FLOTATION
Jord ’ s NovaCell™ potential to be a game changer
The NovaCell , invented by Laureate Professor Graeme Jameson , and part of the portfolio of Australia ’ s Jord international , was developed to deliver step changes in flotation process efficiency and to optimise current processing practices . Its novel configuration produces the ideal hydrodynamic conditions for both coarse and fine particle flotation recovery . IM caught up with Jord Technology Manager , Sherwin Morgan .
Q If you had to highlight one attribute of NovaCell that makes it a game changer would it be sustainability ? Is that something increasingly being appreciated in the market ? A Yes , the NovaCell provides mining operators with options to minimise their energy and water consumption , as well as reduce fine waste material . Over the last year , through extensive testing , these benefits are being better understood and the technology is now being incorporated more regularly in optimisation studies . The NovaCell is unique in that it can achieve high recovery efficiencies across the full particle size distribution . So , irrespective of whether its valuable fines , intermediate or coarse particles , all the available minerals in the feed stream are recovered in one flotation device . Other newer technologies generally focus on a particular size band , whether its fine or coarse . Thus , competing technologies need to rely on hybrid flotation circuits to achieve the same level of recovery and sustainability performance .
Q To what extent has your testing borne out these sustainability claims in terms of real results ? A In a recent case study , the sustainability benefits of the NovaCell for a porphyry copper deposit were demonstrated . The results indicated that the NovaCell , at a P80 of 425 microns , could maintain the current plant copper recovery ( at 90 %), whilst reducing the energy ( up to 50 %) and water consumption ( up to 40 %).
Q Is its fine and coarse Jord NovaCell design flotation capability unique in the market ? What has market feedback been like ? A Yes , the NovaCell is the only commercially available flotation device that can recover valuable particles across the full particle size distribution range in one device . Thus , the NovaCell can treat the full process flow and the circuit is simple to implement and control . The feedback has been very positive , especially for critical minerals . Our customers are surprised by the feed throughput and sustainability benefits the technology offers . In addition , the NovaCell pre-concentration capabilities are also being evaluated , with the objective to extend mine life and reduce mining costs . As an example , the NovaCell was recently selected for innovation funding by OZ Minerals , Amira Global and the International Copper Association Australia .
Q Where is the project to date - have you moved beyond in-house testing to trials of the cell in real concentrator plants with customers ? A The most advanced project is with a consortium of international clients , where the in-house testing has produced very positive results . The group has agreed to progress the project and fund on-site pilot plant trials . The business case is based on a 10 % recovery improvement will be a reduction energy and water consumption . Moving into 2023 we will expand our testing capabilities across multiple locations , open a satellite office in North America and expand our project pipeline in lithium and potash . and as IM reported in 2021 was supplied to Anglo American Platinum . It comprises 16 road transportable ISO frame skids conforming to 40 ft marine container dimensions . After water commissioning , the pilot plant was disassembled and transported to the client site . Site erection was completed within three weeks . Using a modular plant construction methodology removes up to 80 % of site construction activities . An added benefit that off-site construction offers is easier build control , thus these projects enjoy higher safety achievements . They also generate less material waste , reduce energy consumption and reduce the project ’ s carbon footprint , this makes the modular plant build philosophy more environmentally sustainable .
Tanja Marcus , ProProcess Process Lead told IM : “ Historically the South African mining sector executed projects in a traditional manner , due to the size of the process equipment and lack of local modular process plant specialists in this industry . The modular build project philosophy is starting to gain traction locally , especially for processes that lend themselves to this approach . ProProcess has supplied multiple modular process plant systems , where the end-user offloads the units , connects electricity and water if required , fills with chemicals if required , and starts operating the modular plant within a very short time-frame . Flotation processes are typically too large to implement using this project execution methodology . An industry trend over recent years has , however , been to prove the process flowsheet and chemistry using site operating conditions and feed material . This has seen scoping studies being conducted in laboratories and many piloting and demonstration activities taking place on location . This also holds true for minerals processing - including flotation - flowsheets .”
Marcus says the first campaign for the Fines Flotation Mobile Pilot Plant was successfully completed by the client , and further campaigns are still planned . “ The advantage of using this pilot plant on site is that the process can be tested and optimised , without affecting the output of the main process plant . Other operators have expressed interest in owning modular piloting equipment as well , not just for flotation circuits but other unit processes as well .”
Precise dosing of flotation reagents – Solvay Cube
As already stated , the recovery of precious and base metals is increasingly focused on ores with
lower grade content , while mines simultaneously face pressure to reduce their environmental footprint , save energy and improve operational safety . Global flotation chemicals supplier Solvay says it addresses these needs with an encompassing approach to help mining companies optimise their processes , from more efficient processing to replacing hazardous reagents and minimising the loss of valuable minerals during flotation .
According to Genevieve Castillo , Global Marketing Manager for Solvay ’ s Mining Solutions business , as mines increasingly turn to digital solutions to support their productivity and sustainability goals , they are looking not only at equipment and process improvements , but also at adapting reagent formulations in real time with help from plant data and artificial intelligence . “ Solvay brought dynamic formulation to life with the Solvay Cube , a stateof-the-art portable dosing system designed to facilitate precise blending and dosing control of reagent chemicals . A digital mining solution , the Solvay Cube is fully connected with mill systems , enabling near-real-time , on-the-fly reagent adjustments based on plant operating data . In turn , plants get their formulation right the first time , reducing the risk of instability during trials ,
54 International Mining | OCTOBER 2022