Figure 13 – Typical flowsheet of current CPF circuits The NovaCell™ addresses the challenges of current CPF circuits and treats the full process stream. Since the NovaCell™ is a true froth-flotation machine with a froth layer that selectively recovers hydrophobic particles while allowing the drainage of water containing gangue particles, there is no requirement for a deslime circuit or an additional ‘fines’ flotation circuit. The NovaCell™ features a novel configuration that provides optimal hydrodynamic conditions for both fine and coarse particle recovery (Jameson, 2010). Particles and microbubbles first collide in high-shear downcomers, enhancing fine and ultrafine recovery, before the stream enters a fluidized bed where partially loaded bubbles capture coarse particles under low-shear conditions. Morgan et al. (2023) reported on a copper recovery study at the Pinto Valley mine that demonstrated the potential impact of the NovaCell™ at coarser grind sizes, with predicted benefits including a 20% increase in plant throughput and a 15% reduction in carbon emissions per ton of copper produced. To validate these findings, the technology was later benchmarked against conventional flotation cells, which also treat the full process stream. Morgan et al. (2024) presented three case studies of copper mines in Canada, Chile, and Australia, where the NovaCell™ produced higher copper and molybdenum recoveries than conventional flotation technology. The recovery improvements were most evident in the coarse +300 µm, +212 µm, and +150 µm size fractions. They concluded that the NovaCell™ is a viable option for CPF circuits. To fully evaluate the NovaCell™ CPF flowsheet and its ability to address current CPF circuit challenges, it is essential to consider both valuable mineral recovery and selectivity across all size fractions. Figure 14 presents the simplified NovaCell™ CPF flowsheet. The following sections present three case studies that illustrate these aspects, ranging from laboratory testing of run-of-mine (ROM) material to pilot plant trials, highlighting recovery, mass pull, and selectivity across coarse and fine size fractions.
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