. In one embodiment, the inner blades may be formed by casting or molding the body of the rotor and the outer blades may be welded to the rotor body or formed when the rotor body is casted or molded. The outer blades may be offset relative to the inner blades. The body may be structured in some embodiments so that no gas is injected into the inner channel of the body.
Other embodiments of the rotor for flotation machines can include a plurality of outer blades that extend outwardly from the body. Each of the outer blades has an outer edge that extends outwardly from an upper portion of the rotor to an outermost position located below the upper portion of the rotor. The outer edge extends inwardly from the outermost position to which the outer edge extends to a lower portion of the rotor. The lower portion of the rotor is located below the outermost position to which the outer edge extends and is positioned inward relative to the outermost position of the outer edge.
The outer edges of the outer blades may be curved. In some embodiments of the rotor, the outer edges define smooth outer surfaces of the outer blades and at least partially define the shape of the outer blades so that the outer blades are each generally half-heart shaped. The rotor may also include one or more outlets for emitting air. Each outlet may be positioned between immediately adjacent outer blades.
In one embodiment, the lower portion of the rotor is the bottom of the rotor and the outer blades are sized and shaped so that the rotor suppresses a velocity spike in an exit stream of agitated slurry formed via rotation of the rotor. Preferably, the rotor is shaped so that rotation of the rotor at steady state defines a uniform turbulence profile within the slurry.
Other details, objects, and advantages of the invention will become apparent as the following description of certain present preferred embodiments thereof and certain present preferred methods of practicing the same proceeds.
Present preferred embodiments of flotation machines that utilize embodiments of rotors that rotate for generating froth in flotation cells of such machines, embodiments of the rotor and methods of making and using the same are shown in the accompanying drawings. It should be understood that like reference numbers used in the drawings may identify like components.
Referring to
For example, a flotation machine may include a number of cells that are Dorr-Oliver® unit cells to process finely sized particles and cells upstream or downstream of these cells may be WEMCO® or MixedRow™ cells for larger sized particle recovery such as middlings. Of course, it should be understood that other type of cells could be used as substitutes of the above referenced Dorr-Oliver®, WEMCO®, or MixedRow™ cells.
Each flotation cell 2 has a tank that retains slurry, which may also be referred to as pulp, within the tank 3. The tank 3 may have any of a number of different shapes. For example, each tank 3 may be shaped similarly to a large rectangular tank or may be a generally cylindrical tank as may be appreciated from U.S. Pat. No. 5,205,926 (the entirety of which is incorporated by reference herein).
A feed box 13 may be adjacent to one or more of the flotation cells 2 and may be where material is mixed with liquid to form the slurry, or pulp, that is subsequently fed into the tanks 3 of the cells 2. The liquid may be water, salt water, or a solution. The material that is mixed with the liquid may include rock, stone or dirt that includes one or more minerals or metals that are desired to be recovered from the material.
Froth may be generated in the tank above the slurry retained in the tank by a rotation mechanism 8 that is positioned in the tank 3 of a flotation cell. The rotation mechanism 8 may include a column that is attached to a rotor. Air or another type of gas or mixture of gases may be forced through the column and the rotor so that air is ejected from the rotor to help facilitate agitation of the slurry and formation of the bubbles. The column may be positioned so that the rotor is near the bottom of the tank, at the bottom of the tank, or in another position within the tank that is desirable for generating bubbles sufficiently to form a froth for the particular mineral recovery process a flotation cell of the flotation machine may be configured to meet. The column may a part of a drive mechanism or attached to a drive mechanism so that the column may be rotated to rotate the rotor in the slurry to agitate the slurry within the tank to generate bubbles. The rotor of the rotation mechanism 8 may have any of a number of different designs as discussed more fully below with reference to
Launders 6 may be positioned on the top lips of the tank or adjacent the top lips of each tank around at least some of the sides of the tank 3 of each flotation cell 2 to receive froth that may flow over the sides of the tank. The launders 6 may have discharge outlets 7 for discharging froth received by the launders. The discharged froth may then be processed to separate the fine particles of the material that is within the froth to extract, or recover, desirable portions of this material, such as metal, a mineral, or other desirable material. A cross launder 5 may be positioned between the adjacent flotation cells 2 to divide the cells 2.
