Advanced Spray Solutions for Mining Operations: Froth Suppression
Spray Solutions – When a leading coal mines operation required a robust spray system for their de-aeration tank, they sought a custom-engineered solution to perform reliably under demanding mining conditions.
The Challenge
Mining environments demand spray systems that excel in low-pressure and low-flow conditions while withstanding harsh settings where process water contains high levels of solids. Standard equipment often fails to deliver, leading to frequent maintenance and inconsistent performance. The Mine needed a specialized spray header designed to provide uniform coverage and sufficient impact for effective froth suppression, all while minimizing maintenance requirements.
The Solution
Engineers designed a custom spray bar fitted with ¾-inch full-cone spray nozzles, selected for their superior performance in froth suppression. These spray nozzles produce a full-cone spray pattern with medium-to-large droplets (200–500 μm), ensuring even distribution across the de-aeration tank. With a spray angle of 60–120 degrees, they deliver high-impact spray to break down froth effectively, critical for maintaining process efficiency in flotation systems. The nozzles are constructed from corrosion-resistant stainless steel or hardened alloys, featuring large free passages to prevent clogging when handling water with high solids content (up to 10% particulate matter). This design ensures consistent performance in abrasive conditions, with flow rates of 0.5–3 GPM (1.9–11.4 LPM) at pressures as low as 20–80 PSI, optimizing water use. The spray bar was built from lightweight galvanized tubing, offering durability and ease of installation without compromising structural integrity.
Each spray bar was precision-welded to meet ISO 3834 standards for weld quality and hydraulically tested at 1.5 times operating pressure to ensure leak-free performance before delivery.
The Result
The custom spray bar integrated seamlessly into the Mine’s de-aeration system, delivering consistent performance and an extended service life of up to 12–18 months in harsh conditions. The tailored design, centered around the high-performance full-cone spray nozzles, ensured optimal froth suppression, reducing downtime by up to 30% and improving operational efficiency by addressing the site’s specific environmental and process challenges.
Recognizing that every mining operation faces unique conditions, advanced spray solutions leverage high-performance spray nozzle technology to solve complex challenges and deliver reliable, long-lasting results.
For further assistance, contact experts in spray technology.