In the iron ore beneficiation industry, the selection of energy-saving flotation cells is very important. This article will introduce in detail the energy-saving flotation machines used for iron ore beneficiation, including flotation columns, XCF/KYF aerated mechanical agitation flotation machines, and automated control flotation systems, providing customers with professional suggestions for the selection of beneficiation equipment.
1. Features
The flotation column effectively improves the sorting efficiency and reduces energy consumption through the reverse flotation process. In the reverse flotation of hematite, the flotation column can increase the grade of iron concentrate to 69.8%, and the operation recovery rate is as high as 98.24%. It optimizes performance through horizontal smooth flow plates, reduces foam merger problems, and thus improves mineral processing indicators. The design structure of the flotation column gives it a unique advantage in processing fine-grained minerals, and can effectively achieve the sorting and enrichment of minerals.
2. Energy-saving advantages
The flotation column has no mechanical stirring parts. Its working principle relies on aeration dispersion and slurry self-circulation, and its energy consumption is significantly lower than that of traditional flotation machines. This design not only reduces the energy consumption of the equipment, but also reduces the wear and maintenance costs of the equipment. Since there is no mechanical stirring component, the flotation column is more stable during operation and has lower noise than other flotation machines, creating a better working environment for the staff of the ore dressing plant. At the same time, the aeration dispersion and slurry self-circulation system of the flotation column can effectively increase the aeration volume of the slurry and the dispersion of bubbles, thereby improving the flotation efficiency.
3. Application Cases
In actual applications, flotation columns have achieved remarkable results in different iron ore dressing plants. For example, an iron ore dressing plant used flotation columns for reverse flotation operations, which increased the grade of iron concentrate by 5%, the recovery rate by 3%, and the energy consumption per ton of ore by 10%. It can be seen that the flotation column can effectively reduce energy consumption while improving the dressing index, bringing economic benefits to the enterprise. In addition, the flotation column also has the advantages of small footprint and simple operation and maintenance, which is favored by many ore dressing plants.
1. Technical parameters
The single cell volume of the XCF/KYF flotation cell is 16-320m³. Combined with external aeration and mechanical agitation, the impeller is designed as a backward parabolic type, which has high air dispersion efficiency. The cell body is deep, the volume is large, and the floor space is small, which can meet the needs of large-scale mineral processing production. The design of this flotation machine makes it efficient and stable when processing large amounts of slurry, while reducing the investment cost and floor space of the equipment.
2. Energy-saving performance
XCF/KYF flotation cells are widely used in iron ore concentrators. The stepped layout reduces pumping energy consumption, and the unit power consumption is reduced by 15%-20% compared with traditional flotation machines. For example, an iron mine in Qinghai uses an XCF/KYF-40 combined unit, and the flotation recovery rate is increased by 5%, and the energy consumption per ton of ore is reduced by 12%. This energy-saving effect is mainly due to its optimized impeller design and aeration system, which improves flotation efficiency and reduces energy consumption.
3. Technical advantages
XCF/KYF flotation cells have significant advantages in processing different types of ores. They are highly adaptable to pulp concentration and particle size, and can operate stably under different process conditions. For example, when processing high-concentration pulp, the flotation machine can effectively maintain the aeration volume of the pulp and the dispersion of bubbles, thereby improving the flotation efficiency. At the same time, the design of its mechanical stirring components enables it to have a good effect when processing coarse-grained minerals, and can effectively achieve the sorting and enrichment of minerals.
1. PLC optimization control
The automated control flotation system adjusts the valve opening in real time based on parameters such as liquid level and aeration volume, shortens the control response time to less than 10 seconds, and reduces the overshoot of the flotation process by 30%. After application in Mingsuda Iron Mine, the annual power consumption is saved by about 8%. The application of this automated control system can effectively improve the operating efficiency of the flotation machine, reduce energy consumption, and improve mineral processing indicators.
2. System composition
The automated control flotation system consists of sensors, controllers, actuators, etc. The sensor is responsible for collecting the parameters of the flotation machine such as the liquid level and aeration volume. The controller performs real-time calculation and analysis based on the collected parameters, and the actuator adjusts the valve opening according to the instructions of the controller. Each part works together in the system to realize the automatic control of the flotation machine.
3. Advantage Analysis
The automatic control flotation system has significant advantages in improving flotation efficiency, reducing energy consumption, and stabilizing production. It can monitor and adjust the operating parameters of the flotation machine in real time to ensure that the flotation machine operates in the best state, thereby improving flotation efficiency and reducing energy consumption. At the same time, the automatic control system can effectively reduce human operation errors, improve production stability, and bring significant economic benefits to the enterprise.
1. Hematite energy-saving flotation cell
For hematite, it is preferred to use flotation columns combined with reverse flotation processes, and cooperate with KYF type aerated flotation cells to achieve efficient separation of fine particles. This combination can effectively improve the beneficiation index of hematite and reduce energy consumption. The high-efficiency sorting performance of the flotation column and the energy-saving advantages of the KYF type aerated flotation cell make it have a significant application effect in the beneficiation of hematite.
2. Energy-saving flotation machine for magnetite
For magnetite, the use of magnetic column pre-selection can reduce the flotation load and reduce energy consumption by 30% - 40%. The pre-selection effect of the magnetic column can effectively reduce the load of the flotation operation and reduce energy consumption. At the same time, the pre-selection effect of the magnetic column can improve the beneficiation index of the flotation operation, improve the grade of the concentrate, and bring significant economic benefits to the enterprise.
3. Comprehensive considerations
When selecting an energy-saving flotation cell, it is necessary to comprehensively consider factors such as ore properties, beneficiation plant scale, investment cost, and operation and maintenance cost. The ore properties determine the selection of beneficiation technology and equipment, and the scale of the beneficiation plant affects the investment cost and operation and maintenance cost of the equipment. Investment cost and operation and maintenance cost are the factors that enterprises need to consider when selecting equipment. It is necessary to conduct a comprehensive evaluation based on the actual situation of the enterprise and select the most suitable equipment.
We have introduced three different types of flotation cells above, and have given suggestions on the application of flotation equipment in magnetite and hematite concentrators. In actual production, the selection should be made in combination with the actual situation of the concentrator, with energy saving as the premise, and strive to achieve the improvement of flotation efficiency.
