Search Results (293)

This study tackles the challenge of treating high-oil (≥90 mg/L) and high-salinity (Cl⁻ ≥ 6900 mg/L) oilfield-produced water for green hydrogen production. An integrated technology combining electrochemical cascade purification (EDCF: electro-demulsification–coagulation–flotation) with alkaline water electrolysis is developed. The EDCF process effectively reduces oil, suspended solids, and turbidity to <10 mg/L, <20 mg/L, and <20 NTU, respectively, meeting stringent feedwater criteria for electrolysis. An asymmetric electrolysis strategy employing a nickel felt anode/Raney nickel cathode system achieves a low cell voltage of 1.856 V at 1 A/cm² in 6 M KOH at 85 °C, with 96.58% H₂ purity. Crucially, separate anolyte/catholyte (0.5/6 M KOH) mitigates Cl⁻ corrosion, enabling stable 240 h operation (96.66% ± 0.5% H₂ purity) in a duplex steel electrolyzer. The work establishes comprehensive boundary conditions for scalable hydrogen production from treated produced water. Full article

The quantity, size, and distribution of non-metallic inclusions in High-Strength Low-Alloy (HSLA) steel critically influence its service performance. Conventional detection methods often fail to adequately characterize extreme inclusion distributions in large-section components. This study developed an integrated full-process inclusion analysis system combining high-precision motion control, parallel optical imaging, and laser spectral analysis technologies to achieve rapid and automated identification and compositional analysis of inclusions in meter-scale samples. Through systematic investigation across the industrial process chain—from a dia. 740 mm consumable electrode to a dia. 810 mm electroslag remelting (ESR) ingot and finally to a dia. 400 mm forged billet—key process-specific insights were obtained. The results revealed the effective removal of Type D (globular oxides) inclusions during ESR, with their counts reducing from over 8000 in the electrode to approximately 4000–7000 in the ingot. Concurrently, the mechanism underlying the pronounced enrichment of Type C (silicates) in the ingot tail was elucidated, showing a nearly fourfold increase to 1767 compared to the ingot head, attributed to terminal solidification segregation and flotation dynamics. Subsequent forging further demonstrated exceptional refinement and dispersion of all inclusion types. The billet tail achieved exceptionally high purity, with counts of all inclusion types dropping to extremely low levels (e.g., Types A, B, and C were nearly eliminated), representing a reduction of approximately one order of magnitude. Based on these findings, enhanced process strategies were proposed, including shallow molten pool control, slag system optimization, and multi-dimensional quality monitoring. An intelligent analysis framework integrating a YOLOv11 detection model with spectral feedback was also established. This work provides crucial process knowledge and technological support for achieving the quality control objective of “known and controllable defects” in HSLA steel. Full article

In addition to seawater in the injection header (IH) to enhance oil recovery, oil companies reuse produced water (PW), a byproduct of oil extraction, and implement produced water reinjection systems (PWRI). Although the microorganisms in IH are controlled by biocides, PW is generally treated by flotation to remove oil residues before PWRI. However, IH, PW, and PWRI can be sources of sulfate-reducing bacteria (SRB) related to oil reservoir souring. Here, we evaluated hydrogen sulfide (H₂S) production in IH, PW, and PWRI, as well as the microbial dynamics (most probable number–MPN, quantitative PCR, and amplicon sequencing), of a Brazilian oil reservoir. Results revealed that the highest average H₂S concentration occurred in PW samples. However, the dissolved H₂S threshold concentration of 2 mg L⁻¹ was exceeded in 18% of PW and ~16% of PWRI samples, respectively. Although MPN showed no correlation between H₂S and the number of SRB or total anaerobic heterotrophic bacteria (TAHB), qPCR and microbiome data revealed that the SRB Desulfobacterota was the most abundant in PW and PWRI. Overall, flotation was associated with (i) low microbial control in PW; and (ii) the enrichment of SRB (mainly Desulfobacterota), Thermotogota, and Proteobacteria groups in PWRI. Full article

Although intensified flotation cells have been introduced as fast-kinetic and plug-flow-type flotation machines, there is limited empirical verification and information about their fluid flow patterns and dispersion regimes. The present communication paper investigates this for an Imhoflot^TM G-06 cell operated in an open-circuit mode using an impulse method to measure and model the residence time of a liquid–gas system. For experimental measurements, a concentrated KCl solution was employed, and water conductivity was monitored for 20 min. By fitting several relevant models, such as large and small tanks in series (LSTS), Weller, N-Mixer, and perfect mixer, to the experimental data, it was revealed that the N-Mixer represented the dispersion pattern the best (N = 1.3–1.6). Further, the obtained practical mean retention time (MRT) of 4.11 ± 0.16 min was somewhat aligned with the theoretical value, i.e., 5.0 min per pass, indicating a back-calculated gas hold-up magnitude of 18%–22% in the separator. These results provide an in-depth perception of scale-up procedures and requirements for cell modification. Full article

