processes
Communication
Role of Sparger Configuration in Determining Flotation
Performance under Oscillatory Air Supply
Yiming Ji 1 , Ajuan Song 2 , Chao Li 1, *






Citation: Ji, Y.; Song, A.; Li, C.; Cao,
Y. Role of Sparger Configuration in
Determining Flotation Performance
under Oscillatory Air Supply.
Processes 2021, 9, 638. https://
doi.org/10.3390/pr9040638
Academic Editors:
Giancarlo Cravotto and Kostas Matis
Received: 11 March 2021
Accepted: 3 April 2021
Published: 6 April 2021
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iations.
Copyright: © 2021 by the authors.
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This article is an open access article
distributed under the terms and
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Attribution (CC BY) license (https://
creativecommons.org/licenses/by/
4.0/).
Processes 2021, 9, 638. https://doi.org/10.3390/pr9040638
and Yijun Cao 2, *
1 Henan Province Industrial Technology Research Institute of Resources and Materials, Zhengzhou University,
Zhengzhou 450001, Henan, China; jym1311@163.com
2 School of Chemical Engineering, Zhengzhou University, Zhengzhou 450001, Henan, China; saj0806@163.com
* Correspondence: c.li@zzu.edu.cn (C.L.); yijuncao@126.com (Y.C.)
Abstract: Bubble size is crucial for determining flotation efficiency. Fine bubbles can be cost-
effectively generated using a multi-orifice sparger with oscillatory air supply. Sparger configuration is
defined by the orifice size, the plate thickness and the chamber volume. To date, the effect of sparger
configuration on bubble size with oscillatory air supply is not clear yet. To facilitate the control of
bubble size formed with oscillatory air supply, the present work investigated the dependence of
bubble size on sparger configuration. It was found that bubble size was positively correlated with
the chamber volume and the orifice size, while a nonlinear relationship was observed with the plate
thickness. Besides, it was found that flotation recovery decreased over increasing bubble size when
changing the sparger configuration. The results indicated that sparger configuration exhibited a
significant effect on flotation performance via influencing bubble size when oscillatory air supply
was applied.
Keywords: flotation; bubble size; sparger; oscillatory air supply
1. Introduction
Froth flotation is a process for the separation and concentration of minerals and other
particulate materials by exploiting the difference in their affinity to air bubbles in aqueous
medium. Bubble size is of great importance for determining the flotation efficiency. Small
bubbles are beneficial for recovering both fine and coarse particles in froth flotation [1,2].
Recent studies have shown that microbubbles can be cost-effectively generated using
a multi-orifice sparger by replacing steady air supply with oscillatory air supply [3,4].
A bubble usually breaks off at an order of magnitude larger size than the orifice size
under steady air supply, while it would detach from the orifice plate at a much earlier
stage under an oscillatory air supply which provides an additional lifting force for bubble
detachment. Li and wang (2018) investigated the role of the features of oscillatory air
supply in influencing bubble size, and found that oscillatory frequency, on/off time ratio
within one circle and air flow rate were the dominating variables which should be taken
into account. Microbubble generation with oscillatory air supply has been used in algae
harvesting [5], coal flotation [6,7] and fine particle mineral flotation [8,9].
Bubble size generated with a multi-orifice sparger is also determined by the sparger
