3.1 Effect of various conditions on the preparation of ultra-low ash coal by conventional flotation
Experimental studies of pulp concentration, agitation speed and flotation reagents were carried out for investigating the effect of various factors on the preparation of low ash coal. The initial flotation indicators are as follows: stirring speed of 2000 r/min, air charging capacity of 0.25m3 /h, pulp concentration of 60 g/L, diesel oil of 3 kg/t, and MIBC dosage of 1 kg/t. The results of the experiment are shown in Fig. 5 below.
In Figure (a), the yield of concentrate shows a different trend with the increase of pulp concentration. When the concentration of the pulp is 50 g/L, the yield of the concentrate reaches a maximum of 68.63% and the corresponding ash content is 3.1%. Figure (b) shows that at low stirring speed the concentrate yield increases significantly with increasing stirring speed and then decreases slightly. At the rotational speed of 2800 r/min, the lowest ash content of the concentrate is 3%, and the corresponding yield is 68.77%. In the flotation process, the chemical system has a crucial effect on the flotation effect. One of the important reasons is that flotation reagents are the most flexible, effective and convenient means to control mineral flotation behavior. A large number of stable bubbles obtained by flotation agents is also a prerequisite for efficient flotation. To ascertain the impact of collector type on flotation efficacy, diesel oil, kerosene, emulsified kerosene and MJ were selected for flotation experiment. The results demonstrated that the separation effect of kerosene was the worst under the same dosage of chemicals (as shown in Figure c). The ash content of the concentrate exhibits slight variations under the influence of the three types of collectors. In contrast, the yield displays considerable fluctuations. The yield of concentrates combined with MJ, emulsified kerosene and diesel oil are 82.86%, 79.63% and 68.77%, and the corresponding concentrates ash content are 3.22%, 2.92% and 3.31%. In summary, emulsified kerosene is the best collector.
Emulsified kerosene was selected as the collector in the experiment, and its dosage was tested with other parameters unchanged (As shown in Figure (d)). A As illustrated in Figure (d), an increase in the dosage of emulsified kerosene from 1 kg/t to 5 kg/t was accompanied by a notable enhancement in the yield of concentrate, accompanied by a reduction in the ash content of the concentrate, which fell from 3.23–2.89% and then rose to 3.53%. The ash content of concentrate should be given priority in preparing ultra-low ash coal. Therefore, emulsified kerosene dosage of 3 kg/t was selected in the experiment. In figure (e), it can be observed that the yield of the concentrate increases in direct proportion to the quantity of MIBC. When the dosage of MIBC was 1 kg/t, the yield of the concentrate reached the highest (80.17%) and the ash content reached the lowest (2.48%). Finally, in order to obtain better technical and economic indicators, a step-by-step release process is adopted (flotation effect is shown in (f)). As illustrated in Figure (f), with the increase of flotation times, the yield and ash content of concentrate continue to decline. After one roughing-three concentrates, the yield of ultra-low ash coal is 69%. This is accompanied by an ash content of 1.93%. This is the optimal flotation condition.
In summary, through the exploration of conventional flotation conditions, the optimal experimental parameters are as follows: The concentration of coal slurry is 50 g/L, the filling capacity is 0.25 m3/h, the stirring speed is 2800 r/min, the collector is emulsified kerosene and the dosage is 3 kg/t, and the dosage of MIBC is 1 kg/t. After one roughing-three concentrates, the ultra-low ash coal with yield of 69% and ash content of 1.93% can be obtained.
3.2 Effect of stirring speed and time on the preparation of ultra-low ash coal by high-speed shear flocculation flotation
Fluid flow can transport particles and provide an environment for flotation, which is one of the extremely important conditions. Strengthening fluid requires the input of external energy, which can be achieved through agitation(Ni et al. 2022; Chen et al. 2017). Stirring can strengthen the force between particles and particles, between agents and particles, so as to enhance the surface hydrophobicity of particles. The input of sufficient kinetic energy enables hydrophobic particles to easily overcome the potential energy barrier and adhere to each other, forming tight aggregates. In addition, the motion caused by the input of external forces can provide conditions for a reasonable balanced distribution of bubbles in the later stage (Yang et al. 2024). When the coal particles become finer, the collision efficiency between bubbles and particles becomes lower, and the recovery rate decreases. Consequently, it is of considerable importance to ascertain the optimal stirring intensity.
The optimal conditions of conventional flotation in the previous chapter are adopted. The results of stirring speed and stirring time on flotation are shown in Fig. 6 (a) and (b). Under high stirring speed conditions, the concentrate yield increases significantly with increasing stirring speed, but decreases slightly at 6000 r/min. The maximum yield (52.23%) and the minimum ash content (1.49%) were reached at 5000 r/min. Concentrate ash content decreased, then increased. Therefore, the aging is best when the pre-mixing time is 20 min.
Based on the above experimental conditions, the dosage of flocculant in the shear flocculation experiment was explored (as shown in Fig. 6 (c)). As the polyferric sulphate dose increased from 0 g/t to 25 g/t, the yield of concentrate increased from 56.78% to the maximum value (59.97%), and the concentrate ash content decreased to the minimum value (1.42%). One of the key findings of this study is the influence of stirring speed and flocculant addition on the preparation of ultra-low ash coal. Flotation performance is significantly better than conventional flotation under high-speed shear conditions. Specifically, under the condition of high stirring speed, coal particles and collectors collide with each other, the contact surface increases, and the small floc forms a dense large floc, thus reducing the adhesion and entrainment of high ash fine mud. However, when the stirring speed is too high, the formed flocs will be destroyed and reorganized, and the entrainment of fine minerals will be increased, resulting in the increase of ash (Nogueira et al. 2023). Appropriate addition of polyferric sulfate makes the impurities such as fine mud in the pulp tend to be stable, and improves the coating of fine mud particles on coal particles and the role of coal particles agglomeration. Thus, the apparent particle size of cleaned coal is increased and the hydrophobic effect of coal is improved.