The papermaking and recycling industries face increasing demands to improve efficiency, product quality, and environmental performance under conditions of water closure and high furnish variability. This study presents a comprehensive assessment of process control and management strategies for optimizing fines behavior, retention and fixation efficiency, de-inking performance, and ash balance in modern papermaking systems. The surface chemistry of fines was found to play a pivotal role in regulating charge distribution, additive demand, and drainage behavior, acting both as carriers and sinks for dissolved and colloidal substances. Results show that light, targeted refining enhances external fibrillation and produces beneficial fines that strengthen fiber bonding, while excessive refining generates detrimental fines and impairs drainage. Sequential retention programs involving polyamines, polyaluminum compounds, and microparticle systems significantly improve fines capture and drainage stability when operated under controlled pH and ionic strength. In recycling operations, optimized flotation conditions coupled with detackifiers and mineral additives such as talc effectively reduce micro-stickies formation and deposition risks. Ash management strategies based on partial purge and coordinated filler make-up maintain bonding, optical properties, and energy efficiency. Overall, the findings emphasize the need for an integrated wet-end management framework combining chemical, mechanical, and operational controls. Perspectives for future development include the application of biodegradable additives, nanocellulose-based reinforcements, and data-driven optimization tools to achieve sustainable, high-performance paper manufacturing. Full article

Oil and grease (O&G) pollution in municipal effluents represents a critical environmental challenge. This study contributes a novel experimental assessment of how pressure and recirculation time influence oxygen transfer, microbubble generation, and pollutant removal in a pilot-scale DAF system, providing new insights into process optimization for municipal wastewater treatment. This study evaluated the efficiency of a DAF system in removing organic pollutants and solids from municipal effluent by varying gauge pressure (1–5 bar) and recirculation time (1–20 min). The initial concentrations present in the effluent were 800 mg/L total solids (TS), 590 mg/L total suspended solids (TSS), 450 mg/L oil and grease (O&G), 360 mg/L biochemical oxygen demand (BOD₅), and 710 mg/L chemical oxygen demand (COD). The concentration of dissolved air (interpreted as dissolved oxygen supersaturation) reached 102.3 mg/L and removal efficiencies of 84.4% for O&G, 88.9% for BOD₅, 88.7% for COD, and 85% for TSS were achieved, while pH and dissolved solids (DS) remained stable. The saturation factor (f = 0.8) confirmed efficient oxygen-liquid transfer, attributed to the use of Raschig rings in the absorption column. The significance of this work lies in demonstrating that operating conditions directly enhance oxygen dissolution and flotation performance, highlighting an optimization pathway rarely reported for municipal effluents. The results demonstrate that DAF is a robust, stable, and energy-efficient technology capable of effectively removing organic and lipid loads from municipal effluent, providing a sustainable alternative for the pretreatment and reuse of urban wastewater. Full article

Microplastic (MP) pollution is a global concern due to its persistence, ubiquity, and potential ecological and health risks. Although various MP separation techniques exist, flotation has gained attention as a promising approach adapted from mineral processing. This study provides a systematic review, bibliometric analysis, and meta-analysis of MP removal using flotation, covering 31 papers published between 2015 and 2024. Research output has grown rapidly since 2020, with China (including Hong Kong) as the leading contributor with strong international collaborations. Bibliometric mapping highlighted hotspots such as polymer type, particle size, contact angle, and nanobubbles. Meta-analysis showed that flotation achieved high removal efficiencies across water and solid matrices, though performance varies with polymer properties, surfactants used, and experimental design. Studies focused on solid particles remain limited, reflecting greater methodological challenges than in water systems. Critical discussion emphasized the need for standardized protocols, scaling from laboratory to field applications, and integration with wastewater treatment. This review identified knowledge gaps and emerging trends that can inform the future development of flotation as an effective technology for mitigating MP pollution. Full article

