This month’s Spotlight Feature Article focuses on the area of flotation, with Paul Moore looking at newer designs in the latest ‘future flowsheets’. Included within this is coarse particle flotation, or coarse particle recovery, which is billed by many in the industry as providing a way for mining companies to grind to coarser sizes, reduce energy consumption and costs, and recover valuable minerals and metals from tailings streams.
Metso has been awarded a major order worth some €55 million ($59 million) to deliver key concentrator equipment for a copper mining project in Chile.
The Metso delivery scope consists of high-capacity Nordberg® MP1250 secondary cone crushers, MF Series™ vibrating screens and energy-efficient Vertimill® VTM1500 regrinding mills.
For the flotation and separation circuit, Metso will supply multiple TankCell® and ColumnCell™ flotation cells featuring several of the largest available 630 cu.m TankCell units, as well as HCT™ High Compression tailing thickeners. In addition, Metso’s scope includes four MHC hydrocyclone clusters, of which two will be among the largest in the world.
Most of the products in the delivery scope are part of Metso’s Planet Positive offering.
Fernando Samanez, Vice President, Minerals Sales for South America at Metso, said: “Working together with the customer and the engineering company on an open collaborative model has been an extraordinary experience. The model enhanced the efficiency of the engineering process and contributed to the alignment of all parties on the targets set by the end customer. This will be a benchmark to be followed in similar projects all over the world.”
Metso is introducing to its flotation portfolio the Spider crowder upgrade, designed to address the challenges posed by large flotation cells.
Given that flotation operates as a continuous process, ensuring the highest level of equipment availability and efficiency is paramount. The new technology promises superior froth management, safeguarding enhanced metallurgical performance, energy efficiency and improved process control when installed with a Metso Center launder, the company says.
Christian Cardoso, Product Manager, Mechanical Flotation Services, Metso, said: “We are excited to introduce this groundbreaking solution to the challenges of large flotation cells. This innovative technology is set to elevate froth management to new heights, ensuring optimal performance and efficiency. Furthermore, the easy installation of the solution improves employees’ safety during equipment upgrades and maintenance.”
Guillermo Bermudez, Product Director, Flotation Services, Metso, said: “The Spider crowder upgrade represents Metso’s innovative design with several process and customer benefits. The solution optimises air flow rates, potentially reducing air blower energy consumption. This not only contributes to environmental sustainability but also results in significant cost savings over the long term.”
The quick installation process requires little to no modifications, according to Metso, with the latest upgrade seamlessly engineered to be compatible with existing cells. The customisable, modular design ensures safe and easy tank access for efficient maintenance.
Flotation technology has played a pivotal role in Metso’s history for over five decades. Through advancements in the company’s evolution, Metso says it has significantly influenced the trajectory of mechanical flotation technology and helped to propel the industry forward.
Almina Minas do Alentejo S.A. is proceeding with the preparations to upgrade the copper and zinc concentrator at its Almina mine in Aljustrel, in the Iberian pyrite belt in Portugal, with the company having placed an order with Metso as the key equipment supplier for this project in the March quarter of 2023, the OEM says.
Metso has now completed the basic engineering of the grinding island. Delivery of the concentrator plant equipment will take place around the end of the June quarter in 2024, with the project expected to be commissioning by the end of the March quarter of 2025.
Saso Kitanoski, President for Metso’s Europe Market Area, said: “Collaboration between Almina Minas do Alentejo S.A and Metso is strong. We are excited to continue working with Almina on this project, for which they selected us to supply the grinding island, ultrafine grinding technology, as well as flotation, filtration and thickening equipment, as well as all slurry pumps. The deliveries will be fast as the plant will be built already within the next 24 months.”
According to Miguel Santos, Senior Sales Manager for Metso Minerals in Iberia & Italy, Almina chose to collaborate with Metso on the engineering for the grinding island as Metso was able to bring extensive expertise and confidence that the project will deliver robust performance, availability and sustainability results.
Santos said: “Almina trusts Metso as a partner for this project as we can provide them with a comprehensive package of solutions to help them achieve their targets. Several of the solutions to be delivered to Almina feature our Planet Positive technology.”
BASF mining solutions has added two new product brands to its range of flotation solutions as part of its plan to become a full solution provider for the mining industry.
Luprofroth™ has been added to its growing frothers portfolio and Luproset™ is tailored for flotation modifiers.
In recent years, BASF’s flotation business has expanded from niche applications to a broad range of flotation solutions. By introducing two distinct brands for frothers and modifiers, BASF says it can now communicate its flotation portfolio in a clear and consistent way.
