UNLOCKING VALUE THROUGH FLOTATION LAUNDER RETROFITS IN MINERAL PROCESSING PLANTS *Christian Cardoso1, Guillermo Bermudez1, Aino Saikkonen2, Egonk Arriagada3 1Metso, Canada (*Presenting author: christian.cardoso@metso.com) 2Metso, Finland 3Metso, Chile ABSTRACT Maximizing flotation circuit performance hinges on effective froth collection, as it directly influences mineral recovery and financial returns. With rising global demand for metals, mineral processing plants are pushing higher throughputs, driving the adoption of larger flotation cells. While these cells support increased throughput, they also introduce challenges: larger froth surface areas and longer transport distances reduce froth recovery efficiency. To overcome these challenges, an optimized launder configuration was developed to enhance circuit performance and operational efficiency. Among various designs available, the center launder emerges as the most effective. Its geometry enables optimal froth crowding toward a central launder, while minimizing transport distance and surface area. Shorter transport distances improve the likelihood of particle recovery, and reduced froth surface area enhances froth stability through increased crowding. Center launder upgrades can be easily implemented during scheduled shutdowns, allowing tailored solutions for specific process needs. Field data from multiple retrofits has shown notable improvements in both metallurgical recovery and operational performance. These gains have translated into rapid payback periods—often within just a few months. This study presents a detailed analysis of center launder installations, focusing on copper recovery improvements and optimized operating parameters that drive profitability and process control. KEYWORDS flotation, cell retrofit, froth management, crowders, launders, copper, process improvement
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