Analysis of difficult flotation mechanisms for coarse low-rank coal: Comparing fluidized-bed and mechanical flotation technologies

Abstract

Efficient flotation of coarse low-rank coal is essential for enhancing energy utilization in the mineral processing industry. As the beneficiation equipment scales up, the precision of particle size classification before flotation decreases, leading to a higher coarse particle content in the feed, which poses significant challenges to traditional flotation processes. Recent advancements in fluidized bed flotation technology have demonstrated considerable advantages in the flotation of coarse-grained metallic minerals; however, its application to coarse low-rank coal remains relatively unexplored. This study investigates the potential of fluidized bed flotation technology for coarse low-rank coal, employing various analytical methods to elucidate difficult flotation mechanisms. Scanning electron microscopy (SEM), X-ray diffraction (XRD), and X-ray photoelectron spectroscopy (XPS) were utilized to comprehensively characterize the surface morphology and chemical composition of coal samples. The influence of increasing particle size on flotation performance was systematically assessed through measurements of induction time and critical detachment amplitude. Comparative flotation experiments were conducted to evaluate the efficacy of traditional mechanical flotation against fluidized bed flotation technologies. Results indicate that the presence of cracks and oxygen-containing functional groups on the coal surface significantly enhances hydrophilicity, hindering flotation recovery rates. With increasing particle size, the induction time between particles and bubbles lengthens, while the critical detachment amplitude decreases, weakening the attachment and increasing detachment likelihood. Although high-efficiency collectors enhance coal particle hydrophobicity, they cannot fully mitigate the turbulence disrupting bubble-particle interactions in mechanical flotation. Conversely, fluidized bed flotation effectively minimizes turbulence interference, leading to an approximate 40 % increase in the recovery rate of coarse low-rank coal (0.25–1.00 mm) compared to traditional mechanical flotation. This study presents a novel technological approach for the efficient recovery of coarse low-rank coal, contributing to the clean utilization of low-rank coal resources.