Referring to
The body 22 of the rotor 21 may be formed from metal and have an opening 26 formed therein at the bottom of the rotor below the outer blades 24 or adjacent the bottom of the outer blades 24. An inner channel 27 may be formed in the body 22 that is in communication with the opening 26 so that slurry may pass through the opening 26 and into the inner channel 27. A plurality of inner blades 25 are attached to the body 22. For instance, the inner blades 25 may be attached such that the inner blades are integral with the body 22 or are defined in the body 22. The inner blades 25 are positioned adjacent to the inner channel 27 or in the inner channel 27. The inner blades may be members such as plates, inwardly projecting walls, or other structure that is positioned in the body adjacent the inner channel to provide a pumping force or pressure differential, for pulling slurry into the inner channel 27 via opening 26 and out of conduits 28 when the rotor 21 is rotated.
The conduits 28 may be formed in the body 22 and be at least partially defined by the body 22. Immediately adjacent inner blades 25 may also partially define the conduits 28 along with portions of the body 22. For instance, immediately adjacent inner blades 25a and 25b in combination with the body 22 may define conduit 28a as shown in
The body 22 of the rotor 21 may also include a plurality of passageways 31 that are sized to receive air or other gas forced through a column attached to the rotor 21 for expelling out of the rotor body 22 by the outer blades 24. The passageways 31 may include an inlet for receiving air and may be formed in the body 22 of the rotor 21 so that the receive air passes through the passageways 31 and out of outlets 29 of the passageways 31. Each outlet 29 of a passageway is preferably spaced apart from other outlets 29 and each outlet 29 is preferably positioned between two immediately adjacent outer blades 24. For instance, as may be seen in
The outer blades 24, inner blades 25 and rotor body 22 may be sized and shaped so that rotation of the rotor forces slurry along flows A and B shown in
Thus slurry flow B is denser because the slurry flow B is not mixed immediately with air as the slurry flow A because slurry flow A is generated by the outer blades 24 while air is expelled from outlets 29 positioned between immediately adjacent outer blades 24. In embodiments where the conduits 28 feed the slurry flow B out above the air flow C passing out of outlets 29 and slurry flow A generated from the rotation of the outer blades 24, the rotor triggers “Rayleigh-Taylor” instability that enhances slurry gas mixing. Further, small bubbles that could recirculate back to the rotor are more likely to be drawn in by the conduits 28, which may improve the pumping capacity created by rotation of the inner blades 25 and shape of conduits 28, and inner channel 27 since it is contemplated that only the slurry will be drawn into the conduits 28 and inner channel 27.
Due to the shape and structure of the rotor 21, the rotor may be sized to be a smaller diameter than conventional rotors. The rotors may also, or alternatively, be rotated at lower speeds than conventional rotors due to the improved hydrodynamic design and performance of agitating slurry provided by embodiments of the rotor 21. Further, the rotor may provide improved flotation kinetics as compared to conventional rotor designs due at least in part to the use of multiple slurry flows generated by rotation of the inner blades 25 and outer blades 24 of the rotor 21.
Embodiments of the rotor 21 were found to provide a substantially greater ability to recover minerals during flotation machine operations. Testing was conducted on an embodiment of the rotor 21 and found the embodiment of the rotor 21 greatly improved mineral collection from a tank of a flotation cell as compared to the same cell having a conventional rotor for the recovery of minerals in certain types of slurries. Embodiments of the rotor were found to be particularly effective for processing slurry containing minerals in conditions that are typically difficult to recover via flotation machines with conventional rotors. For example, embodiments of the rotor were found to be particularly effective for small bubble generation, which improved mineral recovery of fine particulates from the slurry retained in a flotation cell. It is contemplated that the improvements provided by embodiments of the rotor 21 in flotation cell performance also permit embodiments of the rotor 21 to be fabricated at smaller diameters than conventional rotors, which may help the rotor provide a further reduction in cost associated with the manufacture of the rotor and operation of the rotor.
Another embodiment of a rotor 41 that may be utilized in rotation mechanisms 8 used in flotation machines may be appreciated from
The outer blades 48 may be formed on the body, adhered to the body, cast with the body, integrally attached to the body or otherwise attached to the body via one or more fastening mechanisms such as welding, rivets, or other fasteners. The outer blades 48 may be members such as walls or profiled fins that agitate the slurry when the rotor 41 is rotated.
