How do you select flotation cells for a mining engineering application?

3 Flotation cell number

The number of flotation cells in a circuit determines the layout and the degree of flexibility and control. The flotation circuit can be arranged in different ways, such as rougher-scavenger-cleaner, rougher-cleaner-recleaner, or bulk-sulphide-separation. The number of cells in each stage affects the recovery, the grade, and the selectivity of the flotation process. The more cells in a stage, the higher the recovery and the lower the grade, and vice versa. The number of cells also affects the ability to adjust the operating parameters, such as the air flow rate, the pulp level, the reagent dosage, and the froth depth. The optimal cell number depends on the ore variability, the metallurgical objectives, and the economic constraints.

4 Flotation cell design

The design of the flotation cells includes the shape, the volume, the aspect ratio, the internal components, and the external features. The shape of the cell can be rectangular, cylindrical, or U-shaped, depending on the space availability and the flow pattern. The volume of the cell determines the size and the number of cells required for a given capacity. The aspect ratio is the ratio of the cell height to the cell diameter, and it affects the mixing and the bubble-particle collision. The internal components are the rotor-stator, the sparger, the baffles, and the impeller, and they influence the air dispersion, the turbulence, and the energy consumption. The external features are the feed box, the discharge box, the froth crowder, and the launder, and they affect the pulp distribution, the froth removal, and the froth quality. The optimal cell design considers the hydrodynamic and mechanical aspects of the flotation process.

5 Flotation cell selection criteria

The selection of flotation cells for a mining engineering application involves the evaluation and comparison of different options, based on some criteria and indicators. Some of the criteria are technical, such as the ore type, the mineralogy, the liberation size, the flotation kinetics, the reagent scheme, and the water quality. Some of the criteria are economic, such as the capital cost, the operating cost, the maintenance cost, and the revenue. Some of the criteria are environmental, such as the energy consumption, the greenhouse gas emissions, the water consumption, and the tailings management. Some of the indicators are performance-based, such as the recovery, the grade, the concentrate quality, and the mass pull. Some of the indicators are efficiency-based, such as the air utilization, the power intensity, the specific flotation rate, and the enrichment ratio. The optimal cell selection meets the technical, economic, and environmental requirements, and maximizes the performance and efficiency indicators.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?