Unlocking Value in Flotation

The following article was written by: Alejandro Yáñez, Antti Rinne and Guillermo Bermúdez, Metso. (Review the developments in flotation technologies that are allowing the efficient recovery of fine and ultra-fine particles). 

With growing demand for metals, miners are reevaluating their mineral processing flowsheets to optimize performance. Meanwhile, greenfield and brownfield projects are assessing new, complex ore types that require fine particle grinding to meet metallurgical targets. 

One example is Optimal flotation performance, which occurs within specific size ranges, typically between 25 and 150µm depending on the application. Particles smaller than 25µm are considered to be fine or ultra-fine particles. These particles have distinct characteristics that require specific flotation conditions for effective recovery.

The Concorde Cell™ flotation technology by Metso is designed to efficiently recover fine and ultra-fine particles and previously unachievable ore value. The Concorde Cell technology is the first fine and ultra-fine flotation solution for more finely disseminated and complex ore bodies that have been inaccessible with previous mineral-processing flowsheets (gold, copper, nickel, platinum, silver, lead, zinc and molybdenum, for example). 

Revolutionizing Flotation Efficiency

In the realm of mineral processing, flotation efficiency is paramount, and Metso's Concorde Cell stands as a testament to its commitment to continue pushing the boundaries of what is achievable.

The Concorde Cell is an advanced flotation technology designed to optimize the mineral recovery process. It is a high-intensity pneumatic flotation cell that recovers unachievable fine and ultra-fine particles, resulting in significant revenue gains for mining operations. The Concorde Cell produces very high shear and extremely fine bubbles for faster flotation kinetics and improved selectivity, which increases recovery in particles under the 25 micron range. Furthermore, Concorde Blast Tubes™ treat 100% of fresh feed combined with tailings recycling for improved performance, allowing for finer grinding to gain additional liberation without the risk of valuable particles being reported to tailings.

Concorde technology benefits from induced supersonic shockwaves that exhibit notable attributes, including high energy dissipation and the generation of a finer distribution of bubble sizes. This phenomenon is observed as it contributes to enhanced efficiency in mineral flotation processes.

Forced air provides a key advantage in mining operations, allowing for higher air-to-pulp ratios. This aspect is pivotal in optimizing flotation conditions, resulting in improved mineral recovery and separation efficiency.

Another noteworthy innovation is internal tailings recycling, coupled with integrated level control mechanisms that operate independently of flotation air control mechanisms. This feature not only enhances the overall operational control but also facilitates a more streamlined and efficient management of tailings, contributing to sustainable and resource-efficient mining practices.

Elevating Efficiency in Existing Pneumatic Cells

A direct retrofit from a self-aspirated pneumatic flotation cell to Concorde Cell technology is possible with a Concorde Blast Tube upgrade. A Concorde Blast Tube upgrade makes this transition seamless, offering compatibility with both circular and rectangular self-aspirated pneumatic cells.

For mining operations grappling with complex ores that were previously inaccessible, upgrading existing cells with the Concorde Blast Tube offers an ideal solution. This versatile upgrade is tailored to address the intricacies of various mineral processing flow sheets, providing a strategic pathway to enhance efficiency and address the challenges posed by diverse ore types.  There are also no moving parts, making it easy to maintain.

Metso's commitment to an integrated approach is reflected in its comprehensive global support services, providing mining companies with the expertise needed to flawlessly incorporate Concorde technologies into their existing operations. Training programs, OEM spare parts and ongoing technical support ensure that mining personnel can harness the full potential of these innovations.

Enhancing Flotation Circuit Performance for Inaccessible Ores

Beneficiation plants grappling with inaccessible ores face unique challenges in optimizing flotation circuit performance. Here is a range of useful tips to address these challenges and improve results from existing flotation circuits.

Ore characterization: Ore characterization tools, including mineral liberation analysis and scanning electron microscopy, allow operators to comprehensively understand inaccessible ore mineralogy. 

Reagent optimization: This allows mining professionals to fine-tune reagent formulations. By evaluating different reagent types and dosages, operators can achieve optimal selectivity, improving the recovery of valuable minerals while minimizing the impact on gangue minerals.

Grind size optimization: Grinding solutions contribute to the improved liberation of minerals in inaccessible ores. Tailoring the grind size optimizes the flotation process by enhancing mineral exposure and facilitating more effective separation in the flotation cells.

Froth management: Froth management strategies, incorporating advanced froth formulations and dosage control, enhance froth stability and selectivity. This results in improved flotation performance, especially in challenging scenarios presented by inaccessible ores.

Automation and process control:  Process control and automation technologies ensure real-time monitoring and adjustment of flotation circuit parameters. This enhances stability, minimizes variations, and optimizes overall performance in response to the dynamic nature of inaccessible ores.

Sustainable water solutions:  Water recycling and conservation through innovative solutions, addressing the water scarcity issues often associated with mining operations. Implementing efficient water management practices contributes to both environmental sustainability and operational cost reduction.

Sensor technologies: The incorporation of sensor technologies, such as online particle size analyzers and mineral analyzers, enables real-time data collection. This data-driven approach facilitates quick and informed decision-making, ensuring optimal flotation circuit adjustments based on the ore's changing characteristics.

Continuous improvement programs: Regular monitoring, data analysis, and optimization efforts are integral to ensuring that flotation circuits remain adaptable to variations in inaccessible ore characteristics and operating conditions.

Advanced flotation technologies: Advanced flotation technologies, such as high-intensity pneumatic flotation, offer improved selectivity, higher recovery rates, and greater adaptability to challenging ore types. These technologies provide a pathway to enhanced circuit performance.

A comprehensive suite of technologies offers mining professionals a holistic approach to enhancing flotation circuit performance for inaccessible ores. By leveraging these solutions, operators can achieve improved recoveries, reduce environmental impact, and sustain operational efficiency in the face of challenging ore types.

Integration of Concorde Technologies for Synergistic Benefits

Over the last 50 years, Metso has successfully introduced new flotation technologies to the mineral processing industry. Combining the well-proven TankCell® mechanical flotation technology with Concorde Cells is a low-risk and high-benefit approach for mineral processing flowsheets. The Concorde Cell's smaller plant footprint and ability to produce higher-grade concentrates directly influence downstream processing efficiency and sustainability. This translates to increased throughput and reduced energy consumption in subsequent stages of the mineral processing circuit.

Prospects and Sustainability Considerations

Metso's Concorde Cell and Concorde Blast Tube represent a leap in mining technologies, seamlessly combining enhanced efficiency and sustainability. With its commitment to ongoing research, development, and comprehensive support services, Metso continues to provide mining operations with the tools needed to thrive in an ever-evolving landscape. The Concorde technologies are not just technological advancements; they signify a new era in responsible and efficient mining practices.