基于CFD数值模拟的射流微泡浮选机气泡发生器的设计

为研究气泡发生器结构对其物理参数的影响，以ZWF6500型射流微泡浮选机气泡发生器为研究对象，通过CFD数值模拟，研究了气泡发生器空气入口数量、喷嘴直径、喉管直径以及喉管位置等结构参数对气含率、矿浆射入量、充气量以及充气速率等物理参数的影响。结果表明：空气入口数量、气含率无明显影响，但是在一定的入料压力下，单个进气口有一个极限的进气量；在一定的入料压力下，矿浆射入量只受喷嘴直径的影响，而且喷嘴直径越大，则矿浆射入量越大；气泡发生器喷喉比对气含率的大小至关重要，气含率随喷喉比的增大而增加，且在增加到一定程度后，气含率达到极限，不再随着喷喉比的增加而增加，甚至会出现气含率下降；喉管位置的影响主要体现在充气量，随着喉管位置的升高充气量和气含率呈现先上升后下降的趋势，即有一个最佳的喉管位置使得气含率最大。该研究为气泡发生器结构优化提供了基础数据。     

一种新型浮选柱发泡器生成气泡特性研究

在自行设计的浮选柱模拟系统中,对一种新型浮选柱微泡-逆流接触式浮选柱气泡发生器的发泡特性进行系统研究;以发泡器产生的气泡为研究对象,通过高速摄像记录仪获取气泡图像,采用图像处理软件对气泡直径及速度进行提取、统计,考察气泡发生器在不同充气条件下气泡密度及气泡尺寸分布特征,探索生成气泡的尺寸和速度之间的对应关系。研究结果表明,随充气量增大,气泡平均直径增大,气泡尺寸分布由变宽,微气泡数量减少;在充气量Q=4 L/min时,气泡尺寸分布比较均匀且产生充足的微气泡;气泡上升速度主要取决于充气量和气泡尺寸,通过试验数据分析,提出了该浮选柱气泡发生器生成气泡上升速度与尺寸之间的指数关系式。     

浮选药剂射流乳化参数的试验研究

为了优化射流乳化器的结构参数,对最优结果进行了单因素分析,运用CILAS 1064高精度激光粒度分析仪对乳化效果进行粒度和比表面积测定。试验结果表明喷嘴离喉管的距离、给入水流的压力是影响乳化效果的显著性因素,各因素对乳化效果的影响规律为:给入压力(喷嘴和喉管之间的距离(喉管长度(喷嘴直径(药剂流量。试验获得的最佳射流乳化效果是油滴比表面积为3 541.57 cm2/g,当喷嘴和喉管之间的距离为4mm、喉管长度为55mm、喷嘴直径为6mm、药剂流量为45kg/h时,射流乳化效果最好。     

旋流—静态微泡柱分选方法及应用(之三) 射流微泡与管流矿化的研究

旋流—静态微泡柱分离方法采用射流充气方式,形成射流微泡。通过在气泡发生器后加一个矿化管段,形成了管流矿化。气泡发生器与矿化管段共同构成了旋流—静态微泡柱分离方法的管浮选装置。在完成充气的同时,管浮选装置主要用于矿化经过柱分离与旋流分离形成的循环中矿。1　射流充气原理与过程(图1)采用射流原理的气泡发生器结构包括:喷嘴、吸气室、喉管、喉管进口段、扩散管五部分。旋流—静态微泡柱分离方法采用循环矿浆(或入料原矿)作为射流工作介质,经过加压(压力在0.2MPa左右)的工作介质由喷嘴喷出后形成高速射流,其射流运动分成三部分:…     

不同结构空化气泡发生器的试验研究

气泡发生器是射流浮选柱充气的关键设备,结合空化气泡有利于浮选的特点,自行设计了多孔板气泡发生器和改进型射流气泡发生器2种结构空化气泡发生器,同时在组建了的浮选柱试验系统内进行浮选柱清水试验。试验结果表明,2种空化气泡发生器作为浮选柱的充气装置时,均可使浮选柱内产生细小、密集、分布均匀的气泡,同时对比2种结构空化气泡发生器对浮选柱的充气性能发现,改进型射流气泡发生器要优于多孔板气泡发生器。     

