Metso Flotation Machines

Flotation machine RCS Technology at work for you

 Andrew Wilkinson Metso TR Seminar 

27 April 2012

Features and capabilities Designed for increased capacity, capacity, reduced maintenance, and increased reliability

Contents

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Metso introduction

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Product application

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Features and benefits

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Needed to size

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Reference applications

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Service business line

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Conclusion

Flotation machine RCS Product role Flotation is a mineral separation process, which takes place in a watermineral slurry.

The surfaces of selected minerals are made hydrophobic (water-repellent) by conditioning with selective reagents. The hydrophobic particles become attached to air bubbles that are introduced into the pulp and are carried to a froth layer above the slurry thereby being separated from the hydrophilic (wetted) particles.

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Hydrophobic reagents

 Air bubble

Particle

Particle surface

Flotation machine RCS Benefits

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Create bulk slurry flow patterns - Solids suspension - Particle bubble contact

- Solids resuspension •

Effective air dispersion and distribution

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Extended wearlife

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Minimise absorbed power 

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Flotation machine RCS Features •

Enhanced performance −

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Ideal hydraulic flow zones to maximise recovery of all sizes Minimised slurry short circuiting

Improved access Cell top walkway improves maintenance access to mechanism drive −

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Reduced installation costs Cell top walkway reduces building floor area Single side froth discharge simplifies froth handling Modular tank design simplifies installation −

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Flotation machine RCS Complete flotation machine Motor  Mechanism assembly

Feed box

 Air supply Level control

Main support frame Cross flow froth launder 

Flotation cell tank

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Intermediate and discharge box

Flotation machine RCS Mechanism assembly  Air swivel

Spindle bearing

Mechanism sub frame V-belt drive Stand pipe Motor  Motor sub frame

Diffuser 

Impeller 

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Flotation machine RCS Feedbox, intermediate and discharge box

Level and flow function

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Flotation machine RCS Mechanism drive

V-belt drive < RCS 130 >

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Gear box

Flotation machine RCS Froth launders

Take out of flotated mineral

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Flotation machine RCSTM Patented mechanism design •

Enhanced flotation performance - Maximum particle bubble contact - Effective solids suspension - Controllable aeration

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Reduced operating costs - Cast polyurethane wear parts - Minimised absorbed power 

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Improved maintenance - One piece fully suspended mechanism - Wear parts replaceable in-situ

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Flotation machine RCS Mechanism design Top recirculation

 Aerated radial flow

 Aerated radial flow

Primary return flow 13

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Flotation machine RCS Mechanism design Controlled air addition Hollow shaft

Standpipe

Impeller 

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Diffusor vane

Flotation machine RCS Mechanism design

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Flotation machine RCS Mechanism design

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Flotation machine RCS Mechanism design

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Flotation machine RCS Level control system Ultrasonic transmitter / detector 

Pneumatic actuator 

Target plate

Float Valve stem

Down flow dart valves

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Flotation machine RCS  Aeration control Flexible air hose  Air swivel Pneumatic air control valve  Air flow meter 

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Flotation machine RCS Mechanical cell

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 –

type RSC

Flotation machine RCS CFD Simulation

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Predicted bubble rise velocity in a vertical plane

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Flotation machine RCS Bank design

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Flotation machine RCS Bank design

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Flotation machine RCS Bank design

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Flotation machine RCS Bank design

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Flotation machine RCS Bank design

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Flotation machine RCS Bank design

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Flotation machine RCS Bank design

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Flotation machine RCS Bank design

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Flotation machine RCS Tank design

Single side froth discharge

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Cell top walkway

Flotation machine RCS Bank design

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Flotation machine RCS  A Platinum Plant

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Flotation machine RCS Size range

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Flotation machine RCS  Applications •

Iron flotation, Non-ferrous metals, Industrial minerals

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Flotation machine RCS Installations

LKAB

Gaiski

Boliden

Boliden

 Agnico Eagle

Endomines

Varvariuskoye

Nordkalk

Navoi Mining

Imerys Poltava

Suncor Millenium Zinkgruvan

Rudna Polkowice Ruby Creek

K&S

Stillwater Platinum

SASA Kaltun

 Almagrera

Eti Bakir 

Youssofi

 Asarco Mission

Khouribua BHP Tintaya Volcan Colquisiri Shougang Hiero  Atacocha Copper  Casapalca Tintaya Lead/Zinc SIMSA Platinum Other  35

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El Teniente Date Author Title

Rapu Rapu

Gradir  Buenaventura Sungun Sar Chesmeh Rotem

Luiswishi Carrolindo Crown Mining Ivan Sylvania Mining

Miduk Lonmin Karee Lonmin Karee Bendigo Waterval

Mortimer  Kilken Platinum

 Amandelbult

Impala Rustenburg

Pasminco Elura

Toms Gully

Flotation machines RCS 15 and 40 European Pb/Zn concentrator modernization C

BLYRÅ- SCAVENGER KRETS

Benefits

D

- increased flotation volume - reduced maintenance/operating costs - improved metallurgical performance

SAMREPETERINGS KRETS F

G

Phase 1 modernization program: 1997 4 - cell RCS 15 bulk cleaner  4 - cell RCS 15 lead cleaner 

E

BLYREPETERINGS KRETS

SAMRÅ-SCAVENGER KRETS

H

J 13

11

12

Before

9

10

7

8

6

5

Flotationshall Flotationsdel plan +189

C D

JELE

1998 6 - cell RCS 15 separation rougher  2 - cell RCS bulk cleaner  6 - cell RCS 40 bulk rougher 

E

PF 1-2 PF 3-4 F

Flotationsdel plan +189 SFFlotationshall 1-2 G

Phase 2 Cu circuit 2009 8 - cell RCS 15 Cu rougher  4 - cell RCS 15 Cu cleaner 

H

SR 1-2 OK 38

J 13

12

After 

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ZINKGRUVAN MINING AB

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svenh 98-04-07

FLOTATIONSHALL PLAN +189 rev.

2,700 TPD Lead Zinc Ore 10 - 11% Zn 4% Pb 36

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99-03-04

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6

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Flotation machines RCS 15 and 40 Benefits •

1% increase in Zn concentrate grade maintained Pb concentrate grade more stable production

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Reduced flotation power draw from 2.2 kW/m3 to 1.1 kW/m 3

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Reduced rotating equipment for  maintenance:flotation mechanisms from 156 to 28 pumps from 32 to19

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Increased spare floor area for  further plant improvements Typical Concentrate Grades: Zn concentrate 56% Pb concentrate 74%

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1% Pb 6% Zn

Flotation machines RCS 130 - Copper rougher  Benefits  Additional plant recovery with RCS 130 - 1 - 3% Cu concentrate grade 25 - 28% Cu

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RCS Cell Cu recovery average 37% range 16 - 77%

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RCS Cell Cu concentrate grade average 28% range 17 - 33%

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RCS fully integrated into plant operation with concentrate directed according to feed mineralogy.

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RCS Mechanism power draw 0.70 kW/M3

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18,000 - 20,000 TPD Chalcopyrite Copper Ore Ore grade and mineralization vary widely 0.30 - 0.75% Cu Non sulfide Copper 7 - 20% of total Cu

Flotation machine RCS RCS 50 2 - Cell bank copper rougher  Benefits •

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Improved fines recovery resulting in an additional 1% overall plant recovery

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Flotation machine RCS 6-cell South American iron ore concentrator  Benefits •

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25% reduction in energy costs Improved recovery from 95% to 97 - 98%

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Flotation machine RCS RCS 50

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Flotation machine RCS TM

RCS

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5 Flotation machine test cell

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