Flotation technologies

Outotec is the world leader in flotation technology. We set new standards for superior flotation performance: mixing, aeration and froth recovery for every flotation task. Our solutions are tailor-made for each customer, including flotation packages with support services, modular process sections and even whole concentrators for base and precious metals and industrial minerals.

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Flotation technologies for maximizing metallurgical performance and availability

Time-proven, innovative and efficient solutions

Our Flotation concept:

n Performance driven tailoring n Flexibility in operation n Responsive controls n High availability n Easy and safe maintenance n Commitment throughout the life span of the operation Our Flotation offering is based in the earlier mining and concentrator operations of the Outokumpu corporation. Development of in-house otation cells started in the 1960's to satisfy the need for more ef cient, more reliable and easy-to-use equipment. This development has led to many innovative products and processes. For decades, we used to call these otation technologies with the well-known brand name OK. Outotec continues to offer you the same competitive advantage with otation technology that has evolved through decades of continuous R&D and experience. Forty years in business prove our commitment to customers as well as the operational reliability and performance of our equipment. Our automation and analyzer solutions offer operators the perfect tools to enhance otation performance. In addition, our froth management technology and particle-size-speci c otation lead the eld for optimizing recovery in every application. We are ready to serve you at any time in whichever corner of the world you operate. Flotation cell to match your application Flotation is a technology with over 100 years of history, yet now the development in our offerings is more rapid than ever. To yield maximum pro ts in applications with various particle sizes, we have specialized designs for each in the otation cell. The heart of the cell is the mechanism which creates the bubble-particle interactions, and equally important critetrion is ef cient froth recovery.

Advantages
n Case-proven metallurgical superiority n Minimized capital expenditure through optimum cell size and minimal footprint n Minimized operational cost through ef cient hydrodynamics, robust designs and advanced materials.

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FreeFlow -mechanism for enhanced mixing of coarse and medium-size particles The energy-saving FreeFlow mechanism keeps the slurry in motion without excessive turbulence. Coarse particle contact with air bubbles is maintained by strong and gentle mixing to permit maximum recovery by minimizing bubble-particle detachment. MultiMix -mechanism provides high kinetic energy for fine and medium size particles The MultiMix -mechanism maximizes bubble and particle contact in the shear zone between the rotor and stator. The strong shear forces produce suf cient energy for nes to break through the water lm energy barrier on the air bubbles. The unique, downward-tapering rotor enables fast New FloatForce mechanisms underway To excel on the proven OK-mechanism in MultiMix and FreeFlow con gurations, a whole family of new FloatForce mechanisms is launched. This new technology is not only available in new Outotec otation technology deliveries, but also for existing installed OK, SkimAir and TankCell equipment. Optimum aeration at any altitude The forced air otation principle ensures optimum aeration at any operating altitude. Our blower systems are always designed to the speci c site conditions. High-capacity internal launders, double launders or exible high capacity radial launders recover the concentrate quickly, thereby reducing drop-back, especially of the coarsest particles. Special launder designs Another otation challenge is to keep the froth in constant motion to ensure high recovery or to make maximum concentrate grade. Our otation units feature patented froth crowders to exibly manipulate the froth and keep it in continuous motion. Froth management leads to high recovery with optimal grade start-up under load after a scheduled or unscheduled shut-down. Easy start-up under full load

Chile
Successful site tests and TankCell installations have proven that the cells are easy to operate. Control tools, especially the air control, are very good and the metallurgy is excellent. Operating and maintenance costs are also low. Heavy-duty manufacturing of all otation units and top-quality components are highly appreciated. Assistance and services used most often include training of operators and maintenance staff, proposals for inspections and preventive maintenance activities as well as spare parts recommendations. We also make suggestions for process improvements. Our customers appreciate that we work as partners with them and give them the service they need. We know the process and can really assist them.

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TankCell flotation units superior performance

TankCell units as unit reactors meet all the requirements set for superior flotation performance. They are easy to operate, low on power and air consumption and allow for a flexible layout. Further, the TankCell family comprises the widest size range on the market.

Maximum return on investment We have a simple goal to maximize your return on investment. Our design philosophy is to provide you with the best long-term investment. As operators, we understand the value of every 1% in throughput, grade and recovery. Over the lifetime of the Outotec otation units, operating costs have proven time and again to be by far the lowest. High reliability and low maintenance enable trouble-free operation, contributing to a rapid return on investment. Our otation units are built to last. Components and electrical equipment are selected for maximum operating life. For instance, our rotors and stators have proven to be the most wear-resistant available. The wide range of available cell sizes permits plant design to be compact, economical and efcient, without fear of short circuiting, even for todays high-tonnage operations. Fewer units mean substantial savings in construction costs, piping, cables, instrumentation and auxiliary equipment.

