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Where selective surface chemistry becomes metal recovery
Froth Flotation
Froth flotation is the key separation method for many sulphide and base-metal ores, where fine mineral particles are separated based on their surface properties. Ground ore is mixed with water to form a slurry, then conditioned with reagents such as collectors, frothers, and modifiers that adjust mineral hydrophobicity. Air is introduced into flotation cells, creating bubbles that hydrophobic particles attach to and ride upwards into a froth layer. This froth, overflowing from the cell launders, becomes the concentrate, while hydrophilic gangue particles stay in the pulp and report to tailings. By arranging cells into rougher, scavenger, and cleaner stages, the circuit balances recovery, concentrate grade, and reagent consumption across changing ore conditions.
Typical ores and applications
Typical position in the flowsheet
Complex Design
Material Integrity
Heavy performance
Speed, flexibility
Flotation circuits designed from metallurgical testwork to final layout
The flotation area is designed as part of an integrated process, not as isolated cells in a building.
In system engineering, metallurgical testwork, ore variability and production targets are interpreted to define the role of flotation in the overall flowsheet: rougher duty, scavenger duty, cleaner duty and any regrind or re-cleaner loops.
Basic engineering then sets the number and size of cells, the staging philosophy and how flotation interacts with grinding, classification, thickening and downstream processes such as leaching or smelting.
Detail engineering converts this concept into P&IDs, 3D layouts, structural supports, launder systems, pump stations, access platforms and control logic, with careful attention to maintainability, safety, air and water distribution and room for future debottlenecking.
Throughout this work the flotation area is treated as a controllable process module whose layout, utilities and instrumentation have to support consistent metallurgical performance, not just fit inside a building.
In system engineering, metallurgical testwork, ore variability and production targets are interpreted to define the role of flotation in the overall flowsheet: rougher duty, scavenger duty, cleaner duty and any regrind or re-cleaner loops.
Basic engineering then sets the number and size of cells, the staging philosophy and how flotation interacts with grinding, classification, thickening and downstream processes such as leaching or smelting.
Detail engineering converts this concept into P&IDs, 3D layouts, structural supports, launder systems, pump stations, access platforms and control logic, with careful attention to maintainability, safety, air and water distribution and room for future debottlenecking.
Throughout this work the flotation area is treated as a controllable process module whose layout, utilities and instrumentation have to support consistent metallurgical performance, not just fit inside a building.
Key engineering tasks and deliverables
Flowsheet development :
Mass, water and air balance
Duty definition and sizing:
Layouts and P&IDs:
Commissioning and start-up focus:
Key process units in a typical froth flotation area
Complex Design | Material Integrity | Heavy performance | Speed, flexibility |
Flotation plants that keep performing as ore and chemistry change
Services and optimization
Focused audits keep the flotation circuit performing as designed. Once the plant is in operation, support continues with services that keep recovery, concentrate grade and reagent consumption aligned with targets. Process engineers can carry out structured surveys of cell performance, air rates, froth depth, reagent schemes and pump conditions to identify bottlenecks and improvement options. Mechanical inspections cover cells, launders, screens, pumps and structures for wear, misalignment, vibration and safety concerns that might affect reliability. As ore hardness, mineralogy and throughput change over time, operating set points and even flowsheet details can be adjusted in a controlled way to preserve the original business case for the flotation plant.
Training and long-term partnership
Structured training programs turn operators into real owners of the flotation process. Through dedicated courses and on-the-job coaching, operators, maintenance staff and plant engineers build a clear understanding of flotation fundamentals and the specific behaviour of their own circuit. Training can cover chemistry basics, cell operation and inspection, froth observation and control, reagent handling and safety, and coordination between flotation and upstream and downstream areas. Written operating procedures, checklists and troubleshooting guides then reinforce these skills in day-to-day use. By combining engineering, in-house manufactured equipment, slurry pumps and continuous training, the flotation area becomes a stable, predictable part of the concentrator rather than a recurring source of surprises.
Complex Design | Material Integrity | Heavy performance | Speed, flexibility |