浮选气泡测量及其影响因素分析

针对浮选槽中含气率高、气泡重叠、变形,以及不断发生气泡兼并与破裂的情况,建立了一套浮选气泡测量系统,详细介绍了其原理及测量方法,并在2L XDF机械搅拌式浮选机上,分析了起泡剂用量和充气量对气泡粒度的影响规律。结果表明:使用该系统能够成功测量浮选槽中的气泡直径;气泡最小直径在充气量0.1m3/h,起泡剂用量12.5μL/L条件下测得,为0.32mm;气泡直径受充气量和起泡剂用量的综合影响,仲辛醇作为起泡剂的临界用量为12.5μL/L。     

高气泡表面积通量充气器气泡特征参数试验研究

充气器生成气泡的特征参数是影响气泡表面积通量的关键因素。利用电导探针法和拍照测径法获取了充气器产生气泡的直径、速度及其分布特征。利用CCD高速相机获取了充气器的气泡分散特征。结合浮选柱的清水试验研究,分析了充气器喷嘴直径和充气压力两个关键参数对气泡特征参数影响。研究表明,KYZ浮选柱充气器能形成高气泡表面积通量的柱内分选环境。工业应用表明,KYZ浮选柱高气泡表面积通量充气器能够实现优异的分选性能。     

喷射式浮选机射流搅拌装置流场分析及结构优化

以喷射式浮选机射流搅拌装置结构优化为目的,选用合理的CFD数值模拟计算方案,综合考查引射性能和流场特性两个指标,对面积比、喉嘴距、喉管长度、引射管布置方式和位置进行优化计算;设计了长喉管、短喉管、导流叶片喷嘴和无导流叶片喷嘴共4组不同结构参数的射流搅拌装置试验,考查并验证了喉管长度和喷嘴内导流叶片对引射能力的影响;采用激光粒子测速仪测试了喷嘴内导流叶片对射流流束形态演变的影响。结果表明:面积比a=1.96～3.24,喉嘴距L_e=0.2D_h～0.6D_h(D_h为喉管直径)、引射管采用双侧对称布置、喷嘴内设置导流叶片及喉管长度在6D_z～12D_z(D_z为喷嘴直径),射流装置的混合效率最理想,引射管布置位置对混合效率影响较小;喷射室压力在0.145～0.160 MPa时,喷嘴内设置导流叶片,长、短喉管吸气能力平均至少提高30.73%和33.94%,引射管全开时长喉管较短喉管的吸气能力高出15%以上。结构参数对流场的影响表现在,面积比增大及引射管靠近喷嘴出口布置,喉管内射流流束的中心速度衰减越快,喉嘴距变化对中心速度的衰减影响较小;喉管长度≤6D_z时,流束中心的流核一直持续到喉管出口,引射流体和工作流体在喉管内动、质量交换不完全;喷嘴内设置导流叶片,有利于流束中心的流核区减小,原因是流束以旋转射流的形式从喷嘴喷出,形成了更有利于工作流体与引射流体动、质量交换的湍流流场;基于理想的引射性能和流场特性,面积比a=3.24、喉嘴距L_e=0.6D_h、引射管采用双侧对称且正对流核区域布置方式、喷嘴内设置导流叶片及喉管长度在6D_z～12D_z为射流搅拌装置的最优结构参数。     

射流混合装置多变参数试验优化及分散机制

射流混合装置被广泛应用于各个领域，其参数对引射性能、微粒运动及作用机制会产生重要的影响。但目前应用于煤泥浮选领域的射流混合装置多变参数缺乏系统性优化。为了优化射流装置的多变参数，搭建射流混合测试系统，探究面积比Ar、喉嘴距Le、喉管长度L、引射管开启度γ和喷嘴出口速度V等关键参数对引射性能的影响规律；基于物理模型参数优化值，调节测试系统，研究射流流场对物料的作用机制，考察射流流场对煤粒表面细泥的剥离能力；运用高速摄像仪捕捉射流流束对引射气泡的卷吸破碎情况；采用激光粒度分析仪揭示气泡粒径的迁移规律。结果表明：当面积比Ar=3.24、喉嘴距Le=0.56 D_h(D_h为喉管直径)时，引射流体流量比q最大；综合考虑引射能力和沿程损失，当喉管长度L=9D_z(D_z为喷嘴直径)、喷嘴出口速度V≥15 m/s时，射流装置的引射性能最为理想；引射流体的流量与引射管开启度γ成正比关系，引射速度受限于射流速度(以喷嘴出口速度V表征)，当射流速度达到15 m/s，引射速度达到上限；基于最优引射性能参数，单次射流混合作用对物...     

