Iron Ore Beneficiation: Hybrid Flotation Cell

The Hybrid Flotation Cell for ultra-fine ore recovery is a groundbreaking solution developed by Primetals Technologies. This innovative technology addresses the challenge of separating ultra-fine and problematic particles in mineral concentrates. It uses a combination of two techniques for optimal results. The first technique involves a pneumatic injection of an ore slurry into the upper zone of a flotation cell, targeting fine and ultrafine ore-particle separation and recovery. The second technique utilizes air injection into the lower portion of the flotation cell, with a focus on separating and recovering coarse ore particles. This dual-process approach enhances efficiency and effectiveness in mineral processing, ensuring optimal recovery rates across various particle sizes.

The Hybrid Flotation Cell developed by Primetals Technologies combines a pneumatic flotation principle with a columnar flotation method. Feed slurry and flotation gas are effectively mixed up in the turbulent flow regime of the injector system before entering tangentially into the flotation cell. This enhances the frequency of contact between the gas bubbles and ultra-fine particles, which optimizes the recovery of fines and increases the yield. In addition, the columnar section of the unique hybrid design ensures a second scavenging flotation stage for the particles, contributing to improved recovery. The Hybrid Flotation Cell of Primetals Technologies does not require an impeller system, which means the rotor or stator is not subject to wear or friction. Low energy consumption and less maintenance also ensure lower operational costs.

The Hybrid Flotation Cell for fine ore recovery is designed to improve yield by increasing overall recovery and selectivity, maximizing concentrate product grade, and processing low-grade ores. It reduces the footprint while increasing throughput capacity and ensures environmental compatibility by reducing energy consumption and CO₂ emissions. The technology is adaptable to base metals such as iron, copper, molybdenum, nickel, and zinc, and precious metals such as platinum, gold, silver, and even industrial minerals. The Hybrid Flotation Cell operates with a significantly reduced power requirement compared to conventional systems, and gas and water demands are also considerably reduced.

Benefits of the Hybrid Flotation Cell

• Enhanced fine and ultra-fine particle recovery: achieves high separation quality and enrichment factors, crucial for meeting customer demands for high-grade concentrates
• Cost efficiency: low operational costs are achieved through reduced energy consumption and minimal water demand, addressing the need for economical operations
• Reliability and low maintenance: with no moving parts, the system ensures high reliability and reduced maintenance, minimizing downtime and operational disruptions
• Compact and efficient design: the small footprint and integration of two flotation principles in one cell allow for efficient use of space and resources, ideal for operations with limited space
• Environmental compatibility: reduced CO₂ emissions and lower water usage support sustainable practices, aligning with customer priorities for environmentally responsible operations
• Versatile application: adaptable to various ores and flotation chemical recipes, providing flexibility to meet diverse processing requirements and market demands