Flotation machine RCS - Madencilik Türkiye · Flotation machine RCS Flotation is a mineral...

Flotation machine RCS

Technology at work for you

Andrew Wilkinson

Metso TR Seminar

27 April 2012

Features and capabilities Designed for increased capacity, reduced

maintenance, and increased reliability

© Metso Date Author Title 3

• Metso introduction

• Product application

• Features and benefits

• Needed to size

• Reference applications

• Service business line

• Conclusion

Contents

© Metso Date Author Title 4


Flotation is a mineral separation

process, which takes place in a water-

mineral slurry.

The surfaces of selected minerals are

made hydrophobic (water-repellent) by

conditioning with selective reagents.

The hydrophobic particles become

attached to air bubbles that are

introduced into the pulp and are

carried to a froth layer above the slurry

thereby being separated from the

hydrophilic (wetted) particles.

Product role

Hydrophobic

reagents

Particle

surface

Particle

Air bubble

© Metso

Flotation machine RCS Benefits

Date Author Title 5

• Create bulk slurry flow patterns

- Solids suspension

- Particle bubble contact

- Solids resuspension

• Effective air dispersion and distribution

• Extended wearlife

• Minimise absorbed power

© Metso

Flotation machine RCS Features

Date Author Title 6

• Enhanced performance

− Ideal hydraulic flow zones to

maximise recovery of all sizes

−Minimised slurry short circuiting

• Improved access

−Cell top walkway improves

maintenance access to mechanism drive

• Reduced installation costs

−Cell top walkway reduces building floor area

−Single side froth discharge simplifies froth handling

−Modular tank design simplifies installation

© Metso

Flotation machine RCS Complete flotation machine

Date Author Title 7

Main support

frame

Cross flow

froth launder

Mechanism assembly

Motor

Flotation

cell tank

Feed box

Intermediate and discharge box

Air supply

Level control

© Metso

Flotation machine RCS Mechanism assembly

Date Author Title 8

8

Air swivel

Motor

Motor sub frame

V-belt drive

Stand pipe

Spindle bearing

Impeller

Diffuser

Mechanism sub frame

© Metso

Flotation machine RCS Feedbox, intermediate and discharge box

Date Author Title 9

Level and flow function

© Metso

Flotation machine RCS Mechanism drive

Date Author Title 10

V-belt drive < RCS 130 > Gear box

© Metso



Froth launders

Take out of flotated mineral

© Metso

Flotation machine RCSTM

Patented mechanism design

• Enhanced flotation performance

- Maximum particle bubble contact

- Effective solids suspension

- Controllable aeration

• Reduced operating costs

- Cast polyurethane wear parts

- Minimised absorbed power

• Improved maintenance

- One piece fully suspended mechanism

- Wear parts replaceable in-situ


© Metso

Flotation machine RCS Mechanism design


Primary return flow

Top recirculation

Aerated radial

flow

Aerated radial

flow

© Metso


Date Author Title 14 14

Impeller

Controlled air addition

Standpipe

Diffusor vane

Hollow shaft

Mechanism design

© Metso



Down flow

dart valves

Valve stem

Pneumatic

actuator

Float

Target plate

Ultrasonic transmitter / detector

Level control system

© Metso

Flotation machine RCS Aeration control


Flexible air hose

Air swivel

Air flow meter

Pneumatic

air control valve

© Metso

Flotation machine RCS Mechanical cell – type RSC


© Metso

Flotation machine RCS CFD Simulation


