How Simple Maintenance and Operational Changes Grew Jameson Cell Yield by $50M

When new mining operators took over a long-running coal flotation plant, they found that the existing Jameson Cells were still delivering low-ash product sitting within the 6-8% target, yet overall yield hovered around 55–65%, meaning valuable coal was not recovered and lost to tailings, affecting downstream processes. Keen to restore world-class flotation performance, they invited Glencore Technology to investigate.

Our specialists arrived with two clear priorities: early detection of mechanical/operational inefficneices and a roadmap for flotation optimisation. Combining real-time sensor readings with historical data analysis and a visual audit, we discovered the core flotation equipment; downcomers, air distributors and the feed pipe network, was no longer running under true “normal operating conditions." Wear-induced fouling throttled pulp flow; restricted air inlet paths produced fewer, larger air bubbles, limiting the formation of mineral-laden bubbles essential for high recovery.

The Hunt for More Yield

All mineral processing assets drop in performance over time and require periodic optimisation efforts. This mining operation’s Jameson Cells, commissioned in the early 2000s, were no different.

Glencore Technology was re-engaged to complete operational and mechanical audits. Initial inspection of the Jameson Cells indicated that general wear and tear and mechanical condition were contributing to the decline in cell performance.

Every asset in mineral processing drifts over long periods of continuous operation, and this bank of flotation cells, commissioned in the early 2000s, was no exception. Glencore Technology's audit blended mechanical checks with process diagnostics to pinpoint where shortened service life was colliding with rising maintenance costs.

The inspection highlighted some standard auxiliary equipment required replacement, and key components were identified as needing inspection. All of these were low-cost fixes.

How They Achieved It

Following our audit, the operation completed maintenance to ensure the normal operation of each flotation cell and maximise overall flotation performance across the plant:

• Blocked downcomers in the flotation cells were cleared without taking the cells offline, preventing lost mining operations time.

• Solid build-up of fine particles was removed from the air lines, restoring consistent airflow and lowering power consumption.

• Worn Air Isolating Slurry Eliminating (AISE) valves were replaced to reduce future product build-up in the air distribution system.

• The air distributor underwent inspection and cleaning to ensure even distribution of air.

• Diffusers were replaced or realigned to improve distribution of froth in the Jameson Cell tank.

• The site operations team received targeted training on flotation process fundamentals, real-time monitoring, data analysis, and timely corrective actions, raising worker productivity and safety.

Given the high turnover of operators typical of the mining industry, the training helped create a quick and solid understanding of some fundamental principles and troubleshooting steps for new mineral processors.

Finally, the team discussed site-specific operating strategies that could improve performance and developed an implementation plan designed to significantly impact metallurgical performance, reduce operating costs, and safeguard valuable minerals recovery for the flotation plant.

They earned themselves a 15% increase in flotation yield (flotation concentrate recovery) while keeping ash within the 6-8% target range. Based on an average coking coal price of $262 USD/tonne, this uplift in the flotation process equates to about $144,000 in extra revenue per day for the mining operation.

Over an entire year, this sustained improvement in metallurgical performance could deliver around $50 million in additional coal product.

Crucially, the cost of the site visit, regular inspections, replacement parts, and labour for maintaining equipment came to less than $40,000, well under a single day’s extra revenue generated by the Jameson flotation cells running at peak efficiency.

Performance Comparison: Before vs After Visit

Before Visit:

• Average Flotation Yield: 56%

• Average Flotation Production Ash: 5.3%

• Flotation Tailings: 72 tph

After Visit:

• Average Flotation Yield: 72%

• Average Flotation Production Ash: 6.2%

• Flotation Tailings: 47 tph

• Revenue increase per day: +$144,000

The Value of Preventative Maintenance

These improvements highlight the value that can be obtained by completing regular preventative maintenance on Jameson Cells.

An operation can avoid high-capital, high-risk alterations or replacements of these flotation machines and instead invest a small sum in maintaining equipment such as air distributors, air lines and slurry lenses. Routine test work, adjustments to reagent dosages, and checks on particle-size distribution and feed rate are important to keep a Jameson Cell operating optimally and uphold metallurgical efficiency.

This approach delivers a significant impact on performance and flotation cell efficiency, making it a huge win and a great savings for forward-thinking mining companies.