Delivering nextSTEP^™ performance in forced-air flotation

FLS froth cameras provide a clear image and analysis of froth movement over the launder, allowing for improved control of the flotation circuit and further optimizing performance.

Automatically adjust recovery rate based on an algorithm that works with froth cameras and online sample analysers. 

Optimise the froth pull rate of the entire row with additional crowding to low pulling cells. 

A forced-flotation cell is a type of flotation device used in mineral processing to separate valuable minerals from waste (gangue). They use an external air blower to introduce air into the slurry through a hollow shaft and holes in the rotor. The rotor/stator shear and disperse the air into small bubbles onto which mineral particles attach and rise to the surface and can then be collected into overflow launders. In comparison, self-aspirated flotation cells pull air into the slurry via a vacuum created by the motion of the rotor. 

Forced-air flotation allows for better control over air flow and distribution than self-aspirated flotation cells, allowing optimised mixing of air and slurry for enhanced contacting and attachment. Rotor/stators are located at the bottom of the cell, creating a stabler and deeper froth layer for enhanced recovery and higher-grade concentrate production. The rotor location also helps reduce any sanding build-up and the bottom of the cell.  

Forced-air flotation cells can be used to separate a wide range of metals and minerals and in rougher, scavenger, and cleaner flotation applications. 

Yes! Converting to nextSTEP flotation is simple and low risk. The existing mechanism assembly is utilised. Rotor and stator are attached with adaptor flange and baseplate respectively, and drive sheaves replaced to optimise speed. The FLS conversion process is thorough and proven - with many successful retrofits already undertaken in flotation cells ranging in size for 1.7m³ to 250m³.

FLS offers rectangular nextSTEP flotation cells with active volumes of 1.7m³ to 2.8m³ and round flotation cells with active volumes from 5 m³ to 600m³.

The main factors that drive flotation cell selection are required retention time, desired tonnage, percent solids used for processing, specific gravity of the solids, and estimated concentrate pull rate. These values can be determined by performing thorough laboratory or pilot testing of representative feed material.