Abstract:

Flotation is still the principal separation process in the mining industry although it was first implemented over a century ago. In recent years, existing flotation circuits have been modernized with newer technological advancements that improve metallurgical performance. However, the current drive for more sustainable mineral processing aligns the optimization of existing flotation circuits with sustainability goals.

Process optimization and retrofits deliver sustainability benefits to existing flotation circuits without increasing their footprint. Optimizing a flotation cell involves verifying operational aspects such as airflow rate, froth bed and mixing mechanism rotation speed to maximize its performance, up to the machine’s design criteria. When these limitations have been reached, flotation cell retrofits may unlock additional opportunities. Flotation upgrades and modernizations can have a direct impact on decreasing cell’s energy consumption which can have a direct impact on flotation circuit’s decarbonization, i.e., by replacing the drive system with a newer and more efficient version, or by decreasing the blower’s power consumption and optimizing the froth zone through froth launder retrofits. In these cases, the increased separation efficiency of valuable materials allows for an increase in concentrate production. That improves the concentrator plant’s overall energy consumption per tonne of concentrate. This paper summarizes ways to decarbonize a given flotation cell through process optimization, cell drive system upgrades and froth launder retrofits. The impact digitalization of flotation operations offers for decarbonizing the mining industry is also discussed in detail.

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Matt Gallimore