新型脉冲射流浮选机脉冲充气机理研究

为了探讨脉冲射流浮选机的充气搅拌机理,基于工程流体力学计算和样机试验研究,对浮选机充气搅拌单元进行了设计和研究。研究表明:新型脉冲射流浮选机通过增加脉冲反应器,能使矿浆由连续射流状态转变为脉冲射流状态,优化矿浆的吸气能力和混合效率;在矿浆涡旋及空化作用影响下,新型脉冲射流浮选机试验充气量达到1.8 m3/(m2·min),微泡占气泡总量22%,可为浮选作业提供良好的浮选气泡。     

KYF型浮选机气泡特征参数分析与探讨—KYF浮选机流场测试与仿真研究(五)

浮选机内气泡特征参数和流动规律的研究一直是浮选机研究的重点和难点。本文利用电导探针法和CFD数值方法研究了浮选机内气泡特征参数及其分布特性。通过电导探针法获取了浮选机内气泡直径、速度和气含率等气泡特征参数。利用CFD数值方法揭示了浮选机内气含率的分布特征,预测结果同试验观察一致。并进一步研究了浮选机关键运转参数对气含率分布的影响规律。试验结果表明,CFD预测的气含率同试验测试结果吻合。     

Air entrainment rate and holdup in the Jameson cell

Air entrainment rate and holdup are important and potential control parameters in plunging liquid jet bubble columns. In this study, air entrainment and holdup in laboratory Jameson cell downcomer were investigated in an air–water system. Air entrainment flow rates and holdup were quantified experimentally. The effects of various conditions in the nozzle diameter, the downcomer diameter, the free jet length, the jet velocity and the ratio of air-feed flow rate on gas holdup and air entrainment were studied. Two empirical equations were proposed to estimate gas holdup. The predictions from these equations are in good agreement with the experimental data for holdup.     

工业浮选柱的气含率测定及其影响因素研究

气含率是影响浮选柱分选效果的重要参数之一。采用压差法测定浮选柱内部的气含率,并基于直接数字控制(DDC)技术和MCGS组态软件,设计开发了适合于工业浮选柱的气含率测试系统。通过对循环压力、充气量和起泡剂用量3个因素进行试验,研究了它们对工业浮选柱气含率的影响。结果表明:循环压力、充气量和起泡剂用量对气含率影响显著;在一定范围内气含率随着循环压力、充气量和起泡剂用量增大而增大,当增大到一定程度时气含率增大的幅度逐渐减小。     

新型蒸发室进液支管出口气含率分布的数值模拟

针对易起泡物料在蒸发浓缩过程中经常出现"爆沸"的问题,提出了一种新型的蒸发室结构。利用STAR-CCM+软件对新型蒸发室进液支管出口的气含率及其随支管入口流速、入口气液比、支管管径的变化特性进行了模拟。结果表明,气含率径向分布均匀程度随着支管管径和入口气液比的增加而先增加后降低,随着支管入口流速的增加而降低;大气泡在支管出口形成细小均匀的气泡,能够降低"爆沸"发生的倾向。     

浮选柱气含率及其影响因素对煤泥分选的研究

利用压差法检测浮选柱气含率,通过正交设计和煤泥浮选实验,研究循环压力、进气量和起泡剂浓度对气含率的影响以及气含率对煤泥浮选效果的影响.结果表明,起泡剂浓度对气含率的影响最大,进气量次之,循环压力最小.在一定范围内,随着气含率的增大,精煤产率增大,精煤的灰分也随之增大,精煤质量下降.当气含率为24.17%时,精煤产率为87.35%,精煤灰分为10.02%.随着循环压力增大,精煤产率增大,但精煤灰分有所下降.分析指出气含率大小可作为调节浮选柱矿物分选指标的一个参考标准.     

