ok flotation tech

7/28/2019 OK Flotation Tech

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Flotation technologies

Outotec is the world leader in flotation technology. We

set new standards for superior flotation performance:

mixing, aeration and froth recovery for every

flotation task. Our solutions are tailor-made for each

customer, including flotation packages with support

services, modular process sections and even whole

concentrators for base and precious metals and

industrial minerals.


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002 More out of ore!

Flotation technologies for maximizing

metallurgical performance and availability

Time-proven, innovative and efficient solutions

Our Flotation offering is based in the ear lier mining and concentrator

operations of the Outokumpu corporation. Development of in-house

flotation cells star ted in the 1960's to satisfy the need for more efficient,

more reliable and easy-to-use equipment. This development has led to

many innovative products and processes. For decades, we used to call

these flotation technologies with the well-known brand name OK.

Outotec continues to offer you the same competitive advantage

with flotation technology that has evolved through decades of continuous

R&D and experience. Forty years in business prove our commitment tocustomers as well as the operational reliability and performance of our

equipment.

Our automation and analyzer solutions offer operators the

perfect tools to enhance flotation performance. In addition, our froth

management technology and particle-size-specific flotation lead the

field for optimizing recovery in every application. We are ready to serve

you at any time in whichever corner of the world you oper ate.

Flotation cell to match your application

Flotation is a technology with over 100 years of histor y, yet now the

development in our offerings is more rapid than ever. To yield maximum

profits in applications with various par ticle sizes, we have specialized

designs for each in the flotation cell. The hear t of the cell is the

mechanism which creates the bubble-particle interactions, and equally

important critetrion is efficient froth recovery.

Our Flotation concept:

Performance driven tailoring

Flexibility in operation

Responsive controls

High availability

Easy and safe maintenance

Commitment throughout the

life span of the operation

Advantages

Case-proven metallurgical

superiority

Minimized capital expenditure

through optimum cell size

and minimal footprint

Minimized operational cost

through efficient hydro-

dynamics, robust designs

and advanced materials.

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More out of ore! 003

FreeFlow -mechanism for enhanced mixing of

coarse and medium-size particles

The energy-saving FreeFlow mechanism keeps the

slurry in motion without excessive turbulence. Coarseparticle contact with air bubbles is maintained by

strong and gentle mixing to permit maximum recovery

by minimizing bubble-particle detachment.

MultiMix -mechanism provides high kinetic energy

for fine and medium size particles

The MultiMix -mechanism maximizes bubble and

particle contact in the shear zone between the rotor

and stator. The strong shear forces produce sufficient

energy for fines to break through the water film

energy barrier on the air bubbles.

New FloatForce mechanisms underway

To excel on the proven OK-mechanism in MultiMix

and FreeFlow configurations, a whole family of

new FloatForce mechanisms is launched. This

new technology is not only available in new Outotec

flotation technology deliveries, but also for existing

installed OK, SkimAir and TankCell equipment.

Optimum aeration at any altitude

The forced air flotation principle ensures optimum

aeration at any operating altitude. Our blower systems

are always designed to the specific site conditions.

Easy start-up under full load

The unique, downward-tapering rotor enables fast

start-up under load after a scheduled or unscheduled

shut-down.

Froth management leads to high recovery with

optimal grade

Another flotation challenge is to keep the froth in

constant motion to ensure high recovery or to make

maximum concentrate grade. Our flotation units

feature patented froth crowders to flexibly manipulate

the froth and keep it in continuous motion.

Special launder designs

High-capacity internal launders, double launders

or flexible high capacity radial launders recover the

concentrate quickly, thereby reducing drop-back,

especially of the coarsest particles.

Chile

Successful site tests and TankCell installations have proven that the cells are easy to operate. Control

tools, especially the air control, are very good and the metallurgy is excellent. Operating and maintenance

costs are also low. Heavy-duty manufacturing of all flotation units and top-quality components are highly

appreciated.

Assistance and services used most often include training of operators and maintenance staff,

proposals for inspections and preventive maintenance activities as well as spare parts recommendations.We also make suggestions for process improvements. Our customers appreciate that we work as partners

with them and give them the service they need. We know the process and can really assist them.


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TankCell flotation units

superior performance

Maximum return on investment

We have a simple goal to maximize your return on investment. Our design

philosophy is to provide you with the best long-term investment. As operators,

we understand the value of every 1% in throughput, grade and recovery.Over the lifetime of the Outotec flotation units, operating costs

have proven time and again to be by far the lowest. High reliability and low

maintenance enable trouble-free operation, contributing to a rapid return

on investment.

Our flotation units are built to last. Components and electrical

equipment are selected for maximum operating life. For instance, our

rotors and stators have proven to be the most wear-resistant available.

The wide range of available cell sizes permits plant design to be compact,

economical and efficient, without fear of short circuiting, even for todays

high-tonnage operations. Fewer units mean substantial savings in

construction costs, piping, cables, instrumentation and auxiliary equipment.

TankCell units as unit reactors meet all the requirements set for superior flotation performance.