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Flexible plant layout, minimized footprint The wide range of proven cell sizes from 5 m to 300 m and the symmetrical design allow a exible layout. Internal dart valves minimize the footprint. Availability With large cell size, the reliability of single equipment becomes critical. Countless hours of uid dynamics analyses and mechanical engineering have allowed Outotec TankCell The cylindrical TankCell excels in performance as a rougher, scavenger or cleaner and currently leads the world in otation technology. We use our knowledge of froth crowding and froth transport characteristics to adapt the basic design to the demand of different otation duties. Superior mixing and minimized short circuiting The cylindrical TankCell operates as an ideal mixer and maximizes the number of collisions between the mineral particles and air bubbles, as well as reduces short circuiting. Optimized aeration and froth recovery TankCell units have an optimized froth surface area based on the mineralogy and kinetics in each case. They are designed to handle maximum carrying rates and lip loadings for the speci ed task. us to build ever larger cells with extremely high reliability. Our otation cells are designed and built with availability being a key criterion. They tolerate uctuating feeds and even oversize material without blocking up. Mechanical components are carefully sized to minimize vibration and loading; wear parts provide easy and safe maintenance. Advanced cell controls The TankCell is easy and responsive to operate with the basic level of instrumentation and controls. However, a circuit with a smaller amount of larger cells lends itself nicely to more sophisticated controls. FrothMaster The on-line FrothMaster froth image analysis and advanced controls further enhance the operation of the cells. Froth motion and bubble analysis coupled with higher-level controls for air feed, froth depth and reagents provide a unique way to optimize the concentrate mass pull and grade. The FrothMaster high quality live video feed and easy readouts provide the operator an accurate feel of the process continuously. EXACT level In real life, periodic and uncontrolled plant surges and large uctuations in the otation feed are not uncommon. The EXACT level control solution is designed to monitor upstream processes and feeds a compensation signal to the cell level controller before disturbances interfere otation performance. The EXACT level is based on feed forward control principles and unique automatic tuning functionality. It is tailored to a project specic owsheet and requires no extra instrumentation.

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SkimAir flotation units profit-makers in the grinding circuit

Outotec is known as a forerunner in bringing new technologies to the market. No one comes close when it comes to understanding and utilizing particle dynamics and froth management. Our otation approach focuses on exibility and circuit optimization. Our various types of otation mechanisms have proved capable of handling all kinds of otation processes. Reliability and ease of use are the keys to our continued success.

Flash Flotation In conventional Flash Flotation, we look for grade. The Outotec SkimAir otation unit is used as a stand-alone cell in a one-stage process for producing a high-grade concentrate. Flash Roughing Flash Roughing is recovery-driven. SkimAir operates using Dual Outlet Technology, which has world-wide patent coverage, to produce a lower-grade concentrate at a high recovery. Flash Roughing can comprise two stages: the SkimAir unit is used as the rougher, and a special TankCell is closely linked as the cleaner.

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Flash Roughing owsheet.

Outotec SkimAir Flash Flotation or Flash Roughing by the SkimAir otation unit takes place in the grinding stage.
Minimal

This creates extra capacity and improved control in the existing otation process. A lower-grade concentrate with high recovery can be obtained and blended with the higher grade SkimAir concentrate to increase the overall plant recovery.

overgrinding
Increased

mill throughput

The SkimAir unit oats the valuable liberated particles from the circulating load of the grinding process while still relatively coarse. These liberated particles are not ground further and do not enter the main otation process as slime particles with poor recovery.
Improved Improved

Along with otation improvements, the grinding mill throughput can be increased due to the controlled high density of the SkimAir under ow. dewatering

overall recovery

Dewatering improves because the nal concentrate P80 is coarser due to the elimination of nes.

SkimAir recovers considerable amounts of valuable minerals, resulting in a more stable feed to the conventional otation circuit.

Australia
Outotec is number one in Australia due to the development, successful testing and installation of large TankCell units. The largest Flash Flotation SkimAir cells have also been developed and successfully installed for the Australian market. Our locally-based technical and engineering team, operating with ISO 9001 certication, can quickly respond to customers and engineering companies. This applies to bid requests as well as solving on-site issues. Our quotations have general arrangement drawings in electronic form for further processing as initial plant layouts.

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All under control

Outotec offers the widest range of flotation solutions available to meet all application needs. Each flotation unit can be delivered complete with a customized package of our automation or on-stream analyzers.

