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coarseAIR™

coarseAIR™ coarse particle flotation

The coarseAIR flotation cell is an innovative approach to coarse particle flotation, enabling the recovery of larger ore particles than in conventional flotation. This offers several critical opportunities to a mining industry tasked with meeting a growing demand for minerals while reducing its environmental impact.

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Key benefits of coarseAIR coarse particle flotation

  • Higher throughput and plant capacity

    Coarser grinding allows more material to pass through the mill within the same timeframe without costly investment in additional grinding capacity. This opens the opportunity to increase plant throughput without costly CAPEX in the grinding circuit.

  • Significant energy savings

    Fine grinding is an energy-intensive process. coarseAIR Coarse Particle Flotation reduces energy consumption in the mill and can result in savings of up to 30%, depending on the specific ore and processing conditions. These energy savings reduce operating costs and contribute to mining companies’ sustainability goals by lowering their carbon footprint.

  • Improve tailings and water management

    coarseAIR Coarse Particle Flotation naturally produces coarser tailings, which are easier to dewater. This reduces the water sent to tailings impoundments, improving water recovery rates and reducing the environmental risks associated with tailings dams. In addition, coarse tailings are more amenable to dry stacking, a more sustainable and safer tailings disposal method.

  • Enhance metallurgical recovery

    coarseAIR Coarse Particle Flotation recovers minerals otherwise lost in conventional flotation circuits, ensuring maximum recovery of valuable minerals from the feed material.

How does coarseAIR coarse particle flotation work? 

Prof. Kevin Galvin of the University of Newcastle, Australia, developed the technology in collaboration with FLS. It is based on the REFLUX Classifier® (RC™), a highly efficient fluidised bed separator widely adopted in the mining industry to improve fine particle recovery. The resulting coarseAIR solution combines the hydrodynamic advantages of the RC with the selectivity benefits of flotation to float larger particles than conventional flotation processes, which are typically limited to particles -200μm.  

The coarseAIR cell operates as an aerated fluidised bed separator, where coarse particles are floated without the high levels of agitation seen in conventional cells. This helps to prevent bubble-particle detachment seen with coarse particles in traditional systems. At the same time, the fluidised bed acts as a semi-permeable layer, avoiding the loss of bubble-attached coarse particles to the underflow.  

Above the fluidised bed, a series of inclined lamella plates enhance bubble-liquid segregation, allowing only bubble-attached particles to be carried up into the separation zone and the overflow. The lamella region also rejects any misplaced particles, as unattached particles carried hydraulically into the lamella region are rejected back to the separator, resulting in a high-grade coarse concentrate.  

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Become an early adopter of coarseAIR coarse particle flotation 

FLS is seeking early adopters of coarseAIR Coarse Particle Flotation to participate in pilot trials and early deployments. Modular pilot units are offered that can be deployed at mine sites for testing. These units easily integrate into existing operations, requiring only a small stream of rougher feed. FLS handles shipping, commissioning, testing, and decommissioning and only needs assistance with installation at an appropriate location in the processing plant.  

During the pilot phase, FLS works with the client to optimise the system and ensure it delivers the expected improvements in recovery and efficiency. Once the pilot phase is complete, FLS assists with scaling up the technology to production levels. This includes providing engineering support, equipment customisation, and training to implement the technology seamlessly into the existing operation.  

coarseAIR Coarse Particle Flotation represents a breakthrough in coarse particle flotation, offering mining companies a powerful tool for increasing recovery rates, reducing energy consumption, and improving sustainability. As the mining industry faces increasing pressures to reduce its environmental impact and operate more efficiently, coarseAIR Coarse Particle Flotation provides a solution that meets these challenges head-on.  

Beyond these operational advantages, early adopters of coarseAIR Coarse Particle Flotation can position themselves as leaders in responsible mining during a time of increasing pressure to reduce mining’s environmental and social impact.