Patent Application
20200139380
This invention refers to an ore flotation cell with a significant reduction of water usage. More specifically, the invention refers to an ore concentration magnetic-centrifugal flotation cell that reduces water consumption.
The ore flotation process is an industrial operation widely used to separate sulfide ores containing metals of economic interest. Many researchers have reported that the ore flotation process yields very low efficiencies if the solids percent in the slurry is increased above 40%. The increase of both slurry density and viscosity has been mentioned as one of the main reasons for the efficiency decrease. This means that each flotation cell in a circuit requires at least a 60% water percent to operate correctly. In columnar cells the solids percent is even lower and reaches values around 17%, that is, with water percent around 83%. Even though a great part of the water is recirculated, a makeup of fresh water is still required.
This invention deals with magnetic separation, since there are many documents in the state of the art on this kind of separation, both dry and wet, with a low intensity and for iron ore (of the magnetite type). There is also equipment with a wet high intensity magnetic field operating with up to tens of thousands Gauss or more; but not taking advantage of the flow velocity because they usually involve open systems of filter-style systems that take advantage of field gradients rather than field intensity.
In the state of the art there are several disclosures referred to the separation of particles using devices that generate a magnetic field. For example, document WO 2016/133379 discloses a new device and procedure to enrich magnetic ores (magnetite) by means of the elimination of metal sulfides, silicates, phosphates, and other undesired particles, characterized by a device that comprises a descendent flow tube (mixer) and a separation column surrounded by Helmholtz coils. The slurry is fed into the mixer, where the air bubbles are formed in the presence of the slurry and the particles are collected from this pulp and slurry. The slurry and bubbles mixture are transferred from the mixer into the separation column in a region having a low intensity magnetic field, under 200 Gauss, which may be adjusted. The non-magnetic particles (gangue) are eliminated by the bubbles in the top section of the column generating the process residues, while the magnetic particles settle rapidly at the lower section of the column, where they are taken to constitute the iron concentrate. As a result of the increase in the solids percent of the concentrate stream found at the lower section of the tube, most of the water fed to the device is discharged in the tails, generating an increase of water mass flow rate that takes away the gangue particles that were not captured by the bubbles. In the use of these mechanisms, gangue material is discharged into the tails by two methods: flotation and hydrodynamic resistance. The magnetite particles form aggregates with a weight that suffices for not being transported by the bubbles but rapidly settling at the lower section of the column, allowing the selective separation of magnetite and gangue.
The apparatus described in document WO 2016/133379 is designed for the separation of magnetic ore, magnetite, where a magnetic field has a direct influence on the particles. This apparatus cannot be used in the separation of sulfide ores containing metals having an economic interest.
Document U.S. Pat. No. 5,224,604 discloses an apparatus and a method for the separation of particles in a fluid or gas flow. The fluid flow is directed in a turbulence flow pattern in order to generate centrifugal forces. Optionally, magnetic and/or electric fields may be applied to the system in order to improve the separation of particles. Air bubbles may also be used to additionally improve the separation of hydrophilic particles from hydrophobic particles in a liquid system. Optionally, the turbulence pattern of the flow may leave the downstream end of the separator, where a flow divider is used to divide the turbulence pattern of the flow bursting out into two or more flows that transport particles desirable for recovery. The apparatus is made up of a vertical tube, whose exterior has vertical magnets parallel to the symmetry axis of the tube that generates a magnetic field.
The apparatus disclosed in document U.S. Pat. No. 5,224,604 has the disadvantage that air injection is made across the porous wall of the cylinder mantle, in order to generate a vacuum and to reduce the slurry resistance to the entry of gas. However, this solution is not the best possible because it is extremely difficult to control and the pressure increases significantly.
In addition, the apparatus disclosed in document U.S. Pat. No. 5,224,604 also uses a magnetic field for separation, utilizing the vertical magnets parallel to the symmetry axis of the tube. However, this magnetic field arrangement crosses perpendicularly as opposed to the magnetic field used in this invention, which will be explained below.