An eco-friendly flotation process is of great significance to the green and sustainable development of the mining industry. The purpose of this study is to improve the traditional flotation process. Novel reagents, alkyl ether amine (Alkyl carbon chains with a length of 12 are simply referred to as DOEA) as collector and carboxymethyl starch (CMS) as depressant, were used for flotation uAlkyl ether aminender lower temperature, which did not need to heat the tonnage of pulp and reduced the energy consumption. The micro-flotation tests were carried out with three main minerals (quartz, hematite and magnetite) contained in Qidashan (Anshan, China) iron ore at room temperature in winter (18 °C). The bench-scale tests were carried out with flotation feed (mixture of strong magnetic concentrate and weak magnetic concentrate) from the Qidashan flotation workshop at room temperature (18 °C). And the industrial tests were carried out in the flotation workshop of Qidashan Concentrator of Anshan Iron and Steel Co., Ltd. The temperature of the pulp was 17.5~19.7 °C. The results of micro-flotation tests showed that the floatability of the three minerals under the DOEA system decreased in the following order: quartz > hematite > magnetite. The addition of CMS increased the floatability difference between quartz and ferric oxide minerals. DOEA and CMS could effectively separate quartz and ferric oxide minerals at room temperature in winter. The feasibility of the application of DOEA and CMS in Qidashan iron ore was verified by bench-scale tests, and the pulp circulation process was simulated by locked-cycle tests. The results of bench-scale tests showed that under the conditions of CMS dosage 200 g/t, DOEA dosage 150 g/t, and pulp temperature 18 °C, the iron grade of flotation concentrate was 66.54% and iron recovery was 78.37%. The industrial test results showed that the modified flotation process could continuously output qualified iron concentrate without heating the pulp. Compared with the on-site flotation process, it was found that the modified flotation process could save USD 6,460,100 per year. This technology could significantly reduce the energy consumption of iron ore reverse flotation, reduce the carbon emissions generated by heating tons of pulp, and achieve cleaner production. Full article

Cholesterol (Chol) plays a crucial role in regulating membrane properties and biological processes such as membrane fusion, yet the molecular mechanisms underlying its function remain incompletely understood. In order to elucidate how sterol structure influences phospholipid organization relevant to membrane fusion, we compared the effects of Chol and its biosynthetic precursor lanosterol (Lan) on hydrated phosphatidylethanolamine (PE) assemblies using X-ray diffraction, the neutral flotation method, and osmotic stress measurements. Volumetric analyses revealed that Lan has a larger occupied molecular volume than Chol in the bilayers. These values were largely independent of differences between phospholipids (phosphatidylcholine and PE), indicating that sterols are deeply embedded within the bilayer. In palmitoyl-oleoyl-PE lamellar membranes, both sterols increased bilayer thickness. They both enhanced short-range repulsive hydration forces, but Chol suppressed fluctuation-induced repulsion more effectively, reflecting its greater stiffening effect. In bacterial PE systems forming the inverted hexagonal (H_II) phase, increasing sterol concentration decreased the lattice constant, with a more substantial effect for Lan, which also induced greater curvature of the water columns. These results suggest that while Chol enhances mechanical rigidity and membrane cohesion, Lan promotes molecular flexibility and curvature, properties associated with fusion intermediates. Full article

Quartz and feldspar have similar physical, chemical, and surface properties. Effectively separating them in near-neutral systems has long been a challenging research focus. This study introduces 1-Dodecyl-3-methylimidazolium bromide (DMB), an ionic liquid, as a collector in a quartz–feldspar flotation separation system to investigate its effects on the flotation behavior of quartz and feldspar. The interaction between the collector and the minerals is explained through zeta potential measurements, infrared spectroscopy analysis, and DFT calculations. The flotation test results indicate that DMB exhibits selective flotation separation properties enabling the separation of quartz from feldspar. Across the pH range of 3 to 11, DMB demonstrates high collection capability for quartz, but lower capability for feldspar. In particular, at pH levels of 7 to 8, the recovery difference between the two minerals exceeds 80%, achieving optimal selective separation. Mechanistic studies indicate that DMB primarily adsorbs on quartz and feldspar through electrostatic adsorption. The adsorption energy between DMB and quartz reaches −340.59 kJ/mol, forming a stable adsorption layer on the quartz surface. However, electrostatic repulsion arises over a broad area due to the large volume and cationic nature of DMB’s polar group and the exposed cationic Al sites on the feldspar surface, thereby hindering the interaction between DMB and feldspar. This research establishes the foundation for achieving efficient selective flotation separation of quartz and feldspar in a neutral system. Full article

This study investigated the flotation performance of W8, a blended xanthate collector containing ethyl, butyl, propyl, and amyl xanthates, combined with ammonium dibutyl dithiophosphate (ADD) for treating low-grade arsenopyrite-type gold ore from Golmud, Qinghai. Real ore flotation tests demonstrated the superior efficacy of the W8 + ADD system, achieving 84.06% gold recovery with 0.34 g/t tailings, outperforming conventional sodium amyl xanthate (SAX) + ADD and sodium propyl xanthate (SPX) + ADD systems. Systematic studies on pure arsenopyrite revealed a significant synergistic effect in the mixed SPX-SAX system (1:4 ratio), representative of W8 composition. At pH 9, the mixed collector achieved 73.5% recovery, substantially higher than individual SPX (37.5%) or SAX (45.8%). This enhanced performance was attributed to improved surface hydrophobicity (contact angle 47.68° vs. 36.92° for SAX), greater adsorption density (4.97 × 10⁻⁷ mol/g under depressant conditions), and extensive formation of molecular aggregates observed via AFM, which increased surface roughness to 28.95 nm. Flotation kinetics further confirmed the advantage of W8 + ADD, which reached 72.1% cumulative recovery in 420 s, exceeding both mixed SPX/SAX (69.5%) and single SAX (65.5%) systems. The synergistic interaction among different xanthate components in W8 enables efficient recovery of gold from this refractory ore. Full article

