What are the differences in the main functions and technical requirements of mineral separation agitation tanks in different mineral separation processes

Mineral processing agitation tanks are core equipment in the mineral processing process, and their functions are not static. Agitation tanks play different roles in different mineral separation processes, and their technical requirements vary fundamentally accordingly.

Agitation Tanks in Flotation Processes

In flotation processes, agitation tanks are often referred to as slurry preparation tanks or reagent agitation tanks. Their core function is to provide a uniform and stable chemical reaction environment for the slurry.

First, they ensure the thorough dispersion and dissolution of reagents. Flotation reagents, such as collectors, frothers, and conditioning agents, must be evenly dispersed throughout the slurry to effectively adsorb onto the target mineral surface or modify its hydrophilicity. If reagents are unevenly distributed, some mineral particles may not float due to insufficient reagent action, resulting in reduced recovery rates.

Second, they provide the necessary residence time for slurry activation and reaction suppression. Many chemical reactions on mineral surfaces require time to complete. The agitation tank's volume and rotational speed jointly determine the slurry's residence time within the tank. A sufficiently long residence time ensures that the mineral surface is fully activated or deactivated, creating optimal conditions for the subsequent flotation process.

Therefore, the technical requirements for flotation agitator tanks primarily focus on: efficient mixing to ensure uniform reagent distribution; controlled residence time to accommodate the reaction rates of different minerals and reagents; and gentle shear forces to avoid excessive agitation that could adversely affect reagent or slurry properties.

Agitator Tanks in Magnetic Separation Processes

Magnetic separation is primarily used to separate magnetic and non-magnetic minerals. In this process, the role of the agitator tank is distinct from that in flotation.

The primary function of a magnetic separation agitator tank is to maintain uniform suspension of the slurry. Magnetic separators typically have strict requirements for feed concentration and particle size. If the slurry settles or stratifies before entering the magnetic separator, it will result in unstable feed concentration and compromise separation performance. Agitator tanks ensure that solid particles in the slurry remain suspended, ensuring feed uniformity.

In addition, agitator tanks may also be used for slurry pretreatment in wet high-intensity magnetic separation or low-intensity magnetic separation processes. For example, agitation is used to disperse agglomerated fine particles or to adjust the pH of the slurry to optimize magnetic separator performance.

Therefore, the technical requirements for magnetic separation agitator tanks focus on: strong suspension capacity to handle high-density, coarse-grained slurries; stable slurry feed to meet the process requirements of the magnetic separator; and wear-resistant structural design, as magnetic separation slurries typically contain high levels of abrasive particles.

Agitator Tanks in Gravity Separation Processes

Gravity separation is a separation process that utilizes differences in mineral density. The role of the agitator tank in the gravity separation process is relatively simple but crucial.

Its primary function is to prevent slurry sedimentation and stratification. Gravity separation slurries typically have a high density and coarse solid particles. These characteristics make the slurry prone to sedimentation in pipes or tanks, causing blockages and even disrupting the normal operation of the separator. The agitator tank ensures uniform dispersion of solid particles in the slurry through continuous agitation, providing a stable and uniform feed to the gravity separation equipment.

Unlike flotation and magnetic separation, gravity separation agitation tanks typically do not involve complex chemical reactions or the addition of reagents. Therefore, the requirements for mixing uniformity may be less stringent than for flotation. However, the requirements for suspension capacity and wear resistance are very high.

Technical requirements for gravity separation agitation tanks include: relatively low energy consumption, as their primary function is suspension rather than mixing; reliable mechanical performance to withstand long-term operation with high-density slurries; and a simplified structural design for easy maintenance and cleaning.