Maximizing bubble segregation at high liquid fluxes

This study is concerned with a common class of problem involving two phase separation of a dispersed gas flow from a continuous liquid flow under extreme processing conditions. Relatively fine spherical bubbles of order 500 µm were generated in the presence of a surfactant under a high shear rate within a rectangular, multi-channeled, cuboidal downcomer. Liquid fluxes, as high as 176 cm/s through each channel of the downcomer, sheared bubbles from a sintered surface mounted flush to the channel wall before disengaging the downcomer flow into a vertical vessel. Both high feed fluxes, up to 15 cm/s, and high gas fluxes, up to 5.5 cm/s, ensured a high gas holdup beneath the downcomer and the hindered rising of the bubbles. Enhanced bubble-liquid segregation was achieved using an arrangement of parallel inclined channels incorporated below the main vertical chamber. This novel device, referred to as the Reflux Flotation Cell, prevented the entrainment of bubbles to the underflow, and significantly reduced the liquid flux to overflow, even in the absence of a conventional froth zone. Extreme upward bubble surface fluxes of up to 600 s⁻¹ were achieved, while counter-current downward liquid fluxes reached 14.4 cm/s, arguably four times the bubble terminal rise velocity. Hence successful phase separation was achieved while operating well beyond the so-called flooding condition arising from extreme levels of gas and feed fluxes. This hydrodynamic arrangement should find application in increasing surfactant extraction rates in foam fractionation and ion flotation, gas absorption, and even particulate flotation.