Metso Full portfolio CellStation
CellStation is an intelligent solution for controlling the air feed and pulp level in flotation cells.
Automation interactive tool
Explore different parts of the concentrator plant while clicking on hotspots to learn more about Metso's automation solutions.
Benefits

The solution incorporates ExactLevel controller, which improves the metallurgical performance of flotation cells by enabling more accurate level control and significantly reducing process disturbance.

  • Easy operation
  • Improved recovery and end-product grade with embedded ExactLevel controller
  • Plug-and-play connectivity with FrothSense for increased process stability
  • Short delivery lead time and fast installation and commissioning
CellStation

Accurate level control for improved metallurgical performance

Controlling pulp levels in flotation cells is a complex task with many different aspects, such as the effect of cell structure and valve sizing, to take into account. Control becomes more challenging as the number and complexity of cells in a configuration increases.

The second-generation Metso® CellStation builds on the success of the previous-generation solution and is based on Metso’s strong track record in this field, with more than 400 units sold since its introduction in 2008.

Maximized availability with comprehensive support

Because Metso CellStation uses hardware and software components that are common to many Metso product lines, support is readily available from our extensive team of experts to minimize downtime. This also helps to reduce the need for specialized training of on-site operators

Accurate level control and increased process stability

The pulp level is stabilized by the embedded Metso ExactLevel controller. Compared to traditional PID controllers, Metso ExactLevel enables more accurate level control and significantly reduces process disturbance, resulting in more stable froth conditions and therefore improvements in the flotation cell’s metallurgical performance.

Metso ExactLevel operates in conjunction with the standard PID control and compensates for disturbances generated by upstream sources before they affect the pulp level in the cell.

Metso CellStation has connectivity with the Metso FrothSense sensor system, which measures essential properties of froth appearance, including froth speed, direction, bubble size, froth stability, and froth color and provides statistical data related to these variables.

Typical scope

  • PLC cabinet
  • Instrument air manifold with
    integrated filtering
  • Cables and installation accessories
  • Automation engineering, configuration,
    and factory acceptance testing
flotation cellstation
Typical system layout flotation cells

CellStation main features

Level control valves  (max amount) 3
Flotation air control valves  (max amount) 4
Feedback from valve position Yes
ExactLevel / Feed forward algorithm Yes
Connectivity with the Metso FrothSense Yes
Display7” outdoor-readable
Communication protocol to DCSProfinet.
Modbus TCP/IP
Profibus DP
Power distribution 24VDC x2 (Redundant)
Hardware components
  • 7 inch SIMATIC HMI Comfort Outdoor Panel TP700
  • PLC Siemens Simatic S7-1500
  • Cabinet with pedestal in RAL 7035 (light gray)
  • Instrument air distribution manifold and double filtering (G½”)
  • Main switch
  • Software components
  • Software programming tool: Siemens TIA Portal
  • Programming language based on IEC 61131-3:
  • Function Block Diagram (FBD)
  • Structured Control Language (SCL)
  • Trend logging and visualization with Outotec proprietary standard library software
  • components
  • Pulp level control
  • Flotation air control
  • Trending of all monitored values
  • Embedded adaptive ExactLevel control algorithm
Connections
  • Connection to plant control system (DCS) via Profinet or Modbus TCP/IP
  • Connection to Metso FrothSense camera system via OPC UA
Options
  • Installation accessories (signal cables, instrument air tubes and connectors)
  • Profibus DP module
Installation requirements
  • Operating temperature: 10°C to +45°C
  • Storage temperature: -25°C to +60°C
  • Relative humidity 90 %; no condensation
  • Installation altitude above sea level, max. 3000 m (depending on operating temperature)
  • Enclosure: IP65 (electrical box and main switch)
  • Supply voltage 1 with AC 120 ... 230 V, rated current 2.2A ... 1.2A
  • Supply voltage 2 with AC 230 ... 500 V, rated current 1.2A ... 0.61A
  • Supply frequency 50 ... 60Hz
Dimensions 
  • W 678 x H 1962 x D 378 mm, weight 113 kg

Value calculators & recommender tools

Downloads

Name
Size
Leaflet: CellStation - EN 244 kB
Leaflet: ExactLevel - EN 83 kB
Leaflet: CellStation - EN
Size
244 kB
Leaflet: ExactLevel - EN
Size
83 kB
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