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Last updated on 2024年5月24日

What are the best flotation machines for separating valuable minerals from gangue in ore processing?

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In the complex world of ore processing, separating valuable minerals from the gangue is a critical step, and the efficiency of this process can significantly affect a mine's profitability. Flotation machines play a pivotal role in this separation process by utilizing differences in the surface properties of particles. The right flotation device can mean the difference between a high-yield operation and one that falls short, making the choice of equipment essential for mining engineers.

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Enzo Artone

Minerals Processing Engineer/Architect
Wiku Padmonobo Ir. FAusIMM

Mineral Processing & Metallurgy - Indonesia Mining Professional Association (PERHAPI)

1 Mechanical Cells

Mechanical flotation cells are the stalwarts of the mineral processing industry, thanks to their robust design and proven efficiency. These machines agitate the slurry of ore and water to create bubbles, which adhere to the valuable minerals and rise to the surface, forming a froth that can be skimmed off. The impeller-driven agitation also ensures that the particles are evenly distributed in the cell, increasing the likelihood of contact between the ore and the bubbles.

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Wiku Padmonobo Ir. FAusIMM

Mineral Processing & Metallurgy - Indonesia Mining Professional Association (PERHAPI)
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Great conventional machine to separate minerals. The process after flotation is still an art. Especially with many limitation on environmental concerns. As well as reagents (frother, collector) are not always easy to purchase and not always cheap to be economically viable

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Enzo Artone

Minerals Processing Engineer/Architect
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High energy consumers and maintenance intensive but have served the industry well. Air addition very difficult to control as well as level control sine waves

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2 Column Cells

Column flotation cells are a newer innovation that offers some advantages over their mechanical counterparts. These tall, slender vessels do not rely on mechanical agitation but instead use air sparging and wash water to create a cleaner, more selective froth. The lack of moving parts can lead to lower operational costs, and their ability to operate at finer particle sizes can improve recovery rates for certain mineral types.

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Enzo Artone

Minerals Processing Engineer/Architect
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Misunderstood and misapplied, biggest bang for buck is in eliminating Rougher Cleaner Scavenger mentality. Offer great pulp level and air control

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3 Jameson Cell

The Jameson Cell is a high-intensity flotation device that excels in fine particle recovery and is particularly effective in coal flotation. Its unique design combines a downcomer, where slurry is jetted into the cell at high velocity to create contact between air bubbles and particles, with a separation tank where the froth is collected. The Jameson Cell's small footprint and high throughput make it an attractive option for new installations and upgrades alike.

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4 Pneumatic Cells

Pneumatic flotation cells, such as the self-aspirated varieties, offer a simpler alternative to the mechanically agitated cells. These cells use the natural aeration of pulp to create bubbles, which reduces energy consumption and maintenance requirements. Their design often allows for easier scale-up from laboratory tests to full-scale operations, making them a practical choice for new projects.

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Wiku Padmonobo Ir. FAusIMM

Mineral Processing & Metallurgy - Indonesia Mining Professional Association (PERHAPI)
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It is expected to be more effective by ultrafine buble and more time for the flotation mechanism to work, less carry over. As well as easier to control. This technology is also occupied very small footprint. Often being used in combination with conventional mechanical flotation circuit as final cleaner, because the capability of dealing with ultrafine mineral particles.

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5 Hybrid Machines

Hybrid flotation machines combine the benefits of both mechanical and pneumatic cells, aiming to maximize mineral recovery while minimizing operational costs. These machines typically feature an initial cell that operates with mechanical agitation to ensure thorough mixing, followed by pneumatic cells that provide gentler treatment and improved selectivity of the valuable minerals.

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6 Advanced Control

Advanced control systems are integral to optimizing the performance of flotation machines. Modern control strategies use real-time data from sensors within the flotation cells to adjust operational parameters such as air flow, reagent addition, and froth depth. This adaptive approach allows for consistent performance even when ore characteristics change, ensuring that the separation process remains as efficient as possible.

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Wiku Padmonobo Ir. FAusIMM

Mineral Processing & Metallurgy - Indonesia Mining Professional Association (PERHAPI)
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The advanced control might start with sensors. While major parameters have sensors, digitalization and automation should applied, Programmable Logic Control and DCS (distributed control system) are common tools used by many mineral operations. Automation still need many human involvement in setting the action to response informations that convey by the field sensors, PLC and DCS. This lead to human error or failure in high risk decision. The artificial intelligent is now being used to reduce human decision involvement.

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7 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?

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What are the best flotation machines for separating valuable minerals from gangue in ore processing?

1

2

3

4

5

6

7

1 Mechanical Cells

2 Column Cells

3 Jameson Cell

4 Pneumatic Cells

5 Hybrid Machines

6 Advanced Control

7 Here’s what else to consider

Mining Engineering

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What are the best flotation machines for separating valuable minerals from gangue in ore processing?

1

2

3

4

5

6

7

1 Mechanical Cells

2 Column Cells

3 Jameson Cell

4 Pneumatic Cells

5 Hybrid Machines

6 Advanced Control

7 Here’s what else to consider

Mining Engineering

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