Improving fine particle flotation using the StackCell™ (raising the tail of the elephant curve)

For decades, the conventional flotation machine has been the accepted tool for processing sulfide ores. As plant capacity increases, machine size has evolved to as much as 600 cubic meters to keep pace with the required retention times. However, the excessively large size of these machines requires extreme floor space, foundations and power to operate. Recent work conducted by Eriez has shown that high-efficiency flotation machines which are based on focused energy input can achieve similar results with significantly less retention time, floor space and power. Comparable performance is achieved through intense contacting in a separate chamber which provides concentrated energy input focused specifically on bubble/particle interaction. When compared to conventional technology, data show that this novel approach can achieve the same recovery as a mechanical cell in a fraction of the residence time. This paper will discuss the theory of operation of the StackCell™ and present data from various lab- and pilot-scale test programs.