高硫高砷金精矿三相流化床流动特征模拟

常温常压条件下基于欧拉模型, 利用Fluent软件对高1.6 m、内径0.09 m的高硫高砷金精矿三相流化床流动特征进行了数值模拟。模拟过程以空气为气相且为连续相, 液态水为液相, 密度为3.2 g/cm3、粒径为0.5 mm的高硫高砷金精颗粒为固相。模拟结果显示, 流场的压力从计算域的入口到出口逐渐降低,速度场的变化对气液固局部相含率的分布影响显著; 在径向上, 气含率(ε_g)从计算域中心往边壁降低, 在轴向上也逐渐降低; 固含率(ε_s)从计算域的入口到出口逐渐减小, 从计算域中心向边壁ε_s增加。模拟结果与实验结果一致, 可为合理设置气流速度以及金矿投放量提供依据。     

Frother persistence: A measure using gas holdup

Persistence here refers to the how long a frother remains effective in producing small bubbles, one of its prime functions in flotation. One way to evaluate is to track gas holdup over time while air is sparged into a column: if frother is depleted bubble size will start to increase consequently increasing bubble rise velocity and hence decreasing gas holdup. Persistence of nine frothers was evaluated in this manner. Polyglycol frothers exhibited high persistence with gas holdup virtually constant over 50 h compared with alcohol frothers. The alcohols divided into two groups, one showing steady decline in gas holdup, e.g., 1-hexanol, and a second group exhibiting a sharp decline at a given time, e.g., MIBC. Tests on MIBC showed increasing concentration extended persistence while increasing gas velocity and increasing bubble size decreased persistence. The decrease in gas holdup was related directly to measured decrease in frother concentration. It appears that the transport of frother to and through the froth and from froth to atmosphere needs to be considered.     

Study of gas holdup and pressure characteristics in a column flotation cell using coal

Present work has been carried out to observe the effect of process variables (gas flow rate, feed flow rate, solid concentration and frother concentration) on gas holdup and pressure characteristics in flotation column using coal. Gas holdup has been estimated using phase separation method while piezometers have been used to obtain column’s axial pressure profile. It was observed that gas holdup in collection zone was affected by both air as well as feed flow rates. Up to 6% change in gas holdup may occur when the feed flow rate changes from 1–2 cm/s. It was also observed that addition of coal decreased the gas holdup while addition of methyl isobutyl carbinol (MIBC) had opposite effect. Almost linear variation in columns axial pressure characteristics has been observed with gas flow rate. An empirical relationship between gas holdup in the flotation column with column’s axial pressure difference was developed.     

Industrial testing of a gas holdup sensor for flotation systems

The role of gas holdup in flotation has long been discussed but never demonstrated, arguably because a reliable measurement technique has not been available. Work was initiated to develop a gas holdup sensor for industrial operations based on the use of two so-called flow cells for measuring the conductivity of the pulp with and without air. These are the measurements required to estimate gas holdup using Maxwell’s equation that relates conductivity to concentration of a dispersed non-conducting phase (i.e., bubbles) in a continuous liquid phase (pulp in this case). After a series of prototypes a unit robust enough for industrial use that continuously measures and delivers signals easily integrated into a plant PLC system has been developed. This communication describes the working principle along with some construction details. The experience of plant tests, ranging from paper to mineral pulps, and mechanical cells to columns, is reviewed.     

Dynamic characterization of column flotation process laboratory case study

The objective of metallurgical column control is to achieve the economic optimum combination of concentrate grade and mineral recovery for any given feed. Metal prices and the cost of consumables will dictate the metallurgical concentrate and mineral recovery targets. Furthermore, experience has shown that collection zone height, air holdup and bias water flow rate are key parameters (controlled variables) that affect metallurgical performance. The collection zone height is related, mainly, with the residence time of the particles inside the collection zone, air holdup is correlated to the available surface area of air bubbles and bias water flow rate is an indirect measure of the cleaning action of the froth zone. However, these variables cannot be directly manipulated. Instead, wash water, air and underflow flowrates are the directly manipulated variables [1]. Therefore, if dynamic relationships could be established between the three manipulated variables and the three controlled variables, column metallurgical control may be improved. This study was an attempt to model these relationships using a tool known as System Identification, that includes Transient Analysis.The study consists in experimental tests, transient response analysis and identification of black box type models with cross validation.The experimental work was performed in a pilot scale laboratory flotation column of 3.2 m high by 80 mm of diameter. This flotation column operates in a plant with all the required instrumentation installed. The study considers the operation of the two phase air-water system.