Flow field analysis and engineering application of the turbulence-forced pulp conditioner
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China University of Mining and Technology
2
PingDingShan TianAn Coal Co.Ltd
Publication date: 2025-09-15
Physicochem. Probl. Miner. Process. 2025;61(5):210645
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ABSTRACT
During flotation, a sufficient difference in the surface hydrophobicity of various particles is the key to completing selective separation. The quest for collector adsorption on objective particle surfaces has attracted substantial attention, but faces serious challenges regarding fine slimes with low mass and inertia. To improve the reagent interaction with coal particles, this study developed a Turbulence-Forced Pulp Conditioner (TFPC) that intensifies turbulent shear through multi-stage impellers. Flow field characteristics of the TFPC were analyzed using Computational Fluid Dynamics (CFD) numerical simulations. The conditioning performance was examined by the contact angle measurements and practical flotation experiments. Results showed that agitation frequency at 39 Hz created zones with high turbulent kinetic energy and dissipation, which is necessary for micro-mixing by lowering the Kolmogorov eddy scale across the device below 50 μm. Compared with the previous conditioning device, the TFPC significantly decreased the consumption of flotation reagents by more than 40%, and meanwhile obtained a better surface hydrophobization effect, thus contributing to increasing the cleaned coal yield. Owing to the improved cleaned coal recovery and reagent savings, TFPC can produce a net economic benefit despite the increase in energy consumption. This work is expected to promote the understanding of hydrodynamic enhancement during fine coal flotation and provide significant references for the process optimization in industrial applications.