They are easy to operate, low on power and air consumption and allow for a flexible layout. Further,

the TankCell family comprises the widest size range on the market.


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Outotec TankCell

The cylindrical TankCell excels in performance

as a rougher, scavenger or cleaner and currently

leads the world in flotation technology. We use

our knowledge of froth crowding and froth transport

characteristics to adapt the basic design to the

demand of different flotation duties.

Superior mixing and minimized short circuiting

The cylindrical TankCell operates as an ideal mixer

and maximizes the number of collisions between the

mineral particles and air bubbles, as well as reduces

short circuiting.

Optimized aeration and froth recovery

TankCell units have an optimized froth surface area

based on the mineralogy and kinetics in each case.

They are designed to handle maximum carrying rates

and lip loadings for the specified task.

Flexible plant layout, minimized footprint

The wide range of proven cell sizes from 5 m to

300 m and the symmetrical design allow a flexible

layout. Internal dart valves minimize the footprint.

Availability

With large cell size, the reliability of single equipment

becomes critical. Countless hours of fluid dynamics

analyses and mechanical engineering have allowed

us to build ever larger cells with extremely high

reliability.

Our flotation cells are designed and built

with availability being a key criterion. They tolerate

fluctuating feeds and even oversize material without

blocking up. Mechanical components are carefully

sized to minimize vibration and loading; wear parts

provide easy and safe maintenance.

Advanced cell controls

The TankCell is easy and responsive to operate

with the basic level of instrumentation and controls.

However, a circuit with a smaller amount of larger

cells lends itself nicely to more sophisticated controls.

FrothMaster

The on-line FrothMaster froth image analysis and

advanced controls fur ther enhance the operation of

the cells. Froth motion and bubble analysis coupled

with higher-level controls for air feed, froth depth

and reagents provide a unique way to optimize the

concentrate mass pull and grade.

The FrothMaster high quality live video feed

and easy readouts provide the operator an accuratefeel of the process continuously.

EXACT level

In real life, periodic and uncontrolled plant surges

and large fluctuations in the flotation feed are not

uncommon. The EX ACT level control solution is

designed to monitor upstream processes and feeds a

compensation signal to the cell level controller before

disturbances interfere flotation performance.

The EXACT level is based on feed forward

control principles and unique automatic tuning

functionality. It is tailored to a project specific

flowsheet and requires no extra instrumentation.


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SkimAir flotation units

profit-makers in the grinding circuit

Outotec is known as a forerunner in bringing new technologies to the market. No one comes close when it comes to

understanding and utilizing particle dynamics and froth management. Our flotation approach focuses on flexibility

and circuit optimization. Our various types of flotation mechanisms have proved capable of handling all kinds of

flotation processes. Reliability and ease of use are the keys to our continued success.

Flash Flotation

In conventional Flash Flotation, we look for grade. The Outotec SkimAir

flotation unit is used as a stand-alone cell in a one-stage process for producing

a high-grade concentrate.

Flash Roughing

Flash Roughing is recovery-driven. SkimAir operates using Dual Outlet

Technology, which has world-wide patent coverage, to produce a lower-grade

concentrate at a high recovery. Flash Roughing can comprise two stages: the

SkimAir unit is used as the rougher, and a special TankCell is closely linked

as the cleaner.



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Outotec SkimAir

Flash Flotation or Flash Roughing by the SkimAir

flotation unit takes place in the grinding stage.

Minimal overgrinding

The SkimAir unit floats the valuable liberated

particles from the circulating load of the grinding

process while still relatively coarse. These liberated

particles are not ground further and do not enter the

main flotation process as slime particles with poor

recovery.

Improved overall recovery

SkimAir recovers considerable amounts of valuable

minerals, resulting in a more s table feed to the

conventional flotation circuit.

Australia

Outotec is number one in Australia due to the development, successful testing and installation of large

TankCellunits. The largest Flash Flotation SkimAir cells have also been developed and successfully

installed for the Australian market.

Our locally-based technical and engineering team, operating with ISO 9001 certification, can quickly

respond to customers and engineering companies. This applies to bid requests as well as solving on-site issues.Our quotations have general arrangement drawings in electronic form for further processing as initial plant

layouts.

This creates extra capacity and improved control

in the existing flotation process. A lower-grade

concentrate with high recovery can be obtained and

blended with the higher grade SkimAir concentrate

to increase the overall plant recovery.

Increased mill throughput

Along with flotation improvements, the grinding mill

throughput can be increased due to the contro lled

high density of the SkimAir underflow.

Improved dewatering

Dewatering improves because the final concentrate

P80 is coarser due to the elimination of fines.

Flash Roughing flowsheet.


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All under control

Outotec offers the widest range of flotation solutions available to meet all application needs. Each flotation

unit can be delivered complete with a customized package of our automation or on-stream analyzers.

