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In the absence of any significant legislation, paper recycling in South Africa has grown to a respectable recovery rate of 43% in 2008, driven mainly by the major paper manufacturers. Recently introduced legislation will further boost the recovery rate of recycled paper. Domestic household waste represents the major remaining source of recycled paper. This source will introduce greater variability into the paper streams entering the recycling mills, which will result in greater process variability and operating difficulties. This process variability manifests itself as lower average brightness or increased bleaching costs. Deinking plants will require new techniques to adapt to the increasingly uncertain composition of incoming recycled paper streams. As a developing country, South Africa is still showing growth in the publication paper and hygiene paper markets, for which recycled fibre is an important source of raw material. General deinking conditions pertaining to the South African tissue and newsprint deinking industry were obtained through field surveys of the local industry and assessment of the current and future requirements for deinking of differing quality materials. A large number of operating parameters ranging from waste mixes, process variables and process chemical additions, typically affect the recycled paper deinking process. In this study, typical newsprint and fine paper deinking processes were investigated using the techniques of experimental design to determine the relative effects of process chemical additions, pH, pulping and flotation times, pulping and flotation consistencies and pulping and flotation temperatures on the final deinked pulp properties. Samples of recycled newsprint, magazines and fine papers were pulped and deinked by flotation in the laboratory. Handsheets were formed and the brightness, residual ink concentration and the yield were measured. It was determined that the type of recycled paper had the greatest influence on final brightness, followed by bleaching conditions, flotation cell residence time and flotation consistency. The residual ink concentration and yield were largely determined by residence time and consistency in the flotation cell. The laboratory data generated was used to train artificial neural networks which described the laboratory data as a multi-dimensional mathematical model. It was found that regressions of approximately 0.95, 0.84 and 0.72 were obtained for brightness, residual ink concentration and yield respectively. Actual process data from three different deinking plants manufacturing seven different grades of recycled pulp was gathered. The data was aligned to the laboratory conditions to take into account the different process layouts and efficiencies and to compensate for the differences between laboratory and plant performance. This data was used to validate the neural networks and select the models which best described the overall deinking performances across all of the plants. It was found that the brightness and residual ink concentration could be predicted in a commercial operation with correlations in excess of 0.9. Lower correlations of ca. 0.5 were obtained for yield. It is intended to use the data and models to develop a predictive model to facilitate the management and optimization of a commercial flotation deinking processes with respect to waste input and process conditions. / Thesis (Ph.D.)-University of KwaZulu-Natal, Durban, 2011.

The coalburg seam coal is an example of difficult to float bituminous coal. Laboratory tests conducted on coalburg flotation feed sample revealed recovery values around 28% with 15% product ash when using fuel oil as collector under natural pH conditions. A detailed study showed that increasing pH from natural value of 5.6 to 7.5 provided a significant improvement in recovery of approximately 32 absolute percentage points. The improvement is believed to be result of the release of humic acids from the surface and the dispersion of clay particles thereby leaving a more hydrophobic surface. Based on the tests conducted with various commercially available collectors, oleic acid was selected as a model collector for oxidized coals. Conventional flotation tests found an increase in combustible recovery of 10 absolute percentage points above the pH improvement using 4:1 blend of fuel oil and oleic acid. The problem of higher ash in conventional cell product due to entrainment was minimized by the use of wash water in a flotation column. A flotation concentrate containing less than 7.5% ash was produced while recovering around 75% of the combustible material. Further testing using fatty acids-fuel oil blend also showed evidence of a near 200% increase in flotation rate.