Outotec's range of flotation equipment

n n

TankCell for rougher, scavenger and cleaner otation SkimAir for conventional Flash Flotation or Flash Roughing in the grinding circuit Conventional otation for rougher, scavenger and cleaner otation

Flotation package with support services We deliver otation systems to meet your specic requirements; automation and analyzers can be included. We provide supervision services for installation, commissioning and start-up, and training of plant personnel is an essential part of the package. Comprehensive after-sales service and consultation are proof of our commitment to your continuous operational performance. Each delivery focuses on maximizing the use of local resources.

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Operator interface We also offer a unique control solution for otation units the FrothCon. As a stand-alone control panel positioned on the deck of the otation cell, it replaces conventional eld controllers and performs a variety of additional functions. It can be linked to the Outotec family of analyzers and any plant process control system. The PLC based FrothCon has easy to use graphical displays to follow control loop status, trends and to adjust set points for otation air and slurry levels. By connecting one of the Outotec Courier Modular process sections Sub-assembled process sections are cost-effective and fast to bring into operation. These modules are practical for transportation, and easy to assemble and install in the eld; customized automation, sampling arrangements and analyzers are included. Supervision services and training complete the package. Top safety We set new standards for superior otation performance: aeration and mixing, froth manipulation and recovery for every otation task. Operational safety is one of the primary design criteria and it also applies to the choice of components. All units carry the CE mark. Reducing environmental impact is always the starting point in the design of all Outotec systems. Our equipment is designed for the highest operational cleanliness. Link to high-level automation We can assist you in every step of your automation development, based on our highly recognized achievements in process control and automation. analyzers through a process control system or directly to FrothCon, the operator can access process assay information online. Naturally also the FrothMaster signals can be accessed on the FrothCon. It provides a ready-made solid basis for a high-level control, such as the Outotec Proscon advanced process control system. Service across the globe Our rst class equipment is backed up by rst class people. We provide rapid service to help you achieve high availability and optimized production rates. We have highly-trained personnel dedicated to serve you on all continents and geographical areas where mining and ore beneciation are taking place.

The CIS countries

Outotec has had long experience of modernizing existing plants in the CIS. The company has also delivered complete new plants, comprising equipment for otation, thickening and ltration as well as related automation and analyzers. Years of experience in this market have facilitated timely deliveries and smooth co-operation. Our designers and specialists all have plant metallurgical backgrounds from similar ore processes. We have a long tradition in equipment manufacturing, which is complemented by easy railway transportation from Finland to the CIS.

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100 Tankcell Other

Proven to be superior

50

Fraction size, microns

Case study: superior size-by-size recovery of TankCell.

Market leader Outotec is the technology and market leader. Our commitment to clients and their needs, continuous R&D and proven ability to commercialize novel technologies and improvements have resulted in us holding a majority share of the market. The best, all the time We have experience beyond others. Our client plant audit services have contributed to optimized plant performances. From the 1970's onwards, Outotec has developed solutions for many speci c otation tasks, from base metals to oil sands separation. In the independently organized comparative studies between competing otation technologies, Outotec has always been reported to be superior in terms of metallurgical performance.

The chart above illustrates the difference in recovery between TankCell and competing technology in actual plant operation. The size-by-size results show that in some size fractions the increase in recovery was over 20 percentage units. Based on four cell comparative test, the client decided to retro t the competing technology. The total plant recovery was improved as a consequence, and the payback time for the improvement was very short. Most efficient technology available TankCell is known to have the fastest otation kinetics available; this has been proven by fullscale tests in South America, Canada, Europe and Australia. In the otation kinetics case study depicted below, Outotec TankCell was able to make the required gangue reduction from the feed with 10 minutes' retention time, which is much faster than competitors' 15 minutes' retention time.
Case study: fast kinetics of TankCell.

3 2.5 Tankcell Other 2 Target reduction below one

1.5

0.5

0 0 5 10 15

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We offer you a long-term partnership through local presence, supported by a global network of professionals. We provide flotation packages, modular process sections or whole concentrators.

Canada
We value the Outotec otation units because they suit the specic purpose and have a metallurgically benecial design, meeting or exceeding metallurgical expectations in terms of grade and recovery. Operation is trouble-free. Compared with competitor units, the Outotec units operate at low power consumption. As a company, our expertise in recommending the cells, cell sizes and cell placement is recognized, along with our design and application competence. Similar application references, quality of after-sales performance and on-site service are highly appreciated by our customers.

Outotec is a worldwide technology leader providing innovative and environmentally sound solutions for a wide variety of customers in minerals and metals processing as well as related process industries. Outotec Oyj is listed on the OMX Nordic Exchange Helsinki.

otation@outotec.com www.outotec.com

Copyright 2007 Outotec Oyj. All rights reserved. Outotec and More out of ore! are registered trademarks of Outotec Oyj.

3007EN. Pinta/Libris, Helsinki, Finland. January 2008