The launch of the Luprofroth brand comes with the introduction of a brand-new range of sulphidic frothers formulated to enhance the overall flotation circuit performance.
Graeme Stewart, Sulphide Flotation Specialist for BASF, explains: “Our new sulphidic frother portfolio comes with a wide spectrum of products suitable for diverse process conditions, such as bubble size, bubble coalescence, presence of fine and coarse particles, induction time and froth stability. A key feature of the new range is its enhanced EHS profile, with lower toxicity and ecotoxicity values and reduced flammability risks, which are often major concerns for our customers.”
The Luproset portfolio consists of multiple innovative technologies designed to improve mineral recovery, maximise concentrate grades and reduce reagent consumption with clear downstream benefits.
Benjamin Hepe, Head of Global Segment Flotation, BASF Mining Solutions, said: “Because BASF recognises the challenges and transformation in the mining industry, our priority is to develop solutions that enable our customers to achieve more with less. An example I particularly like is the Gold Activator Luproset A 1127, an innovative technology that improves gold recovery at low dosage rates.”
One of the key advantages of Luprofroth and Luproset is BASF’s extensive integrated chemical value chain, the company says. As a result of the backward integration, along with BASF’s global scale operations, the company is are able to use resources more efficiently and expand its mining portfolio continuously through innovation.
Caren Hoffmann, Vice President Mining Solutions for BASF, concluded: “I am very excited about the launch of the new brands; it sets a consistent base that will enable us to continue growing our flotation business for frothers and modifiers alongside our collectors. Our team is constantly working on the development of new technologies, and we expect to advance further in this field with the expansion of a dynamic pipeline.”
Metso has signed a contract for the delivery of a new copper concentrator to be built in Kazakhstan, banking some €85 million ($90 million) in its Minerals segment’s September quarter 2023 orders received in the process.
The company’s scope of delivery consists of the main process equipment for grinding, flotation and dewatering and includes HIGmill® high-intensity grinding mills, TankCell® flotation cells in different sizes in the 30 to 630 cubic meter range, Larox® PF pressure filters, HRT High-Rate Thickeners, an on-line sampling and analysing system, as well as field instrumentation and Proscon® automation for the whole concentrator plant.
The flotation cells, pressure filters and high-rate thickeners are part of the company’s Planet Positive portfolio, thanks to their superior energy and water efficiency, it says.
This month’s Spotlight Feature Article looks at the all-important process of flotation; a sector that is getting more cutting edge by the year. Included within this is a focus on the cutting edge of froth flotation technologies and a taste of some of the topics that will be presented at the forthcoming Flotation ‘23 conference in Cape Town in November.
Metso is celebrating 50 years of mechnical flotation this month, reflecting on the pivotal role flotation technology has played in the company’s history over the last five decades.
Evolving from humble beginnings at Outokumpu, and then further developed by Outotec, Metso has shaped the course of mechanical flotation and propelled the industry forward, it says.
The OK cell was taken into commercial use in 1973 with a capacity of 16 cu.m. At that time in flotation history, tanks were square-shaped when viewed from the top. As demand for even larger tanks escalated, a 38-cu.m version was introduced to optimise processes and achieve higher recoveries, and, ultimately, to enhance profitability.
During development of the larger flotation cells, the team noticed square-shaped tanks posed challenges in terms of load-bearing capacity at the corners. As a result, the entire industry shifted to round-shaped tanks. Thus, the TankCell® was born in 1995.
“TankCell is a great example of our history in flotation,” Antti Rinne, VP, Flotation at Metso, said. “Everybody who talks of TankCell flotation cells is speaking of our technology. We remain the original and leading provider of TankCell technology.”
Today, Metso TankCell boasts the world’s best flotation performance and offers a wide variety of cell sizes, currently ranging from 5 to 630 cu.m, the company says. This enables compact and cost-effective plant designs, even for high-tonnage operations. Fewer large units result in significant savings in construction costs, piping, cables, instrumentation and auxiliary equipment.
Rinne said: “Now, the biggest cell is almost 20 times larger than the original 38 cu.m. And, when we introduced the FloatForce® mixing mechanism in the TankCell design, it gave customers up to 30% savings in energy consumption and significantly better recoveries.”
Today’s flotation circuits are often designed and optimised with Metso’s HSC simulation tool, thus enabling optimisation of total flotation cell volume and other key flotation parameters, the company says.
