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Conference Proceedings

Mill Operators Conference Proceeding 2026

Conference Proceedings

Mill Operators Conference Proceeding 2026

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Opening up flotation hydrodynamics – linking gas hold-up with recovery

Flotation is a central unit operation in mineral processing, yet its performance is often constrained by the hidden world of cell hydrodynamics. Over the last 100 years, equipment designers have continually sought to optimise the hydrodynamics of their units. Unfortunately, conventional optimisation tools such as laboratory assays and froth imaging only offer indirect glimpses of what is really happening inside the cell, leaving operators to adjust circuits without a clear link to metallurgical outcomes. Recent development of the FlotSense® for real time hydrodynamic measurements has enabled direct observation of individual cell behaviour. In field studies, some of which are described here, gas holdup (Ɛg) data has shown a strong correlation with respect to mineral recovery, as not only a descriptive parameter but also as a powerful predictor of metallurgical and operational performance. These findings highlight the importance of incorporating hydrodynamic insights when defining operational targets for individual cells. This paper shares on-site learnings from applying Ɛg monitoring across nine flotation circuits representing different markets from copper, gold and poly metallic ore types. We demonstrate how reliable hydrodynamic data, can deliver measurable gains in recovery, selectivity and plant reliability. In doing so, we highlight a pathway for operations to bridge fundamental flotation hydrodynamics within everyday plant performance.
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  • Published: 2026
  • Pages: 14
  • PDF Size: 0.31 Mb.
  • Unique ID: P-05650-T4Q9S8

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