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REFLUX technologies

Optimising mineral recovery with REFLUX technology

The mining industry is grappling with calls to maximise resource recovery while minimising environmental impact. This is spurring the development of technologies such as the REFLUX range of solutions to enhance ore recovery rates and reduce energy use and water consumption.

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What is REFLUX technology? 

REFLUX technology was pioneered by Prof. Kevin Galvin from the University of Newcastle, Australia, focusing on gravity separation techniques for fine particle recovery. The first major application of the concept was the REFLUX Classifier (RC™), which combines inclined lamella plates with a fluidized bed to create an efficient, compact system capable of handling a wide range of particle sizes and densities. The REFLUX concept has since been incorporated into several other innovative products, such as the REFLUX Flotation Cell (RFC™), the GradePro™ Classifier, the Graviton™ Separator, and the coarseAIR™ coarse particle flotation solution.  

The REFLUX concept combines a conventional fluidised bed separate with parallel inclined plates forming lamella channels. The fluidised bed helps to maintain particle mobility and acts as a semi-permeable layer, preventing the loss of valuable ore particles and allowing precise particle separation based on differences in particle density or size. The inclined lamella plates promote laminar flow, accelerating the settling process and reducing turbulence, improving overall separation efficiency.  

Key benefits of REFLUX technology

  • Increased recovery of fine and coarse particles

    REFLUX technologies recover particles typically lost in traditional systems, from ultra-fines to coarse particles, depending on the application. This means more ore can be recovered from each tonne mined.

  • High throughput and reduced footprint

    REFLUX technologies offer high throughput, processing larger volumes of material in a smaller footprint than conventional systems. This is particularly important for operations with limited space or high CAPEX concerns.

  • Energy efficiency and sustainability

    REFLUX technologies reduce energy and water consumption compared to traditional methods. The RFC, for example, reduces energy use by up to 60%, while coarseAIR cells enable the recovery of coarse particles, reducing over-grinding and optimising water recovery.

  • Cost-effective solutions

    Lower energy and water use, higher recovery rates, and compact design translate into cost savings and improved profitability for mining companies.

  • Scalability and versatility

    REFLUX technologies are scalable, making them suitable for various applications, from pilot plants to large-scale operations. Their versatility allows them to be used across multiple mineral types, including iron ore, copper, rare earth metals and coal.

The REFLUX family

The REFLUX Classifier

The REFLUX Classifier offers gravity-based separation of fine particles based on density or particle size. It has been widely used in iron ore, mineral sands, and coal operations. Inclined lamella plates enhance fine particle separation by promoting laminar flow, while a fluidised bed located below the laminar region allows particles to settle based on their density and size. An underflow valve discharges the heavier settled reject; the fine product is collected via the laminar overflow.  

  • High recovery rates of fine, high-density particles, typically lost in conventional systems 
  • Compact footprint is easily integrated into existing plants
  • Operates with minimal water and energy, lowering costs and environmental footprint

Learn more

Equipment comparison

Choosing the right REFLUX technology for your application

REFLUX Classifier
GradePro™ Classifier
Category
Hydraulic separation
Hydraulic separation
Overview
Fine-particle gravity-based classification
Enhanced classification for low‑grade ore & tailings
Applications
Iron ore, chrome, mica rejection in spodumene, manganese, mineral sands, potash, coal
Low concentration high-value commodities, tin, tantalum
Best fit for
Gravity based separation and particle size classification
Processing of low-grade or tailings streams upstream
Key benefits
High-efficiency fine separation at scale. High-capacity, low maintenance and downtime
Boosts value recovery from low-grade and tailings feed. High-capacity, low maintenance and downtime
Water / energy use
Low-energy operation; no mechanical input
Gravity-based design with extremely low energy and water use
Target feed size
~38µm to 2 mm (maximum top to bottom ratio of 8:1)
~38µm to 2 mm (maximum top to bottom ratio of 8:1)
Throughput capability
High throughput (~500 tph per unit)
Scalable via modular banks
Automation & control
Simple to operate with low ongoing intervention
Simple to operate with low ongoing intervention
Footprint / installation
Compact, modular plants
Small footprint; easily integrated into existing plants
Maintenance profile
Minimal wear; no rotating parts
Very low-maintenance gravity setup

Setting new standards for recovery optimisation

REFLUX technologies offer the opportunity to raise standards for mineral processing, delivering significant improvements in recovery rates, energy efficiency, and water consumption. Whether the REFLUX Classifier, GradePro Classifier, or REFLUX Flotation Cell, or new technologies like the coarseAIR cell and Graviton Separator, REFLUX technologies are providing opportunities to enhance mining companies’ bottom line and reduce environmental impact.  

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