The disadvantage of conventional flotation cells is that they use a large amount of water, where some cells require at least 60% of water. In columnar cells the percentage of solids can be as low as 17%, that is, with water percents around 83%. The purpose of new designs for flotation cells is to increase treatment capacity (showing a tendency to giant cells of up to 600 m3) or to increase process efficiency (recovery of valuable material and/or generation of concentrated product with a greater ore percentage or grade containing the element with economic value). There is no industrial evidence of new flotation cell designs that effectively reduce the use of water.
This invention uses ore slurry with greater density and viscosity, caused by the application of an axial magnetic field, where it is possible to benefit from the Lorentz force, the force exerted by an electromagnetic field that receives a charged particle or an electric current.
In a generated magnetic field, it is possible to find that the Lorentz force depends on the magnitude of the charge, its velocity, and field intensity, where the force may be increased not only increasing the magnetic field or the charge buy also its velocity. Many sulfide minerals having economic value do not develop net charges as important as the ones observed, for example, in magnetite. In order to increase the force, it is possible to independently vary the intensity of the magnetic field and the charge velocity. The key point behind these variations is that the force must have a preferential direction given by the cross product (vector product) between the axial magnetic field vector and the particles' velocity vector. This is achieved with helicoidal trajectories and other more complex trajectories acquired by the particles and the fluid once they tangentially enter the cell and the axial magnetic field aligned with the axial axis of the cell.
The solution is a cell that uses, in addition to the forces habitually acting in conventional flotation cells, external forces that, in principle, produce a synergy in the separation of ore particles.
The attached drawings are included to provide a greater understanding of the invention and constitute a part of this description and help to explain its principles.
This invention refers to a magnetic-centrifugal flotation cell for the concentration of ore that reduces water requirements. The operation of this flotation cell will be explained based on the attached drawings and the theoretical principles of the phenomena that take place inside the same.
In the first place, it is accepted that the impact of centrifugal effects habitually brings together mass separation (density and size, because mass is proportional to the product of density times the size to the cube) of particles, where the particles with a greater mass, in principle, will move eccentrically while the lighter particles will be initially transported by the concentric axis of the cylinder or the eddy located at the center of the tube. This commonly observed motion of particles is subsequently modified by the magnetic field applied that exacerbates the separability of semiconductor material of the sulfide type. It is expected that the movement of bubbles and particle-bubble aggregates towards the external mantle prevents coalescence and promotes the dispersion of the gas phase because the bubbles will experience shear stresses that will help gas dispersion.
One of the ends of the tubular container (2) holds a first face (11) and the other end holds a second face (12). The air entrances (4) are found in the first face (11) and on the side of the tubular container mantle (2) and the ore entrance (3) is located close to the air entrances (4). The material eccentric lateral exit (5) is found close to the second end and perpendicular to the symmetry axis of said tubular container (2), which may or may not follow the flow mainly governed by the helicoidal motion of the complex fluid. The material concentric exit (6) is placed on the second face (12). The axial magnetic field (10) is found around the tubular container (2) and positioned towards the turbulence area, close to the second face (12).
The axial magnetic field (10) in the first embodiment of the invention is provided by a coil (13) with its respective power supply and, alternatively, permanent magnets may be used in order to avoid the electric energy expense at the coil (13).
Experiments were conducted on the basis of the preceding scheme and the first embodiment of the invention, whose results indicate that the eccentric lateral exit (5) displays foam similar to the foam seen in conventional concentrate flotation cells with watery slurry, preliminarily indicating that particulate matter containing valuable material was obtained at this exit. This indicated that the centrifugal effect, the magnetic effect, or both, when air comes into the system as shown in
As shown in
As already indicated, an axial magnetic field (10) is applied to the flotation cell. Thus, it is possible to analyze the Lorentz force, to determine how a magnetic force acts on a particle with charge q as shown in Equation 1.