configuration. It has been well known that, under steady air supply, bubble size is closely
related to plate thickness [10], orifice size [11] and the chamber volume [12]. However, the
role of sparger configuration in determining bubble size under oscillatory air supply is not
clear yet, which hinders the optimization of bubble size in practice to some extent. Thus,
for the first time, the present work studied the effects of sparger features on bubble size and
corresponding flotation recovery with oscillatory air supply, the underlying mechanisms
for which were also discussed.
https://www.mdpi.com/journal/processes
 2.1. Materials
Fine quartz (>99% pure) purchased from Yijing China was used as a flotation mate-
rial. Its particle size was measured using a Malven Mastersizer 3000E. The particle size
distribution of the quartz is shown in Table 1. An ether amine, 3-(2-Ethylhexyloxy) prop-
Processes 2021, 9, 638 ylamine (>99% pure, Aladdin, Shanghai, China) was used as both collector and frother 2 offor
7
silica flotation, and acetic acid (>99.5% pure, Yong Da, Suqian China) was used to neutral-
ize the ether amine (at 20% w/w) to enhance its solubility [13]. Deionized water was used
throughout the work.
2. Materials and Methods
2.1. Materials
Table 1. The particle size distribution of quartz used in this study.
Fine quartz (>99% pure) purchased from Yijing China was used as a flotation material.
Passing (%) 10 30 50 70 90
Its particle size was measured using a Malven Mastersizer 3000E. The particle size distribu-
tion of the quartzSizeis(μm)
shown in Table 1. An 3.1ether amine,
9.8 16.7
3-(2-Ethylhexyloxy)27.4 propylamine
45.4
(>99% pure, Aladdin, Shanghai, China) was used as both collector and frother for silica
2.2. Experimental
flotation, Set-Up
and acetic acid (>99.5% pure, Yong Da, Suqian China) was used to neutralize
Figure
the ether 1 schematically
amine (at 20% w/w) depicts the experimental
to enhance its solubility set-up, which comprises
[13]. Deionized a flotation
water was used
throughout the work.
column (50 mm in diameter and 1120 mm in height) with a sparger of porous plate placed
at the vicinity of the column bottom. The sparger were made of stainless steel plates with
Table 1. The
different particle sizeand
thicknesses distribution of quartz
orifice sizes used inThe
as needed. thischamber
study. volume of the sparger could
be justified between 5 cm and 200 mL
Passing (%) 10 30 50 70 90
A solenoid valve (Festo, Shanghai, China) was used to change the flow pattern of air
Size (µm)
supply from steady to 3.1oscillatory. The9.8 features that16.7 can be adjusted 27.4
included the45.4
switching
frequency and the on/off time ratio within every switching cycle. The pressure and gas
2.2.
flow Experimental
rate passingSet-Up
through the solenoid valve were controlled using an air pressure regu-
latorFigure
and air flow meter, respectively.
1 schematically A laser probe
depicts the experimental (A2 which
set-up, Photonic Sensors,a Grenoble,
comprises flotation
France) was used to measure bubble size in situ. The probe
column (50 mm in diameter and 1120 mm in height) with a sparger of porous is made of an optical
platefiber with
placed
ata the
micromachined
vicinity of thetip. It operates
column bottom.by The
contact and measures
sparger were madeallofbubbles
stainlessthat getplates
steel pierced by
with
the tip. The
different measurement
thicknesses reliessizes
and orifice on theas analysis
needed. Theof the reflected
chamber light as
volume ofathe
bubble is pierced
sparger could
byjustified
be the probe.
between 5 cm and 200 mL.