Metso Concorde Cell, entering the market as recently as 2021, stands out as a significant milestone in flotation, according to Metso. The Concorde Cell is capable of recovering the unachievable fine and ultra-fine particles, increasing profitability while reducing operating costs, energy consumption and water usage.
This patented technology – the first of its kind – is tailored for finely disseminated and complex orebodies that were once considered inaccessible. For optimal results, it is best when used in conjunction with TankCell technology, Metso claims. Both are part of Metso’s Planet Positive offering and ensure unmatched metallurgical performance, it added.
“Combining the well-proven TankCell technology with Concorde Cells is a low-risk and high-benefit approach,” Rinne says. “The cell produces very high shear and extremely fine bubbles, which increases recovery in particles under 20 microns. Despite being the newest technology in Metso’s flotation portfolio, it has already been deployed at several operations globally.”
Since flotation is a continuous process, maintaining high availability and efficiency is crucial. Metso’s developments in flotation cell technology enable upgrading and retrofitting of older flotation equipment for enhanced performance, the company says. These advancements not only extend the lifespan of existing equipment, but also align operations with environmental and safety standards, ensuring long-term viability and compliance.
For more information on this flotation technology evolution, click here
Canada-based First Quantum Minerals (FQM) has placed an additional order with Metso for the delivery of minerals processing equipment to its Kansanshi copper mine S3 expansion.
Metso’s scope of delivery includes apron feeders, Nordberg® MP800™ cone crushers, TankCell® e630 and TankCell® e300 mechanical flotation cells, high-intensity Concorde Cell™ units, ColumnCell™ units, HRT thickeners and a clarifier.
Most of the separation equipment are part of Metso’s Planet Positive offering.
The First Quantum Minerals Ltd Board of Directors signed off on the S3 Expansion last year, bankrolling a project that could see Kansanshi’s life pushed out to 2044. Once the expansion is completed, copper production from Kansanshi is expected to average approximately 250,000 t/y for the remaining life of mine.
Metso says the value of the order exceeds €20 million ($21. 8 million).
Antti Rinne, Vice President, Flotation at Metso, said: “Kansanshi’s flotation flowsheet combines the well-proven, energy efficient TankCell flotation cells with the new Concorde Cell, unlocking the potential for further improved flotation performance. Concorde Cell high-intensity, forced-air pneumatic flotation cells allow operations to enhance fine and ultrafine particle selectivity.”
The Metso Outotec global network of testing, research and product development facilities covers the whole process flowsheet from comminution through separation, to filtration, refining and pyrometallurgical/hydrometallurgical processing.
It has centres all over the globe – in Australia, Brazil, Chile, Germany, Finland, Peru, USA and more – able to, the company says, offer extensive expertise and circuit simulation to a wide range of industries.
Metso Outotec’s research and testing services include evaluation of ore types, mineralogical characterisation, feed material testing, sampling, materials selection, analytical chemistry and flowsheet development.
To get a flavour of this extensive research and testing portfolio, IM spoke to Alan Boylston, Director, Process Engineering at Metso Outotec, and Rodrigo Grau, Technology Director – Minerals Processing at Metso Outotec, about the capabilities of two of the company’s facilities – York (USA) and Pori (Finland), respectively, while also touching on Metso Outotec’s global testing and research capabilities.
In 2022, the company announced a consolidation of its minerals testing services in USA into a single 5,500 sq.m facility in York able to eventually cover the full minerals value chain and support the mining industry worldwide. Pori, meanwhile, focuses on mineral technology, hydrometallurgical processes development, pyrometallurgy and ferroalloys technology and material technology. In other words, the company conducts laboratory and pilot test work, flowsheet development as well as validation and development of new technologies for the industry.
IM: Will the York facility now be seen as your ‘testing centre of excellence’?
AB: The York facility is a centre of excellence for testing, but we have many of these within the company. Our global presence, the knowledge and our expertise at each of these locations is one of the factors that sets us apart.
Each of our locations is a centre for excellence in its own field. Pori, for example, has extensive research capabilities, Sorocaba in Brazil focuses on comminution and beneficiation testing, while Lappeenranta Dewatering Technology Center concentrates on thickening and filtration. Each location is an integral part of our global testing offering. In addition to these, we have various facilities around the globe covering also aggregates and pyrometallurgical testing, research and development.
That being said, the effort we have made to expand the York Test Center gives us a much better advantage for research and testing in North America, compared to a few years ago. We can now do more pilot-scale testing, especially with equipment like our HRC™800e high pressure grinding roll (HPGR). We can also carry out pyrometallurgical testing, plus conduct magnetic separation tests. At some point in 2023, we also expect to add thickening and filtration testing to this remit. But this is a very high-level view of what we have to offer in the York location.
