Modeling and optimizing the flotation of coal fines: an investigation utilizing the Box-Behnken design in conjunction with response surface methodology

Abstract

ABSTRACT This study investigates a novel approach for upgrading coking coal fines by combining wet sieving with flotation. Using a Box-Behnken design and response surface methodology (RSM), we optimized the flotation parameters – collector concentration, pulp density, and frother concentration – to enhance clean coal recovery. Analysis showed that these parameters significantly impacted coal quality and yield. With a fixed pulp density of 10% and an 18% ash target, RSM identified optimal flotation conditions as 0.200 kg/T frother and 0.885 kg/T collector concentrations. The optimal conditions for an 18% ash content were a 6.645% pulp density, 0.200 kg/T frother, and 1.1869 kg/T collector. Under these conditions, clean coal with 18.00% ash content and yields of 34.27% and 39.72% were achieved, with deviations from predicted values under 2%. The study indicates that the RSM-based method is effective, with parameter selection influenced by collector cost and clean coal market price. These findings provide a basis for future research to assess the method’s industrial applicability and economic and environmental viability.