BEYOND THE STATOR: BAFFLES AS A TOOL TO IMPROVE COARSE PARTICLE SUSPENSION AND REDUCE POWER CONSUMPTION IN MECHANICAL FLOTATION CELLS *G. Lastra1, B. Awatey1, J.J. Frausto1, D. Deglon2, K. Runge1 1Julius Kruttschnitt Mineral Research Centre, The University of Queensland, Australia (*Presenting author: g.lastra@uq.edu.au) 2Centre for Minerals Research, University of Cape Town, South Africa ABSTRACT In mechanical flotation cells, the stator promotes key hydrodynamic processes such as mixing, bubble break up, and bubble-particle interactions. However, flotation research suggests that the rotor-stator combination could be suboptimal for particle suspension. In contrast, baffles are widely used to promote suspension in mixing applications. Compared to baffles, the stator may increase the impeller speed required for just suspension (Njs), which can be particularly detrimental for coarse particle recovery. Higher impeller speed typically leads to increased turbulence and power input, promoting bubble-particle detachment. It may also cause greater oscillations at the pulp-froth interface, potentially increasing drop-back. Despite these implications, the role of baffles in conventional flotation systems has not been thoroughly investigated. This study examines the effect of replacing the stator with baffles in a 1 m3 mechanical flotation cell. A Design of Experiments (DOE) approach and statistical regression modelling were employed to compare stator and baffles configurations across varying air rates. Three parameters were measured at the just suspension condition: the impeller speed (Njs), specific power draw, and interface oscillations. Coarse silica was used as the tracer for suspension behaviour. Results showed that baffles significantly reduced Njs and power draw, particularly at higher airflow rates. The stator more effectively dampened interface oscillations under aerated conditions. These findings reveal a trade-off between improved suspension and energy efficiency with baffles, and enhanced interface stability with the stator. Understanding these relationships provides new opportunities to optimize flotation performance, particularly coarse particle recovery. KEYWORDS Flotation Cell, Stator, Baffles, Coarse Particle Suspension, Power Draw, Interface Oscillations 1. INTRODUCTION
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