Figure1.1.Schematic
Figure Schematicofofthe
theflotation
flotationset-up
set-upwith
withoscillatory
oscillatoryair
airsupply.
supply.

A solenoid valve (Festo, Shanghai, China) was used to change the flow pattern of air
supply from steady to oscillatory. The features that can be adjusted included the switching
frequency and the on/off time ratio within every switching cycle. The pressure and gas
flow rate passing through the solenoid valve were controlled using an air pressure regulator
and air flow meter, respectively. A laser probe (A2 Photonic Sensors, Grenoble, France)
was used to measure bubble size in situ. The probe is made of an optical fiber with a
micromachined tip. It operates by contact and measures all bubbles that get pierced by the
Processes 2021, 9, 638 3 of 7

Processes 2021, 9, xtip.

FORThe
PEERmeasurement
REVIEW relies on the analysis of the reflected light as a bubble is pierced by 3 of

the probe.

2.3. Experimental
2.3.Procedure
Experimental Procedure
The flotation tests were carried
The flotation tests out
wereatcarried
a continuous
out at amode. The sparger
continuous mode. The with required
sparger with require
orifice size andorifice
plate thickness was mounted
size and plate thickness to themounted
was column bottom before bottom
to the column flotation, and the
before flotation, an
chamber volume the was adjusted
chamber volume as needed.
was adjustedFor each test, 0.76
as needed. Forkg of test,
each quartz
0.76with
kg of14.5 kg of
quartz with 14.5 k
water was pre-conditioned
of water was in a 30 L conditioning
pre-conditioned in a 30sump and the neutralized
L conditioning sump and the collector was collecto
neutralized
added to the feed
wasatadded
a dosage
to theof feed
500 g/t
at a for 10 min
dosage prior
of 500 g/ttofor
the
10flotation
min priortests.
to the Several other
flotation tests. Sever
preparation stages
otherwere undertaken
preparation stagesbefore
werestarting
undertakenthe flotation: firstly,the
before starting theflotation:
flotationfirstly,
column the flotatio
was prefilled with water
column wasto prefilled
avoid sparger blocking
with water during
to avoid feeding;
sparger then, the
blocking solenoid
during valve
feeding; then, the s
was turned onlenoid
and run at the
valve wasswitching
turned on frequency
and run at of the40 Hz and the
switching ratio ofofon/off
frequency 40 Hz andtimethe ratio o
of 0.2. Air was introduced to the column at a superficial gas velocity of 1.70 cm/s velocity
on/off time of 0.2. Air was introduced to the column at a superficial gas and of 1.7
air pressure wascm/ssetand air pressure
at 200 KPa. Feed was set pumped
was at 200 KPa. intoFeed
thewas pumped
column into
at 0.8 the column
L/min and the at 0.8 L/m
and the
tailing volumetric tailingwas
flowrate volumetric
regulated flowrate
at the was
sameregulated at the same froth
time to maintained time to maintained
depth at frot
100 mm for each depth
test.atAfter
100 mm for each test.
the flotation systemAfter the flotation
achieved system
a steady achieved
status which awas steady
aboutstatus whic
twice particle was about twice
residence particle residence
time according time according
to preliminary tests, to
thepreliminary
laser probe tests,
wasthe laser probe wa
placed
50 mm above the placed 50 mm
sparger above thebubble
to measure sparger to measure
size, after which bubble
thesize,
frothafter
andwhich
tailingsthestreams
froth and tailing
were collectedstreams
for 2 min.wereThe collected for 2 samples
collected min. Thewere collected
driedsamples were dried
and weighted toand weighted to ca
calculate
culate flotation recovery. Some conditions were repeated
flotation recovery. Some conditions were repeated three times and the error bars represent three times and the error ba
represent one standard error obtained from
one standard error obtained from the three independent experimental runs. the three independent experimental runs.

3. Results and3.Discussion
Results and Discussion
3.1.
3.1. Chamber Volume Chamber Volume
Figure 2 shows Figure 2 shows
the effects of the
the effects
chamberof the chamber
volume volumesize
on bubble on bubble size (solid
(solid lines) and lines) an
flotation recovery (dash lines). In these tests, the orifice size was 63 µm and the plateplate thick
flotation recovery (dash lines). In these tests, the orifice size was 63 μm and the
thickness was ness was The
0.1 mm. 0.1 mm. The chamber
chamber volumevolume was at
was varied varied
5 mL, at 25
5 mL,
mL,2550mL,
mL,50 mL,
100 mL,100 mL, 15
mL and 200 mL,
150 mL and 200 mL, respectively. respectively.

2.0 100

90

80
1.5
70
Bubble size (mm)

60
Recovery (%)

1.0 50

40
Oscillatory air supply
30
0.5 Steady air supply
Constant Oscillatory air supply 20
Intermediate
flow
condition Steady air supply
10

0.0 0
0 20 40 60 80 100 120 140 160 180 200 220
Chamber volume (mL)

Figure
Figure 2. Effects of2.chamber
Effects of chamber
volume onvolume
bubble on bubble
size size and recovery.
and flotation flotation recovery.

Figure
Figure 2 reveals that2 the
reveals that thevolume
chamber chamber volume exhibited
exhibited significant
significant effects
effects on on bubble siz
bubble
and flotation recovery. Under oscillatory air supply, bubble size
size and flotation recovery. Under oscillatory air supply, bubble size was dramaticallywas dramatically in
creased from 1087 μm to 1695 μm (a 55.9% increase) and consequently
increased from 1087 µm to 1695 µm (a 55.9% increase) and consequently quartz recovery quartz recover
Processes 2021, 9, x FOR PEER REVIEW 4 of 7
Processes 2021, 9, 638 4 of 7