Production of platinum and associated metals is a major source of revenue for South Africa. Significant losses occur in the concentrating stage (10 to 15 per cent) and this research is focused on optimising platinum flotation. Research begins by conducting laboratory batch flotation tests. However, subsequent pilot-plant tests often produce different results. It is believed these differences arise from the artificial nature of laboratory techniques. This project was focused on improving flotation techniques in the laboratory. The largest source of platinum in South Africa is the UG2 reef and two samples of this ore were used for testing: ‘good’ and ‘bad’ ore. These had different characteristics with regards to the recovery of PGMs and the presence of talc. The latter is an unwanted floatable mineral, which must be depressed to prevent excessive recovery. The conventional laboratory test procedure makes use of batch tests in various sizes of flotation cells. The procedure was made more realistic, by using four stages of flotation, rather than just two, to mimic a typical platinum flotation plant. The use of four stages made it possible to separate the fast-floating and slow-floating stages and to control froth conditions accordingly. Attention was also given to the fact that in laboratory tests, water is often added to the ‘cleaner’ stage of flotation, to make up the level. Experiments showed that this dilution, which does not take place in practice, had a significant impact on overall efficiency. A method of measuring frother concentration was developed and used to determine the realistic level of frother in cleaning tests. Tests at these levels of frother concentration showed that significant improvements could be made to plant performance, by making use of a thickener to reduce the frother concentration in the cleaning stages. The improved test procedure was used on both good and bad ores, and the effect of regrinding was also tested. A combined solids recovery of 2 % over both cleaners was targeted for all test work. At this recovery, the regrinding of the bad ore increased the PGM recovery from 67 to 76 per cent at the cost of an additional 8 g/t depressant. An investigation of the effect of frother concentration in the cleaning stage, using good ore, demonstrated that that rejection of chromite could be improved significantly by reducing frother concentration. The tests mimicked the use of a thickener to separate some of the water with a high concentration of frother. Tests conducted on the good ore showed that use of two thickeners, as opposed to none, reduced the Cr2O3 content of the final concentrate from 4.2 to 3.2 per cent for the equivalent concentrate mass and PGM recovery. The depressant requirement was also reduced from 67 to 55 g/t. These tests provided insight on how to improve performance on a platinum flotation plant, particularly when floating the bad ore.

Dissolved and Colloidal substances (DisCo) and metals are released from wood during thermomechanical pulp (TMP) production. The mechanical treatment causes that these components have a tendency to accumulate in process waters, as the water circulation systems in integrated paper mills are being closed. Disturbances such as pitch depositions on the paper machine (pitch problems), specks in the paper, decreased wet and dry strength, interference with cationic process chemicals, and impaired sheet brightness and friction properties appear in the presence of DisCo substances. The presence of transition metal ions such as manganese results in higher consumption of bleaching chemicals (hydrogen peroxide) and lowers the optical quality of the final product, and addition of complexing agents, such as EDTA or DTPA, to prevent this is needed. The never ending trends to decrease water consumption and increase process efficiency in pulp and paper production stress that it is very important both to know the effects of wood substances on pulping and papermaking and to be able to remove them in an efficient way. Carried out investigations presented in this thesis show that the lipophilic extractives can be removed from TMP press water to high extent. A 90% decrease in turbidity and a 91% removal of lipophilic extractives from TMP press water can be obtained by addition of a cationic surfactant as foaming agent during flotation. Additionally, fibres located in TMP press water are not removed with the foam fraction but purified. A retained concentration of hydrophilic extractives in the process water indicates that the flotation is selective. Moreover, by introduction of a new recoverable surface active complexing agent, a chelating surfactant, manganese ions in the form of chelates can be successfully removed from the pulp fibres and separated from the process water in the same flotation process. iii The findings presented above indicate new possibilities for internal water cleaning and decreased emissions to water if flotation technology is applied in an integrated mechanical pulp mill. / ReGain/FORE

The presence of hydrodynamically generated air bubbles has been observed to enhance fine particle flotation in a high intensity agitation (HIA) flotation cell. In this study, the cavitation in an HIA cell, used in our laboratory, is studied by hydrodynamic computational fluid dynamics. Different types of impellers are studied to obtain flow characteristics such as velocity and pressure distributions and turbulent dissipation rate in a two-baffled HIA cell. A cavitation model in conjunction with a multiphase mixture model is used to predict the vapor generation in the HIA cell. Cavitating flow is simulated as a function of revolution speed (RPM) and dissolved gas concentration to understand the dependency of hydrodynamic cavitation on these operating parameters. For comparison, cavitation in a pressure driven flow through a constriction is also modeled. A population balance model is used to obtain bubble size distributions of the generated cavities in a flow through constriction. / Chemical Engineering