FLS has thrown down the gauntlet in the mining sector with the launch of its coarseAIR™ Flotation Cell, a game-changer designed to revolutionize coarse particle recovery in base/precious metals and industrial mineral operations. This isn’t just another piece of equipment; it’s a bold statement about the future of mineral processing, promising significant operational and ESG benefits.
The coarseAIR Flotation Cell is set to disrupt the status quo by increasing plant throughput. FLS claims that by reducing milling requirements, it effectively boosts throughput in the grinding circuit without necessitating substantial capital investment. This is a direct challenge to traditional methods, which often require extensive grinding to achieve similar results. “The coarseAIR Flotation Cell reduces milling requirements, effectively increasing throughput in the grinding circuit without significant capital investment,” FLS asserts. This could mean a seismic shift in how mining companies approach their processing strategies, potentially leading to more efficient and cost-effective operations.
But FLS doesn’t stop at throughput. The coarseAIR Flotation Cell also aims to improve overall recovery rates. By capturing coarse particles typically lost in conventional flotation circuits, it raises overall plant recovery rates. This is a significant development, as it addresses a longstanding issue in the industry. Mining companies have long grappled with the challenge of recovering coarse particles, which often end up in tailings. The coarseAIR Flotation Cell promises to change this, potentially leading to a more sustainable and profitable mining landscape.
Energy consumption is another area where the coarseAIR Flotation Cell shines. A coarser grind results in significant energy savings per tonne of ROM material processed, reducing operating costs and potentially lowering the plant’s carbon footprint. In an industry under increasing pressure to reduce its environmental impact, this is a welcome development. “A coarser grind results in significant energy savings per tonne of ROM material processed, reducing operating costs and potentially lowering the plant’s carbon footprint,” FLS states. This could pave the way for more sustainable mining practices, aligning with global efforts to combat climate change.
The coarseAIR Flotation Cell also has the potential to enhance tailings and water management. Coarse tailings are easier to dewater, allowing more water to be recovered, reducing water loss, and improving tailings stability. This is a critical development, as water management is a significant challenge for many mining operations. By improving tailings stability, the coarseAIR Flotation Cell could help mining companies meet increasingly stringent environmental regulations.
Lance Christodoulou, Global Product Director – REFLUX™ Technologies, underscores the importance of this innovation. “In the face of depleting ore grades, mining companies face the prospect of processing larger volumes of material just to maintain – let alone increase – production levels,” he said. “By improving the efficiency of recovery, the coarseAIR Flotation Cell offers important support for mining companies as they seek to meet the demand for metals and minerals economically and sustainably.”
The coarseAIR Flotation Cell, based on the design of the REFLUX™ Classifier, comprises a low-turbulence, high-density aerated fluidised bed. This design reduces the probability that coarse mineral particles will travel to the tails. Inclined lamella channels effectively separate ore from gangue by leveraging the boycott effect. The coarseAIR Flotation Cell captures particles up to 850 µm in sulphide and >1 mm in industrial minerals, making it ideal for rougher applications to process a coarse ball mill cyclone overflow product. It can also reprocess tailings streams to scavenge valuable coarse particles lost in conventional flotation processes.
The coarseAIR Flotation Cell’s small footprint allows easy integration into existing mineral processing operations. Modular accessory equipment has been specifically designed to facilitate fast and straightforward implementation. No moving internal parts means simpler operation, reduced energy consumption, and lower maintenance requirements than conventional flotation cells. This could lead to a more streamlined and efficient mining process, reducing downtime and increasing productivity.
FLS is not just adding another tool to its belt; it’s setting a new standard. The coarseAIR Flotation Cell is part of FLS’s broader MissionZero initiative, which aims to provide zero-emissions mining by 2030. This includes enhanced ore recovery rates, reduced energy use, and lower water consumption. The coarseAIR Flotation Cell is a significant step towards this goal, and it’s a challenge to the rest of the industry to follow suit.
The coarseAIR Flotation Cell is available in various sizes, from the pilot cA-100 unit to the commercial cA-3000 unit. This range ensures that mining companies of all sizes can benefit from this innovative technology. The launch of the coarseAIR Flotation Cell is more than just a product launch; it’s a call to action. It’s a challenge to the mining industry