including a regrinding step before cleaning. However, operational experience has shown that in some cases the concentrate from the first rougher cell already achieves sufficiently high grades, making further grinding unnecessary. This has led to renewed interest in “scalping” strategies— recovering well-liberated, hydrophobic valuable particles as early as possible to produce high- or final-grade concentrate. By removing these particles upfront, unnecessary regrinding can be avoided, circuit capacity can be freed to treat more complex material, and overall circuit size and cost can potentially be reduced. While this concept is not new and is fundamental to flash flotation, it can be further enhanced when particle size conditions are suitable by using the Concorde Cell as a scalper in roughing, scavenging, or cleaning duties. On-site laboratory test work with the Concorde Cell was conducted in parallel with several Pb, Cu, Au, and Zn operations, with Cu and Au cases highlighted. In a copper plant treating fine, clay-rich material (P80 45 µm), the existing fines rougher–scavenger circuit achieved 57% Cu recovery at 6% grade. The Concorde Cell, operating as a scalper, demonstrated the potential to increase recovery by around 10% at similar grade, or alternatively to sacrifice grade and boost recovery by 20–30%. In a Cu–Au concentrator where stirred-stage flotation cells already acted as a scalper after regrinding, the circuit recovered 52% of the gold at 14 g/t. Test results indicated that a single Concorde Cell could outperform the existing system, delivering up to 15% higher gold recovery at comparable or improved concentrate grades. Together, these emerging flotation technologies enable a rethinking of traditional flotation circuit design by incorporating pre-concentration using the CPF Cell and scalping with the Concorde Cell. This integrated approach offers substantial reductions in both capital and operating expenditures, while simultaneously improving metallurgical performance and advancing sustainability objectives. 2. REIMAGINED CONCENTRATORS By integrating Coarse Particle Flotation (CPF) for early-stage ore pre-concentration together with the Concorde Cell as a scalping device, flotation circuits can be redesigned in a more streamlined and efficient way. A conceptual “base case” copper flotation circuit can therefore be developed, drawing on established chalcopyrite processing flowsheets and supported by real plant flotation performance data. That said, any proposed circuit must ultimately be dictated by the ore itself. Key parameters such as mineralogical composition, degree of surface liberation, particle size distribution, specific gravity differences, and variability across the deposit all play a decisive role in determining the most appropriate technologies, electrochemical conditions, and circuit layout. Consequently, the flowsheet described here represents just one possible configuration. Depending on ore characteristics and project objectives, sections of the circuit may operate in open configuration, additional cleaner stages may be required, or alternative equipment selections may be more suitable. In the proposed arrangement, the Metso CPF Cell is installed on the screened SAG mill discharge. Depending on liberation characteristics, other placement options—such as cyclone
RkJQdWJsaXNoZXIy MTM0Mzk2