F=q[E+vxB] (1)
where q is the charge, E represents the electric field, v is the particle velocity, and B is the magnetic field.
The experiments were conducted with continuous current so that the effect of the electric field is negligible. Equation 1 becomes Equation 2.
F=q[vxB] (2)
The force on particle (8) increases with the increase of the magnetic field obtained using electric current, which may involve an expense, particularly at high capacity ore treatment industrial levels.
Since ore particles exhibit a low charge, it is necessary to increase their velocity. In this apparatus, this is achieved using the centrifugal effect on the particles along the tubular container (2).
In short, it is possible to conclude that the position of the axial magnetic field (10) causes particles, bubbles, and/or particle-bubble aggregates slightly charged by their tangential motion velocity and the field direction to move eccentrically and be recovered in tangential exits.
One of the preferred modes of this invention is shown in
In another embodiment, the cover (14) may also be used to protect permanent magnets that provide an axial magnetic field (10).
The cover (14) is placed outside the mantle of the tubular container (2), covering the coil in the second segment (20) as shown in
As already mentioned, the tubular container (2) has a flow segment (19) with the entrance of ore and air, so that this segment becomes a turbulent zone where bubbles are formed. Likewise, the tubular container (2) has a second segment (20) with the eccentric lateral exit (5) and the materials concentric exit (6), where the flow of bubbles is stabilized and the heavier particles flow eccentrically while the light particles will be transported by the concentric axis of the tubular container (2).
Since the slurry flow in the second segment (20) of the tubular container (2) is relatively more stable, with and eddy flow and a concentric flow, it is in this segment where it us useful to install the coil (13), given that the axial magnetic field exercises its effect on an ordered flow of particles.
Although the preceding condition is quite reasonable, it is not proper to dismiss having a short turbulent first segment (19) and a longer stability segment in an eddy flow and a concentric flow, so that the coil (13) may cover the entire tubular container (2). The same would happen if permanent magnets are used to generate the axial magnetic field (10).
The axial magnetic field for the tubular container (2) may also be generated with permanent magnets. It is well known that using coils (13) demands electric current, which may limit the large-scale application of the invention. The permanent magnets may be made of neodymium or something similar.
The field intensity used herein was approximately 0.001 T using 2 Amp direct current and a copper wire solenoid with approximately 500 turns in a segment approximately 20 cm long. The electric energy was provided by an 18 volt power supply.
Table 1 shows the experiments carried out.
The samples were taken at both exits of the apparatus and sent to an automated mineralogical analysis using QEMSCAN®. In order to reconcile the copper grades, the feed was backcalculated, and the recoveries were estimated.
The recovery results for each one of the elements measured using the QEMSCAN® technique are shown in Table 2.
It may be seen that copper recovery ranges between approximately 19% and 52% and it is difficult to get these recoveries in conventional cells with a 50% of solids. Therefore it is possible to claim that this magnetic flotation cell considerably brings down water requirements. The maximum observed recovery ranged approximately between 10%, the customary value in rougher cells, and 40%.
As expected, the recovery vs copper grade relationship has a behavior like the one observed in conventional cells, as shown in the recovery vs copper grade chart that only considers the tangential exit in
The copper enrichment ratios range between 2 and 15, also observed in conventional cells with lower percentages of solids (30% and less).
The magnetic flotation cell invention obtains important recoveries and grades compared to those observed in conventional flotation cells operating with 50% of solids. Preliminarily, the best experimental condition was achieved working with the new cell in a horizontal position with the application of a magnetic field. In only one run, this condition obtains enrichment ratios above 10% and recovery ratios above 20%. In theory, it may be expected that the cell should also allow working with up to approximately 70% of solids.
| Number | Date | Country | Kind |
|---|---|---|---|
| 3331-2016 | Dec 2016 | CL | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/CL2017/000042 | 12/22/2017 | WO | 00 |
