Column flotation hydrodynamics operating in the heterogeneous regime estimated by electrical resistance tomography and multi-phase CFD model

This paper investigates the two-phase flow hydrodynamics of a column flotation operated from a homogeneous to a heterogeneous flow regimes using experimental and computational fluid dynamics (CFD) techniques. Experiments were conducted in a lab scale column flotation of 0.1 m internal diameter and 2.5 m length at various superficial gas velocities using a dual plane electrical resistance tomography (ERT). The mean gas holdup increased from 2 to 18% with the increase in superficial gas velocity from 0.6 to 7.2 cm/s. The gas holdup-based bubble swarm velocity method identified four distinct flow regimes, i.e. homogeneous bubbling regime, narrow discrete bubbling regime, a sustained helical flow regime and churn turbulent flow regime in the column. Further, transient simulations were conducted using a two-fluid model coupled with a population balance model to assess the flow behavior inside the column. Virtual mass, lift and drag forces were incorporated into the model to account for the interphase forces. Numerical simulations predicted mean gas holdup was matching with the experimental data at low gas velocities (<2.4 cm/s), and a marginal deviation was noted at higher gas velocities (>2.4 cm/s). The predicted radial gas holdup profiles were found to change from flatter to parabolic with the increase in gas velocities, i.e. similar to the experiments. The effect of particle size on the rate constant and recovery was estimated with Luttrell and Yoon's performance model using the particle floatability input data and the two-phase experimental data. The developed CFD model can be useful to optimize the operating and design parameters for efficient operation of the column flotation process.