Numerical modelling of two-phase flow hydrodynamics of column flotation - validation against ERT data

Abstract

ABSTRACT In mineral processing, column flotation is being used extensively for fine particle beneficiation. Although a few attempts were made to develop computational fluid dynamics (CFD) models for column flotation in the past, validation against comprehensive experimental data is yet to be demonstrated. This work employs an Eulerian-Eulerian model coupled with the standard k-ε turbulence model for modeling the hydrodynamics in the column flotation. The two-phase simulations were performed on both laboratory and industrial-scale column flotations. The two-fluid model was further modified with the appropriate interphase forces (Ishii-Zuber drag force and Tomiyama lift force) and population balance method (PBM) to accurately simulate and predict the bubble dynamics. The axial and radial gas holdup variations along with the axial liquid velocity are predicted at different air and liquid superficial velocities. The numerical predictions were then validated against the Electrical Resistance Tomography (ERT) data in a 4-inch laboratory column flotation and conductivity probe data in an industrial column flotation. The modified two-fluid model was able to predict accurate hydrodynamics close to ERT data. The gas holdup was found to increase with the superficial air velocity, liquid height, and liquid velocity. The gas holdup found uniformly dispersed radially at low superficial air velocities and heterogenous dispersed bubble flow at higher superficial velocities. A parabolic profile of liquid flow observed at higher superficial air velocities.