IM: Even with this consolidation in USA, are you expecting to collaborate with other global facilities when it comes to testing processes throughout the flowsheet?
AB: Yes, absolutely. For example, we have a project coming in right now where the sample was first in Tampere (Finland) for some crushing test work, before they split off a sample for us for grinding test work in York and then Pori is also receiving a sample for some broader mineralogy testing.
This speaks to why we are able to claim to have global capabilities. No matter the testing or research need, we are able to assist our customers to get the job done. This all goes towards one goal – the customer’s benefit.
IM: How do you see these testing capabilities interacting and benefitting from other modelling work you carry out in-house? For example, do you anticipate using these facilities and the likes of the Geminex digital twin in unison to offer clients physical and digital representations of flowsheet options?
RG: Modelling is very important for us. In each project we work on, modelling and simulation are at the heart. Here in Pori, we carry out flowsheet development and technology validation. One of the outputs of our work is to end with a simulation of an industrial plant. Going from that simulation into Geminex is just one more step we will be taking in the future.
AB: At the York lab, we are now moving to a SCADA-based system to run everything: when a sample comes in, it gets tagged and identified and we then automatically know what test to run. We have tablets to, for instance, setup all the parameters of a test for an HRC 800e. We can start and stop the test on that tablet and see the real-time information coming in as the test is being carried out. That data is also being stored for future use.
We’re undergoing a program right now to build out a database function where all the post processing of this data goes on in the background and can then be seamlessly integrated into things like our HRC simulation software. We are building the backbone to carry out that real-time digital twinning.
IM: Do you anticipate your global testing capabilities to lead to a higher uptake of Planet Positive solutions?
AB: With our customers having a huge focus on sustainability, I do. As an example, since we have had the pilot-scale HRC 800e available for testing, it has been fully booked. In 2023, we are preparing for a test plan where we could take the HRC product and go directly into a pilot Vertimill. Those are two Planet Positive approaches we are putting together in a single test plant to show how far we can push energy efficiency and media consumption reduction.
RG: I would definitely agree with Alan. And to add to that – for example at Pori, we do a lot of hydrometallurgical testing and piloting, and that is only increasing with the rising demand for lithium and other battery minerals. And our customers are really looking at how our equipment is reducing their carbon footprint and other sustainability benefits.
You will hear us say it time and time again, but this is definitely a trend that we are seeing at all of our facilities.
IM: Will these expanded testing facilities also benefit your equipment and process R&D work?
AB: I think so. We built this lab to not just be a materials testing facility, but also a research hub, especially for grinding, but also for any other Metso Outotec business area needs. There is definitely a huge opportunity out there for us!
RG: And this rings true around the globe at all our facilities. For example, in separation, we have been testing the Concorde Cell™ flotation technology in Pori for a long time. And that is how we’ve approached development of a lot of our other innovations that go to market.
IM: How would you say industry testing requirements have changed over, say, the last five years?
AB: From our perspective, I am seeing more comprehensive test programs come through.
Instead of, say, one certain test, it is an entire test program with specific timings around evaluations and the ability to develop the flowsheet through the testing required. There is more collaborative designing of the flowsheet taking place through testing than there was five or 10 years ago.
RG: It is certainly more comprehensive now than it previously was.
For example, we carry out early engagement with our customers in Pori and start developing a flowsheet and evaluating the ore types.
The amount of material that is tested nowadays is much bigger than it was before. Obviously, it is not just limited to this example, because, as Alan mentioned before, we’ve got this connection between all our facilities to ensure our customers get exactly what they need from their testing program.
Also, our customers think about different drivers in the process very carefully and want that reflected in the test work. That could be more evaluation on the water they consume. They also look at the energy expended, on top of the expected recoveries and metal grades.
There is more emphasis on sustainability, even at these early stages, in addition to looking at how the ore types may change over time and what impact this will have on the processing requirements.
This is where our extensive simulation and modelling capabilities are leveraged for the biggest impact.
IM: Anything else to add?
RG: Pori and York are but a fraction of the expertise of the wider Metso Outotec research and testing portfolio; one that continues to expand in line with customer requirements. We don’t just cover mining, either – like our equipment offering, we provide research and testing services for the whole flowsheet.
And we are continually improving our capabilities in this space for our customers. So, stay tuned for the future and where we can take research and testing!
