630 SIMPLIFYING THE FUTURE OF FLOTATION WITH ORE PRE-CONCENTRATION AND SCALPING *A. Yáñez 1, Michel Carlo2, Alex Olivas2, Nathalie Kupka1 1Flotation Product Group, Metso Finland Oy, (*Presenting author: alejandro.yanez@metso.com) 2Separation Processes Sales, Metso Peru ABSTRACT Froth flotation circuits are complex systems of highly interconnected equipment and processes, designed to maximize metal recovery and grade. These systems require precise control over variables like reagent dosage, air flow rate, and residence time. The design and complexity of the circuit vary based on factors such as ore type, characteristics, location, and the desired product specifications. Typically, duties include roughing, scavenging, and cleaning. With more than 50 years of experience in manufacturing innovative flotation equipment, Metso introduced the Concorde Cell™ in 2021, a high-intensity pneumatic flotation cell designed for the recovery of fines and ultrafines. In 2026, the company plans to launch the CPF Cell (name still to be disclosed), a quiescent pneumatic flotation system that combines flash flotation with particle segregation in froth, enabling the flotation of even the coarsest and least liberated particles. The Concorde Cell boasts multiple installations across the world while Metso's CPF will be tested at industrial scale in a copper concentrator in South America. These groundbreaking flotation technologies offer a new way to approach flotation circuits, utilizing pre-concentration (CPF Cell) and scalping (Concorde Cell). This results in significant cost savings in both CAPEX, such as equipment sizing and plant footprint, and OPEX, particularly in energy and water usage, all while enhancing metallurgical performance and supporting true sustainability. KEYWORDS Flotation, ore pre-concentration, fines flotation, flowsheet optimization 1. FINES AND COARSE PARTICLES FLOTATION Froth flotation circuits are complex systems composed of tightly interconnected units and processes. They are meticulously designed to maximize metal recovery and concentrate grade, which requires accurate regulation of operating variables such as reagent addition, air flow, and residence time. However, conventional froth flotation equipment is typically limited to a specific particle size range. For instance, studies indicate that in most copper concentrators, approximately 50% of the copper lost to tailings is associated with particles smaller than 20 µm, while an additional 30–40% is lost with particles coarser than 150 µm (Janishar Anzoom et al., 2024). On one side, Coarse Particle Flotation (CPF) aims to minimize unnecessary energy consumption by reducing excessive grinding of gangue material. In this context, Metso has been developing an alternative to existing fluidized-bed CPF technologies. Metso’s CPF solution (name pending) is based on quiescent pneumatic flotation and integrates flash flotation with particle segregation within the froth, enabling the recovery of even very coarse and poorly liberated particles. This technology has been described by de Avila Carvalho et al. (2024), Emer et al. (2024), de Avila Carvalho et al. (2025) and Kupka et al. (2025).
RkJQdWJsaXNoZXIy MTM0Mzk2