How To Make Your Flotation Circuit Twice as Strong

Flotation circuits are the backbone of many mineral processing operations, and their efficiency directly impacts the recovery of valuable minerals and overall mineral separation. Traditionally, flotation cells have been designed to meet the required recovery based on ore type, grind size, and reagents. However, as ore grades decline and operational costs rise, the industry is seeking more effective ways to boost performance. This is where innovations like the Jameson Cell can change the game. In this article, we'll discuss how this technology makes your flotation circuit twice as strong by improving performance, reducing costs, and enhancing sustainability.

How Does a Flotation Circuit Work?

A flotation circuit is designed to separate valuable and desired minerals from gangue (waste rock) using a process called froth flotation. In this process, ground ore is mixed with water and chemicals in flotation cells, where air bubbles are introduced into the slurry. These bubbles attach to the mineral particles, lifting them to the surface, forming a froth that is then skimmed off. The minerals of interest are recovered in the concentrate, while the waste materials sink to the bottom and are discarded as tailings.

Each flotation circuit typically consists of stages like rougher, scavenger, and cleaner flotation, each designed to separate the minerals progressively and enhance their purity. The efficiency of this process is critical to maximise mineral recovery and reduce the volume of tailings.

How do you Calculate Flotation Recovery?

Flotation recovery is a measure of the amount of valuable mineral that has been separated from the ore relative to the amount initially present. It is calculated using the formula:

Recovery (R) = (Concentrate Grade × Concentrate Tons) / (Feed Grade × Feed Tons)

Where:

• Concentrate Grade is the percentage of valuable minerals in the concentrate.

• Concentrate Tons is the mass of material recovered into the concentrate.

• Feed Grade is the percentage of valuable minerals in the original ore.

• Feed Tons is the total mass of ore processed.

A higher flotation recovery means more valuable minerals are being recovered, which translates into greater profitability for the operation.

How to Make Your Flotation Circuit Strong

To build a robust flotation circuit, the goal is not simply to increase its size but to improve its efficiency. The Jameson Cell is a game-changer in this regard. Unlike traditional flotation cells that increase in size to accommodate larger volumes, the Jameson Cell can boost flotation performance by increasing the flotation rate, ‘k’, which leads to higher recoveries and better concentrate grades without scaling up the circuit.

By incorporating Jameson Cells into your flotation circuit, you can achieve significant reductions in energy consumption, space requirements, and overall costs. A well-designed circuit that uses Jameson Cells can provide high-performance flotation with fewer units, resulting in a smaller, more efficient setup.

For example, replacing multiple conventional flotation cells with Jameson Cells has shown to reduce the size of flotation circuits by up to 60%, significantly cutting down on capital costs, energy use, and maintenance. These savings are further amplified over the life of the mine, offering substantial operational cost reductions.

How Does the Jameson Cell Improve Flotation Performance?

The Jameson Cell stands out in the flotation industry due to its ability to increase flotation efficiency by changing the dynamics of the flotation process. Unlike traditional flotation cells that require large volumes and long residence times, the Jameson Cell creates smaller bubbles, offering six times more surface area for the particles to attach to. This leads to a faster flotation process with higher recovery rates.

Jameson Cells operate with no moving parts, ensuring maximum availability and easy maintenance. The cell’s high-performance design allows it to be used across a wide range of applications, from base and precious metals to industrial minerals and coal.

A key feature of the Jameson Cell is its ability to change the flotation rate, ‘k’, enabling operations to significantly improve recoveries. For example, the Jameson Concentrator, which integrates a series of Jameson Cells into one continuous flotation circuit, reduces circuit complexity while maintaining high recovery rates.

In many instances, Jameson Cells have replaced large conventional flotation circuits, offering a more efficient and cost-effective solution. The Jameson Cell’s advanced design reduces the need for oversized equipment, lowering capital costs, energy consumption, and the environmental impact of mining operations.

For more information on how Jameson Cells can improve your flotation circuit, visit our Jameson Cell product page.