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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.
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.
The RFC extends the REFLUX concept to flotation-based separation, altering perceptions of what is possible in froth flotation. Operating with significantly higher flotation kinetics than conventional flotation cells, it supports substantially higher throughput and enhanced recovery and grade, while reducing operating costs. Meanwhile, its compact footprint is easy to retrofit into existing sites without extensive modifications. The result is a much lower-impact flotation system for more sustainable mineral processing.
The GradePro Classifier refines the design of the REFLUX Classifier to maximise the recovery of valuable material when processing low-grade ores and tailings.
The coarseAIR cell applies the operating principles of REFLUX technology to coarse particle flotation, offering a solution with widespread benefits for upstream (grinding) and downstream (separation) processes. Combining a low-turbulence aerated fluidised bed with lamella plates, the coarseAir coarse particle flotation solution enables the flotation of larger particles that would otherwise be lost in conventional systems.
The Graviton Separator is an innovative new technology that integrates REFLUX Classifier modules into a high-speed centrifuge to offer powerful desliming and ultrafine particle recovery.
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.
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.
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.
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.
Lower energy and water use, higher recovery rates, and compact design translate into cost savings and improved profitability for mining companies.
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.
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.