3.3 Discussion
Scanning electron microscopy (SEM) was used to analyses and quantify the coal samples after conventional flotation and high-speed shear flocculation. The SEM micrographs of the samples are shown in Fig. 7. After high-speed shear flocculation, most of the inorganic minerals such as quartz and silicaluminate are removed. Among them, (a) and (b) are SEM images after conventional flotation. The content of quartz, alumina and calcium oxide in the sample is high (c) and (d) are SEM images after shear flocculation. After high-speed shear pretreatment, the ash component and clay particles in the concentrate are partially removed.
Figure 8 (a) shows the contact angle analysis of the high-speed shear flocculated coal sample. It is evident from the figure that the contact angles of the coal particles initially increase and then decrease as the mechanical stirring intensity increases. Stirring intensity increased from 2000 r/min to 6000 r/min, contact Angle increased from 55.50% to the maximum (80.5%). Subsequently, as the speed is too large, the contact Angle is reduced to 53.5%. This indicates that increasing the mechanical agitation speed can improve the effective collision adsorption of coal particles and chemicals, improving the hydrogen brittleness of the coal surface and facilitating the effective separation of concentrates and inorganic minerals (Yang et al. 2024).
In addition, the effect of increasing shear speed on the pulp will affect the particle size of the aggregate, and this effect difference can be quantified by the particle size distribution of the aggregate (as shown in Fig. 8(b)). When the stirring intensity is 2000 r/min, the maximum average particle size of coal particles is 242µm, and there is insufficient stirring. However, with the agitation intensity increasing to 6000 r/min, the average particle size of coal particles increases first and then decreases. This shows that in the process of hydrophobic agglomeration flotation, with the increase of stirring speed, the probability of effective collision and attachment between particles is increased, and the phenomenon of small particles adhering to large particles or clumping between large particles occurs, which increases the size of the coal particles and improves the recovery rate.
The adsorption of flotation agents is commonly influenced by the surface electrostatic properties of minerals during the flotation process. The examination and regulation of the change in surface electrical properties of minerals represents a significant methodology for the investigation of chemical processes, judge the floatability of minerals and realize the separation of different minerals. The double electric layer on mineral surface affects the separation effect of mineral in many aspects, especially the effect of electrokinetic potential. Therefore, the analysis of electrokinetic potential has practical significance in flotation research.
Figure (c) and (d) are respectively Zeta potential change and infrared analysis of coal. According to the variation trend of Zeta potential, upon increasing the dosage of polyferric sulfate from 0 g/t to 165 g/t, the Zeta potential first decreased from − 21.8mV to -23.5mV, and finally increased to -18.7mV. It shows that SO42−. FeOH2+ and Fe3+ plasma exist in the aqueous solution after the addition of polyferric sulfate, which will adsorb onto the surface of the emulsified kerosene or coal, thus changing the surface charge and changing the interaction between them (Cebeci et al., 2002). Specifically, the SO42− ion is in equilibrium in an aqueous solution. The adsorption capacity of FeOH2+ and Fe3+ to coal becomes stronger when the dosage of chemical reagent continues to increase. The dominant role is the positive charge, these cations adsorb on the surface of emulsified kerosene and coal will neutralize part of the negative charge, making the Zeta value larger. As the amount of polyferric sulfate continues to increase, the double electric layer between minerals and coal is compressed, and the gravity becomes larger, resulting in an increase in the ash content of the concentrate (Dong Zilong et al., 2019).
To gain further insight into the impact of the flocculant, FT-IR comparative analysis was performed on PFS without PFS and PFS with different dosage (as illustrated in Fig. 8(d)). A broad absorptive peak associated with the -OH hydroxyl group is observed at a wave number of 3434 cm− 1. However, after the addition of electrolyte, the peak gradually weakens to disappear, indicating that the addition of polyferric sulfate makes the impurities in the pulp tend to be stable, and the wide absorption peak of the hydrophilic functional group -OH gradually disappears. At the wave number of 1626cm− 1 is the resonance absorption peak of hydroxyl > C = O or -OH hydroxyl group formed with the hydrogen bond. The wave number of 1035cm− 1 is the absorption peak of inorganic minerals (Si-O-Si). These two absorption peaks decrease first and then increase. This phenomenon could be caused by the decrease of hydrophilic functional groups and the strong hydrophobicity of coal particles in the process of agglomeration. Upon increasing the dosage of polyferric sulphate from 25g/t to 165g/t, the absorption peaks at the three places were also slightly larger, which was due to the strong hydrophilicity and poor hydrophobicity of coal particles caused by excessive drug dosage. The conclusion obtained is consistent with the above.
Based on the above analysis, the shear flocculation mechanism diagram applied in the experiment in this paper is shown in 9. The turbulent environment of high-speed agitation promotes the dispersion of non-stick coal particles and gangue particles, and makes the flocculant aqueous solution displays selective adhesion to the surface of hydrophobic particles. The energy input from high-speed stirring makes the non-stick coal particles close to each other, increasing the actual collision probability between the particles, and eventually leading to the agglomeration of particles. In addition, high-speed stirring results in the crushing of minerals, which makes the coal particles effectively separate from gangue particles and other inorganic minerals, thereby improving the quality of the aggregates. It can be seen that, when high-speed stirring is employed, the size of the agglomeration formed by the hydrophobic particles increases continuously, and the quality of the agglomeration is also enhanced. The recovery rate of flotation concentrate is significantly influenced by the size of the aggregate particles. Accordingly, improvements in aggregate quality are also a significant contributing factor to the enhancement of concentrate grade.