Phosphate ore is essential for global food security and industry. However, the depletion of high-grade deposits necessitates processing complex low-grade ores, posing significant separation challenges. Flotation, the main beneficiation method, exploits minor differences in surface properties, yet conventional approaches offer limited molecular-level insight, resulting in inefficiency, high reagent use, and pollution. Molecular simulation has emerged as a transformative solution, integrating quantum chemistry, molecular dynamics, and mesoscale modeling to accurately predict electronic structures and optimize flotation systems. This review systematically examines its applications in phosphate ore processing, highlighting four key advances: a multi-scale framework linking atomic mechanisms to macro-performance; structure–activity models for rational reagent design; insights into interfacial micro-environments for intelligent control; and machine learning integration for high-throughput screening. Key challenges such as force field accuracy and simulation scalability are addressed, along with emerging directions like in situ dynamic simulation and integration with process engineering. This review aims to support the development of efficient, sustainable, and intelligently optimized phosphate beneficiation technologies. Full article

The flotation of coarse-sized particles is an important step in the pathway to sustainable recovery as it can reduce reagents usage, energy consumption, and environmental impact, as well as minimise overgrinding. This study assessed the floatability of coarse-sized scheelite, a mineral containing the critical element tungsten (W), using plant-derived samples from the Kara mine magnetite–scheelite skarn deposit in Tasmania, Australia. The recovery of three sizes of coarse-size scheelite (+150, +300, and +425 µm) was tested under optimised conditions determined through laboratory experiments (i.e., 900 rpm, pH 9, collector sodium oleate 5 g/t, and depressant mixture of 4 g/t of sodium silicate and 4 g/t of quebracho). Results show that WO₃ recoveries of 91.76% and 84.14% and grades of 61.03% and 58.73%, respectively, were achieved for samples containing the +425 µm and +300 µm size scheelite. These samples had lower mass recoveries (70.95% and 84.15%), reflecting the selective flotation of coarse scheelite. Lower WO₃ recovery (79.44%) and grade (45.76%) but higher mass recovery (88.81%) were obtained for the samples with +150 um scheelite. This paper provides details of the test work and provides a framework for adapting coarse scheelite particle flotation strategies to other scheelite skarn deposits and high-density mineral systems to help enable improved recovery and enhanced economic efficiency in mineral processing plants. Full article

In salt lake KCl cold decomposition–direct flotation for K-Na separation, octadecylamine hydrochloride (ODA-H) acts as a collector, reducing product purity and limiting high-end applications of salt lake KCl. To study KCl purification mechanisms and optimize crystal properties, this study investigates ODA-H aqueous systems. By regulating the cooling rate, stirring rate, and ODA-H concentration, the crystallization purification of KCl and precise control of its morphology were achieved, ultimately yielding three typical crystal morphologies: cubic, spherical, and ellipsoidal. Of the three crystal morphologies, spherical crystals have the best flowability but lowest purity. Ellipsoidal crystals have better flowability than cubic ones: their purity exceeds that of cubic crystals before washing but falls below it after washing. Cubic crystals, with poorer flowability, reach the highest purity post-washing. This study provides a theoretical basis for enhancing purity via crystal morphology regulation and industrial-scale purification of salt lake KCl. Full article

Chalcopyrite and bornite are typical copper sulfide minerals; however, the interaction mechanisms between these minerals and conventional collectors—sodium butyl xanthate (BX) and ammonium dibutyl dithiophosphate (ADD)—when used in combination remain unclear. To address this issue, this study integrated flotation tests, FTIR spectroscopy, adsorption measurements, and AFM to investigate the effects of BX, ADD, and their mixture on the floatability of the two minerals. Flotation results showed that chalcopyrite exhibited excellent floatability in all collector systems, with above 90% recovery. Within the pH range of 3 to 11, BX outperformed ADD in enhancing bornite flotation. The BX/ADD mixture at a mass ratio of 3:1 had no significant effect on chalcopyrite recovery but significantly improved bornite recovery to 84.20% at pH 9. FTIR confirmed chemical adsorption of both collectors on the mineral surfaces. AFM further visualized stronger adsorption of BX on both chalcopyrite and bornite. Compared with single BX or ADD alone, the BX/ADD mixed collector exhibited more effective adsorption on chalcopyrite and bornite. The study provides guidance for reagent selection in the industrial flotation of chalcopyrite and bornite. Full article