was decreased from 85.1% to 49.8% (a 41.5% decrease) as the chamber volume was en-
larged from 5 mL
was decreased fromto 200
85.1%mL. toDifferently,
49.8% (a 41.5% under steadyas
decrease) airthe
supply,
chamber bubble size was
volume experienced
enlarged
afrom
much less increase from 1506 μm to 1641 μm (only 8.96%
5 mL to 200 mL. Differently, under steady air supply, bubble size experienced increase) and quartz recovery
a much
was
less only decreased
increase from 1506 fromµm63.3%
to 1641 to µm
56.8% (only(a 8.96%
10.3% increase)
decrease).and Note thatrecovery
quartz the difference
was only in
bubble
decreasedsizefrom
and corresponding
63.3% to 56.8% silica (a 10.3%recovery between
decrease). Noteoscillatory and steady
that the difference air supply
in bubble size
progressively
and corresponding decreased silicawhen
recoverythe chamber
between volumeoscillatory wasandincreased
steady air to 150 mL, progressively
supply above which
no significant
decreased when difference
the chambercan be observed.
volume was The resultstoshow
increased 150 mL, thatabove
the chamber
which novolume ex-
significant
hibited a more significant effect on silica recovery for oscillatory
difference can be observed. The results show that the chamber volume exhibited a more air supply than for steady
air supply via
significant effectinfluencing bubble size.
on silica recovery for oscillatory air supply than for steady air supply via
The effect
influencing bubbleof chamber
size. volume on bubble formation can be evaluated using the di-
mensionless
The effect capacitance
of chamber numbervolume Nc. onThebubble
flow condition
formationincan the bechamber
evaluated can be classified
using the di-
into constant capacitance
mensionless flow condition number(Nc <Nc. 1), The
intermediate
flow conditionconditionin the(1chamber
< Nc < 10) canand constant
be classified
pressure condition
into constant flow (Nc > 10) [14,15].
condition (Nc < 1), intermediate condition (1 < Nc < 10) and constant
pressure condition (Nc > 10) [14,15].
4𝑔𝜌 𝑉
𝑁 = (1)
NC =
𝜋𝑑
4gρ g V𝑃C
(1)
πd2 PC
where 𝜌 is gas density (kg/m3), Vc is chamber O volume (mL), 𝑑 is orifice size (mm), g is
gravity
where ρacceleration (m/s2) and 3𝑃 is the pressure of air supplied to the chamber.
g is gas density (kg/m ), Vc is chamber volume (mL), do is orifice size (mm), g is
For acceleration
gravity the constant(m/s flow2 condition
) and Pc is in thea pressure
small chamber, the status
of air supplied to ofthethe gas exiting the
chamber.
chamber (i.e., entering the bubble) is the same to that
For the constant flow condition in a small chamber, the status of the gas of the gas entering theexiting
chamber. the
Thus
chamber (i.e., entering the bubble) is the same to that of the gas entering the chamber.at
the lifting force resulting from oscillatory air flow drives bubbles detaching an
Thus
early stage; for the intermediate condition, the flow pattern
the lifting force resulting from oscillatory air flow drives bubbles detaching at an early of air exiting the chamber
becomes
stage; fornotthenecessarily
intermediate synchronous
condition,to the that of air
flow entering
pattern of airthe chamber;
exiting further enlarging
the chamber becomes
the
notchamber
necessarily to reach the constant
synchronous pressure
to that of airflow, the chamber
entering the chamber; impose a cushioning
further enlarging effect
the
on the air flow pattern and thus the air pressure at the orifice
chamber to reach the constant pressure flow, the chamber impose a cushioning effect on the is transitioned to be constant.
Hence,
air flowthe liftingand
pattern force
thusprovided by the oscillatory
the air pressure at the orifice flow recedes in the
is transitioned chamber
to be constant.andHence,
con-
sequently bubbles detach at a much later stage. It is calculated
the lifting force provided by the oscillatory flow recedes in the chamber and consequently that, in this study, the crit-
ical chamber
bubbles detach volume for constant
at a much later stage.flowIt condition
is calculated is 46.46
that, inmL. thisThis explains
study, why the
the critical bub-
chamber
ble size for
volume foroscillatory
constant air flowsupply was much
condition is 46.46 smaller
mL. Thisthan that
explainsfor steady
why the air supply
bubbleinsize small
for
chamber
oscillatory volumes,
air supply whilewas the difference
much smallerdecreased
than that as forincreasing
steady airthe supplychamber volume,
in small chamberes-
pecially
volumes, in while
the intermedia
the differencecondition region.
decreased as increasing the chamber volume, especially in
the intermedia condition region.
3.2. Plate Thickness
3.2. Figure
Plate Thickness
3 shows the effects of the plate thickness on bubble size and consequent silica
Figure
recovery. In 3these
shows the the
tests, effects of the
orifice plate
size wasthickness
500 μm on
andbubble size and
the camber consequent
volume silica
was main-
recovery. In these tests, the orifice size was 500 µm and the camber volume was
tained at 5 mL. The plate thickness was varied at 0.05 mm, 0.1 mm and 0.5 mm, respec- maintained
at 5 mL. The plate thickness was varied at 0.05 mm, 0.1 mm and 0.5 mm, respectively.
tively.