Each of the outer blades 48 has an outer edge 49. As shown in
The upper portion 50 of the outer edge tapers inwardly toward the rotor body 42 and the lower portion of the outer edge 49 is positioned below the outermost position 51 also tapers inwardly to the rotor body 42. An intermediate section 48a of each outer blade 48 that includes the outermost position 51 is therefore wider than the upper section 48b and lower section 48c of the outer blade 48. It should be understood that the upper portion 50 of the outer edge 49 may be a portion of the upper section 48c and the lower position 53 and inner position 55 of the outer edge 49 may be portions of the lower section 48c.
The shape of the outer edge 49 of each outer blade may be defined as a curved path along with the outer edge travels. As may be seen from
The outermost position 51 of the outer edge 49 may extend for a certain distance, or height, to define a portion of a certain height of the outer edge 49 that is in the outermost position. The outermost position 51 is referred to as Section 2 in
The lower section of the outer edge 49 of each outer blade, which is referred to as Section 3 in
It should be understood that the values of x for the above noted formulas may define a height of the outer blades and the values of y may define the width of the outer blades normalized for the maximum radius of the rotor, which is the radius as measured to the outermost position 51 of the outer blade. The height of the outermost position 51 of the outer edge may extend to 18.9% of the overall height of the outer blade and define the intermediate section 48a of the outer blade. The height of the upper portion 50 that tapers from the upper portion of the outer blade to the highest point of the outermost position 51 of the outer edge 49 may extend along 51.1% of the overall height of the outer blade and may define the upper section 48b of the outer blade. The lower section of the outer edge that tapers inwardly from the lowermost point of the outermost position 51 of the outer edge may extend generally inwardly from this position as may be appreciated from
As may be seen in
Embodiments of the rotor 41 were found to consume substantially less horsepower than conventional rotor designs. Indeed, testing was conducted on an embodiment of the rotor 41 compared to conventional rotors and the results of that testing found the embodiment of the rotor 41 consumes much less horsepower as compared to conventional rotors, which provides a substantial reduction in operational costs associated with operation of the rotor and flotation cell using such a rotor. Further, the testing showed that embodiments of the rotor 41 provided an improved recovery of coarse particles from a slurry of a flotation cell as compared to conventional rotor designs.
It should be understood that numerous changes may be made to the embodiments of the rotor and flotation machine discussed above while still being within the scope of the following claims. For instance, the shape and geometry of the tanks of the flotation cells may be any of a number of different shapes and sizes. As another example, the type of material to be recovered by the cells of a flotation machine may be any of a number of different minerals or metals such as, for example, copper, iron, coal, a base metal, a special metal, other minerals or other types of metal. As yet another example, the column used to rotate the rotor may be any of a number of rotatable members such as rods or shafts that are part of a rotation mechanism used to rotate the rotor. As yet another example and as those of at least ordinary skill in the art will appreciate, the types of reagents, types of depressants/activators, use of different pH levels, use of different collectors, frothers, or modifiers in the slurry may be utilized as needed to meet different material recovery objectives, or other design objectives. As yet another example, the number of external blades for an embodiment of the rotor may be two, five, seven, eight or any other number that is more than two as needed to meet one or more design objectives. Similarly, the number of internal blades of an embodiment of the rotor that may be utilized may be any number that is needed to meet one or more design objectives. As yet another example, the body of the rotor and the external and internal blades may be formed of a metal such as steel or an alloy or may be formed from another material that is found to be suitable to meet a particular design objective.
While certain present preferred embodiments of the flotation machines, rotors and methods of making and using the same have been shown and described above, it is to be distinctly understood that the invention is not limited thereto but may be otherwise variously embodied and practiced within the scope of the following claims.
The present application claims priority to U.S. patent application Ser. No. 13/535,566, which was filed on Jun. 28, 2012. The entirety of U.S. patent application Ser. No. 13/535,566 is incorporated by reference herein.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2013/040057 | 5/8/2013 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 13535566 | Jun 2012 | US |
| Child | 14405215 | US |
