Effects of micro- and nano-bubbles on the flotation separation of unburned carbon from coal fly ash

Nanobubble technology has found extensive use in enhancing the flotation efficiency of various minerals. The utilization of nanobubbles in flotation encompasses bulk nanobubbles, surface nanobubbles, and microbubbles; however, a comprehensive comparison of their respective roles is lacking. Furthermore, there is a dearth of studies on employing nanobubble systems in the flotation of coal fly ash. The coal fly ash characters were initially studied to reveal its ultrafine size (d50: 24.80 μm) and porous structure that includes a multitude of hydrophilic functional groups. These attributes contribute to the inadequate hydrophobicity of unburned carbon within the ash. Subsequently, the effects of different collector types, frother types, and air flow rates on the efficiency of carbon removal using conventional flotation methods were examined. Comparative analysis showed that conventional flotation using diesel oil outperformed that which employed kerosene as the collector. Additionally, higher carbon removal efficiency was achieved using MIBC, with a longer carbon chain length, as the frother, as opposed to sec-Octyl alcohol. Furthermore, a direct relationship between air flow rate and coal fly ash flotation performance was observed – higher air flow rates corresponded to improved flotation outcomes. Finally, a comparison between conventional flotation and nanobubble-assisted flotation (utilizing bulk nanobubbles, surface nanobubbles, and micro-nanobubbles) was conducted. Remarkably, micro-nanobubble flotation yielded the most promising results, with the lowest loss-on-ignition in flotation tailings (3.15%) and the highest removal efficiency of unburned carbon (85.01%). These findings satisfied the loss-on-ignition requirements of Grade I fly ash standards.