Outotec's range of flotation equipment

TankCell for rougher, scavenger and cleaner flotation

SkimAir for conventional Flash Flotation or Flash Roughing

in the grinding circuit

Conventional flotation for rougher, scavenger and cleaner flotation

Flotation package with support services

We deliver flotation systems to meet your specific requirements;automation and analyzers can be included. We provide supervision

services for installation, commissioning and start-up, and training of plant

personnel is an essential part of the package. Comprehensive after-sales

service and consultation are proof of our commitment to your continuous

operational performance. Each delivery focuses on maximizing the use of

local resources.

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Modular process sections

Sub-assembled process sections are cost-effective

and fast to bring into operation. These modules are

practical for transpor tation, and easy to assemble and

install in the field; customized automation, sampling

arrangements and analyzers are included. Supervision

services and training complete the package.

Top safety

We set new standards for superior flotation

performance: aeration and mixing, froth manipulation

and recovery for every flotation task. Operational

safety is one of the primary design criteria and it

also applies to the choice of components. All units

carry the CE mark. Reducing environmental impact is

always the star ting point in the design of all Outotec

systems. Our equipment is designed for the highest

operational cleanliness.

Link to high-level automation

We can assist you in every step of your automation

development, based on our highly recognized

achievements in process control and automation.

Operator interface

We also offer a unique control solution for flotation

units the FrothCon. As a stand-alone control panel

positioned on the deck of the flotation cell, it replacesconventional field controllers and performs a variety

of additional functions. It can be linked to the Outotec

family of analyzers and any plant process control

system.

The PLC based FrothCon has easy to use

graphical displays to follow control loop status, trends

and to adjust set points for flotation air and slurry levels.

By connecting one of the Outotec Courier

analyzers through a process control system or directly

to FrothCon, the operator can access process assay

information online. Naturally also the FrothMaster

signals can be accessed on the FrothCon. It provides a

ready-made solid basis for a high-level control, such as

the Outotec Proscon advanced process control system.

Service across the globe

Our first class equipment is backed up by first class

people.

We provide rapid serv ice to help you achieve

high availability and optimized production rates. We have

highly-trained personnel dedicated to serve you on all

continents and geographical areas where mining and ore

beneficiation are taking place.

The CIS countries

Outotec has had long experience of modernizing existing plants in the CIS. The company has also delivered

complete new plants, comprising equipment for flotation, thickening and filtration as well as related automation

and analyzers. Years of experience in this market have facilitated timely deliveries and smooth co-operation.

Our designers and specialists all have plant metallurgical backgrounds from similar ore processes.We have a long tradition in equipment manufacturing, which is complemented by easy railway transportation

from Finland to the CIS.


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Market leader

Outotec is the technology and mar ket leader. Our

commitment to clients and their needs, continuous

R&D and proven ability to commercialize novel

technologies and improvements have resulted in us

holding a majority share of the market.

The best, all the time

We have experience beyond others. Our client plant

audit services have contr ibuted to optimized plant

performances. From the 1970's onwards, Outotec has

developed solutions for many specific flotation tasks,

from base metals to oil sands separation.

In the independently organized comparative

studies between competing flotation technologies,

Outotec has always been reported to be super ior in

terms of metallurgical performance.

The chart above illustrates the difference in recovery

between TankCell and competing technology in actual

plant operation. The size-by-size results show that in

some size fractions the increase in recovery was over

20 percentage units. Based on four cell comparative

test, the client decided to retrofit the competing

technology. The total plant recovery was improved

as a consequence, and the payback time for the

improvement was very short.

Most efficient technology available

TankCell is known to have the fastest flotation kinetics

available; this has been proven by fullscale tests in

South America, Canada, Europe and Austr alia. In the

flotation kinetics case study depicted below, Outotec

TankCell was able to make the required gangue

reduction from the feed with 10 minutes' retention

time, which is much faster than competitors' 15 minutes'

retention time.


100

50

0 Fraction size, microns

Tankcell

Other

Case study: superior size-by-size recovery of TankCell.

Proven to be

superior

3

2.5

2

1.5

1

0.5

0

0 5 10 15

Tankcell

Other

Targetreductionbelowo

ne

Case study: fast kinetics of TankCell.


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We offer you a long-term partnership through local presence,

supported by a global network of professionals. We provide

flotation packages, modular process sections or whole

concentrators.

Canada

We value the Outotec flotation units because they suit the specific purpose and have a metallurgically bene-

ficial design, meeting or exceeding metallurgical expectations in terms of grade and recovery. Operation is

trouble-free. Compared with competitor units, the Outotec units operate at low power consumption.

As a company, our expertise in recommending the cells, cell sizes and cell placement is recognized,

along with our design and application competence. Similar application references, quality of after-sales

performance and on-site service are highly appreciated by our customers.


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Copyright 2007 Outotec Oyj. All rights reserved.

Outotec and More out of ore! are registered trademarks of Outotec Oyj.

[email protected]

www.outotec.com

3007EN.

Pinta

/Libris,

Helsinki,Finland.

January2008

Outotec is a worldwide technology leader providing innovative and

environmentally sound solutions for a wide variet y of customers in

minerals and metals processing as well as related process industries.

Outotec Oyj is listed on the OMX Nordic Exchange Helsinki.

ok flotation tech

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