3.0 70

2.5 60

50
Bubble size (mm)

2.0
Recovery (%)

40
1.5
30
1.0
20
0.5 10

0.0 0
0.05 0.1 0.5
Plate thickness（μm）
Bubble size Recovery

Figure
Figure3.3.Effects
Effectsof
ofplate
platethickness
thicknesson
onbubble
bubblesize
sizeand
andflotation
flotationrecovery.
recovery.
Processes 2021, 9, x FOR PEER REVIEW 5 of 7

Processes 2021, 9, 638 5 of 7

Figure 3 shows that a nonlinear correlation exists between bubble size and plate thick
ness. More specifically, the bubble size for the plate thickness of 0.1 mm was 2147 μm; it
Figure 3 shows that a nonlinear correlation exists between bubble size and plate thick
was 2559 μm and 2858 μm for the plate thickness of 0.05 mm and 0.5 mm, respectively.
ness. More specifically, the bubble size for the plate thickness of 0.1 mm was 2147 µm; it
Oppositely, quartz recovery increases firstly and then decreases with the increase of ori-
was 2559 µm and 2858 µm for the plate thickness of 0.05 mm and 0.5 mm, respectively.
fice thickness. It is expected that capillary resistance is the factor which determines bubble
Oppositely, quartz recovery increases firstly and then decreases with the increase of orifice
size when varying the plate thickness, especially in a channel like the micro-orifice in this
thickness. It is expected that capillary resistance is the factor which determines bubble size
study. Capillary resistance is directly related to the channel length. When the 0.05 mm
when varying the plate thickness, especially in a channel like the micro-orifice in this study.
plate was used,
Capillary the orifice
resistance channel
is directly length
related is far
to the smaller
channel than its
length. Whendiameter,
the 0.05which results
mm plate was in
aused,
low channel
the orifice resistance.
channel Given
lengththat airsmaller
is far was supplied
than itsin diameter,
an oscillatory
whichpattern,
results airinsupply
a low
was closed for a certain period of time within every cycle. Thus the
channel resistance. Given that air was supplied in an oscillatory pattern, air supply wasweeping phenomenon
could
closedappear whenperiod
for a certain air was ofshut
timedown
withinasevery
the low channel
cycle. resistance
Thus the weeping could not hold water
phenomenon could
flowing downward in the channel. The weeping phenomenon
appear when air was shut down as the low channel resistance could not hold water would hinder theflowing
bubble
formation
downwardand cause
in the bubble
channel. Thedetachment at a late stage
weeping phenomenon [12]. hinder
would The capillary resistance
the bubble formation in-
creases as increasing the thickness of the orifice plate, which will
and cause bubble detachment at a late stage [12]. The capillary resistance increases as retard the downward
flow of the liquid
increasing inside the
the thickness of orifice channel
the orifice plate,and avoid
which theretard
will weepingthephenomenon
downward flow [10].of Note
the
that with an over thick plate the capillary resistance could also weaken
liquid inside the orifice channel and avoid the weeping phenomenon [10]. Note that with an the lifting force
originated from the
over thick plate the capillary
oscillatory air flowcould
resistance patternalsoand resultthe
weaken in bubble detachment
lifting force originated at afrom
late
stage. Therefore,
the oscillatory airanflowappropriate
pattern and plate thickness
result in bubbleshould be selected
detachment at ato avoid
late theTherefore,
stage. weeping
and meanwhile plate
an appropriate minimize the energy
thickness should dissipation
be selected ofto
oscillatory
avoid theair supply and
weeping imposed by the
meanwhile
channel
minimizeresistance.
the energyThis explains
dissipation of why the medium
oscillatory air supplyplate thickness
imposed by thegenerated the finest
channel resistance.
bubbles in thiswhy
This explains study. the medium plate thickness generated the finest bubbles in this study.

