HIGH PROFILE
the digital world . That is not to say that chemistry advancements will not still be made but bringing flotation into the autonomous and digital age is really bringing some big wins today . It is also important to point out that as ore grades decrease , the effect of variability can actually be much more marked without the advantage of these digital solutions .
SmartFloat enables operators to respond faster to changes in ore composition , helping avoid loss of valuable metals
pilot scale , or also at a full scale flotation plant ? A We already have a “ live ” system operating at a customer copper concentrator facility with other sites in progress of implementation . You could call it a full scale pilot as we are still monitoring the system to check that it is responding appropriately and delivering the expected improvements .
Q Does it have the greatest applicability in large throughput copper operations or does it offer equal upside say in other base metals or industrial minerals ? What stage of the flotation process is it used at ? A The concept is valid for any flotation operation in mining – looking at the incoming feed , identifying the ore ’ s mineralogical characteristics , selecting the right algorithms for those and responding with the most applicable reagent solutions . It can be used at any point in the flotation plant where reagents are being added but of course most of the work is done in the rougher stage . However , you often also have depressants added at the cleaner stages so SmartFloat would be just as appropriate there .
Q Do you add sensors with the system or are you using existing available data ? A We are using existing systems in the plant that measure particle size distribution , pH , or elemental analysis using XRF . This is partly because we also use historical plant data in developing the algorithms . The models work partly on what was measured and observed with different ore types over long periods . That said , we are also looking at other and better ways of measuring incoming ore to the plant .
Q Would you say SmartFloat development has been driven by customers , or by Solvay or both ? A I would say it is part of Solvay ’ s overall digitalisation and innovation drive . A lot of what is possible has already been achieved with reagents in terms of chemistries – big leaps like our AEROPHINE ® formulation example – so today , a lot of extra value therefore is now being driven by
Q Does it change how reagents are stored and delivered onsite ? A When you start using multiple reagents instead of just one or two then yes you need multiple tanks and pumps . You are changing from mainly having just a few ratios of a small number of reagents to using a number of different reagents at different points at different times . It makes the operation more complex so for that reason you need these digital tools to guide the system .
Q And it is fair to say that every mine is still different and needs a different approach ? A We have been selling reagents for 100 years so the algorithms start from that vast knowledge base . But every mining operation is different – there is never a one size fits all option – so as stated already , historical data from that particular plant also plays a role . There is always a significant calibration effort to make sure that the solution for that mine delivers the best value . And SmartFloat is very much an extension of that . It means that when you have chalcocite as the main copper mineral but then also a second copper mineral like chalcopyrite , and the relative amount of each changes , that you are able to manage that . IM
Q Is the drive to do this partly driven by mines wanting to move to more fully autonomous processing plants ? A The idea is not to have less people , it is to have a better operation . Actually at mineral processing plants there is no one person dedicated to reagent dosing – it is a collective decision that happens three or four times a shift . As stated before it now becomes real time , automatic and systematic . You remove some variability , adapt your reagents to the incoming feed and thereby maximise recovery . It is a bit like changing from a manual gearbox to an automatic gearbox – you still need a driver but there is much less intervention .
It is intended as a perfect complement to the Solvay Cube , a state-of-the-art dosing system
NOVEMBER / DECEMBER 2022 | International Mining 21