The end of the SAP flotation era and the transition to advanced forced air cells

Reasons for transitioning

Self-aspirated pneumatic (SAP) flotation cells have been identified as lacking in several critical areas:

• Operational Flexibility: Limited adaptability to varying operational conditions.

• Low air-to-pulp ratios (APR): Inefficient air dispersion leading to suboptimal flotation performance.

• Poor ultra-fine recoveries: Inability to effectively recover ultra-fine particles, which are increasingly important in mineral processing.

Due to these limitations, the time has come to adopt advanced technologies that provide enhanced performance and increased flexibility.

Introducing self-aspirated pneumatic flotation cell upgrades with enhanced features

We recommend upgrading traditional downcomers with more advanced technology such as the Concorde Blast Tubes™ for operations utilizing SAP flotation cells. This upgrade involves the addition of a blower and, if necessary, a feed distributor upgrade. This transition promises:

• Enhanced Operational Flexibility: Better adaptability to varying feed conditions and operational demands. The figure below reflects the operating limitations of self-aspiration. The relationship between the downcomer air-to-pulp ratio and recovery can be understood using the air-to-pulp ratio versus the vacuum graph shown here. It is understood that when the air-to-pulp ratio is below 0.2, the mixing zone within the downcomer is minimal, resulting in a bubbly flow regime. As the air-to-pulp ratio increases and vacuum decreases, a distinct mixing zone with high turbulence forms, transitioning into a turbulent pipe flow regime. Eventually, further increases in the air-to-pulp ratio do not entrain more air but instead decrease the vacuum, leading to a regime dominated by turbulent mixing. The use of external forced air allows control beyond these limitations and allows the operator to push the envelope in terms of recovery. (Reference: Recovery interactions between the froth zone, pulp zone and downcomer with a Jameson Cell – G Harbort, J Crowburn, E Manalpig, 2004)

• Higher Air-to-Pulp Ratios: Improved air dispersion for more efficient flotation.

• Superior Metallurgical Performance: Enhanced recovery rates, especially for ultra-fine particles.

The benefits of upgrading

By transitioning to upgraded downcomers with external blowers, operations will experience:

• Enhanced operational flexibility: Easily adapt to changing operational conditions and requirements.

• Higher air-to-pulp ratios: Achieve better air dispersion and flotation efficiency.

• Superior metallurgical performance: Gain improved recovery rates, particularly for ultra-fine particles.

The era of SAP flotation cells is over. Upgrading today allows sites to leverage the latest advancements in flotation technology, ensuring operations stay ahead of the competition.

Upgrade solutions

To support our customers through this transition, we offer three comprehensive product life cycle upgrades:

• Process change notification: For customers needing to adjust to new operational requirements—such as increasing fines to ultra-fines, or boosting recovery or grade, we provide upgrades to traditional downcomers with a forced air control system. This upgrade offers increased operational flexibility and higher APRs.

• Unlimited product support: We include extensive pilot testing to ensure high-performance process guarantees and robust after-market support. This service ensures that customers achieve optimal results from their upgraded systems.

• End-to-end product support: For operations concerned about significant process changes, we offer digital metric solutions to monitor performance. This end-to-end support ensures seamless adaptation to the upgraded systems.