How To Make Your Flotation Circuit Twice as Strong

In Flotation, we use a formula to size the circuit we need to chase the recoveries we want. R = 1 – exp(-k.t)...

Recovery is regarded as a function of residence time, t.

Then we optimise the grind size and get the reagents right.

And, voila!

...We quietly treat the flotation rate, k, as a constant...

And that means we design our flotation circuit with as many conventional cells as it takes to process the volume we need in thetime that's given by the equation... plus a 2.5 scale up factor, "just because".

After all, once we’ve optimised grind and reagents, we don’t change kinetics… do we?

But we can! That flotation rate, k, is not meant to be a constant. Jameson Cell lets us lets change it. And when we do, we get a massive jump in results.

Let’s step back for a second. What’s wrong with how things are done? They HAVE worked, haven’t they?

In a way.

From an engineering view, it’s easier to build things bigger than to make them more efficient. Cell sizes have increased from 2m3 in 1940, up to 630m3 in 2018.

But as ore grades worsen, we can’t keep getting bigger.

If this trend continues, we’ll see volumes above 1,000m3 by 2030. And that’s getting ridiculous if we process it the old way. Concentrators are already large. To build them even larger is too much in costs, carbon footprint and energy.

So one of our Jameson Concentrator experts, Dr Chris Anderson, presented “How the Jameson Concentrator Changes Circuit Design to Deliver More from Less” at MetPlant2023 this month.

The Jameson Concentrator features a full circuit of Jameson Cells. And while most people are aware of the Jameson Cell’s high performance in cleaning duties, many people are not aware of its performance in the rougher and scavenging duties.

Truth is, Jameson Cell can produce final grade from one cell!

So if we design a flotation circuit entirely of Jameson Cells, what we achieve is an incredible improvement.

Recoveries and volumes are no longer just about ‘t’ and a multiple of conventional cells.

Instead, a small circuit of Jameson Cells can do the work of a large conventional circuit. Because we change ‘k’.

Chris took the audience through a case-example performed by Ausenco. A comparison designed to process the same scenario -

The old way… 5 rougher-scavengers, 12 cleaners, 3 third-stage cleaners and a regrind mill.
The new way… 2 rougher scavengers, 2 cleaners, 1 recleaner and a regrind mill.

It got the same results from less than half the asset!

The new way, using Jameson Cells, replaced a circuit that had an area of 3,744m2 with one less than half that at 1,628m2. And instead of a height of 24m it was just 16m.

Concrete was 45% less and equipment and steel were 71% less. Capital costs were 24% less. Power consumption was 36% less. CO2e was 56% less during construction and gave a 36% saving over the estimated life-of-mine.

By changing the circuit design, they got a 56% reduction in CO2e emissions during construction and a 36% reduction in CO2e emissions during operations.

These are phenomenal achievements!

An EPCM delivering these or an Operation enjoying them are going to be incredibly competitive.

And that gives all of us a safer and more sustainable solution to meet the industry’s processing needs.

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Learn more about the Jameson Processing Complex...
https://www.glencoretechnology.com/en/technologies/jameson-cell

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