Orifice Size
3.3. Orifice Size
Figure 4 shows the effects of the orifice size on bubble size and flotation recovery of
quartz. In
In these
these tests,
tests, the
the plate
plate thickness
thickness was
was 0.05
0.05 mm
mm and
and the
the chamber
chamber volume
volume was
was 55 mL.
mL.
The orifice size was varied at 20 µm, 50 µm, 80 µm, 110µm and 140µm, respectively.
μm, μm, μm, 110μm and 140μm, respectively.

45 100
1.4 (a) (b)
40 90
The ratio of bubble size to aperture size

1.2 35 80

70
1 30
Bubble size (mm)

Recovery (%)

60
0.8 25
50
20
0.6 40
15
30
0.4
10 20
Bubble size
0.2 5
The ratio 10

0 0 0
0 30 60 90 120 150 20 50 80 110 140
Aperture size (μm) Aperture size (μm)

Figure
Figure 4.
4. Effects
Effects of
of orifice
orifice size
size on
on bubble
bubble size
size (a)
(a) and
and flotation
flotation recovery
recovery (b)
(b) under oscillatory air
under oscillatory air supply.
supply.

seen from
As can be seen from Figure 4a, bubble size
size increased
increased with
with increasing
increasing the
the orifice
orifice size,
size,
which is consistent with literature [16,17]. It is interesting to note that the ratio of bubble
size to orifice size decreased with the orifice size since the capillary resistance decreases
size
over the orifice size [10]. Figure
over Figure 4b
4b shows
shows that increasing the orifice size decreased the
flotation recovery owing to increased bubble size, which falls the same trend compared to
chamber volume and plate thickness.
Processes 2021, 9, 638 6 of 7

4. Conclusions
This present work investigated the effect of sparger configuration on bubble size and
consequent flotation recovery under oscillatory air supply. The results showed that bubble
size was positively related to the chamber volume and orifice size. A thin plate could cause
weeping while increasing the plate thickness would also result in the energy dissipation in
the orifice channel owing to capillary resistance, implying that an appropriate thickness
should be selected for bubble generation with oscillatory air supply. In addition, it was
observed that in this study the flotation recovery of fine quartz significantly decreased
over increasing bubble size. It was concluded that the sparger configuration exhibited
significant effects on flotation recovery via influencing bubble size. Care should be taken in
the design of sparger configuration under the use of oscillatory air supply. More specifically,
the chamber volume and aperture size should be as small as possible when microbubbles
are needed. In addition, the plate should maintain a certain thickness to avoid weeping
although it might compromise the effectiveness of oscillatory air supply to some extent.

Author Contributions: Conceptualization, C.L.; methodology, Y.J.; formal analysis, Y.J. and A.S.;
data curation, Y.J.; writing—original draft preparation, Y.J.; writing—review and editing, C.L. and
Y.C.; supervision, C.L.; project administration, C.L. and Y.C.; funding acquisition, C.L. All authors
have read and agreed to the published version of the manuscript.
Funding: This research was funded by National Natural Science Foundation of China, grant number
52004248; China Postdoctoral Science Foundation, grant number 2019M652580; Key R & D and pro-
motion program in Henan Province, grant number 212102310011; Program for Innovative Research
Team (in Science and Technology) in University of Henan Province, grant number 19IRTSTHN028.
National key research and development program, grant number 2018YFC0604702.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: The data presented in this study are available on request from the
corresponding authors. The data are not publicly available due to restrictions.
Conflicts of Interest: The authors declare no conflict of interest.

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