• Predicted bubble rise velocity in a vertical plane

© Metso 22

Flotation machine RCS Bank design

© Metso

Flotation machine RCS Tank design


Single side

froth discharge

Cell top walkway

© Metso

Flotation machine RCS A Platinum Plant


© Metso

Flotation machine RCS Size range


© Metso

Date Author Title

34

Flotation machine RCS Applications

• Iron flotation, Non-ferrous metals, Industrial minerals

© Metso

Flotation machine RCS Installations


Copper

Lead/Zinc

Platinum

Other

Asarco Mission

Agnico Eagle

Boliden

Zink-

gruvan

Almagrera

Luiswishi Sungun

Miduk

Sar Chesmeh

Pasminco Elura

BHP Tintaya

Shougang Hiero

Impala Rustenburg

Lonmin Karee Ivan

SIMSA

Suncor Millenium

Mortimer

Amandelbult

Stillwater Platinum

Crown Mining

Waterval

Casapalca

Polkowice

Rudna

Kilken Platinum

Poltava

Nordkalk

LKAB

Imerys

Boliden

K&S

Youssofi

Khouribua

SASA

Rotem

Rapu Rapu

Toms Gully

Bendigo Tintaya

Atacocha

Volcan

Colquisiri

Gaiski Varvariuskoye

Navoi Mining

Kaltun

Eti Bakir

Endomines

Gradir

Buenaventura

Sylvania Mining

Lonmin Karee

Carrolindo

El Teniente

Ruby Creek

© Metso

Flotation machines RCS 15 and 40 European Pb/Zn concentrator modernization


Flot at ionshall Flot at ionsdel plan +189

121 3

C

D

E

F

G

H

J

567891 01 1

SAMRÅ-SCAVENGER KRETS

SAMREPETERINGS KRETS

BLYREPETERINGS KRETS

BLYRÅ- SCAVENGER KRETS

Before

5 6 7 8 9 10 11 12 13

C

D

E

F

G

H

J

Flotationshall Flotationsdel plan +189

JELE

OK 38

SF 1-2

SR 1-2

PF 3-4 PF 1-2

ZINKGRUVAN MINING AB

FLOTATIONSHALL PLAN +189

svenh 98-04-07

rev. 99-03-04

After

2,700 TPD Lead Zinc Ore

10 - 11% Zn 4% Pb

1997 4 - cell RCS 15 bulk cleaner

4 - cell RCS 15 lead cleaner

Benefits

1998 6 - cell RCS 15 separation rougher

2 - cell RCS bulk cleaner

6 - cell RCS 40 bulk rougher

Phase 1 modernization program:

- increased flotation volume

- reduced maintenance/operating costs

- improved metallurgical performance

2009 8 - cell RCS 15 Cu rougher

4 - cell RCS 15 Cu cleaner

Phase 2 Cu circuit

© Metso

Flotation machines RCS 15 and 40 Benefits


Typical Concentrate Grades:

• Increased spare floor area for

further plant improvements

• 1% increase in Zn concentrate

grade maintained Pb concentrate

grade more stable production

• Reduced flotation power draw from

2.2 kW/m3 to 1.1 kW/m3

• Reduced rotating equipment for

maintenance:flotation mechanisms

from 156 to 28 pumps from 32 to19

Zn concentrate 56% 1% Pb

Pb concentrate 74% 6% Zn

© Metso

Flotation machines RCS 130 - Copper rougher Benefits


• RCS Cell Cu recovery average

37% range 16 - 77%

• RCS Mechanism power draw

0.70 kW/M3

• RCS fully integrated into plant

operation with concentrate

directed according to feed

mineralogy.

• RCS Cell Cu concentrate grade

average 28% range 17 - 33%

• Additional plant recovery with

RCS 130 - 1 - 3% Cu concentrate

grade 25 - 28% Cu

18,000 - 20,000 TPD Chalcopyrite

Copper Ore

Ore grade and mineralization vary

widely 0.30 - 0.75% Cu

Non sulfide Copper 7 - 20% of total Cu

© Metso

Flotation machine RCS RCS 50 2 - Cell bank copper rougher


Benefits

• Improved fines recovery

resulting in an additional

1% overall plant recovery

© Metso

Flotation machine RCS 6-cell South American iron ore concentrator


Benefits

• 25% reduction in energy costs

• Improved recovery from 95%

to 97 - 98%

Thank you

43

Flotation machine RCS - Madencilik Türkiye · Flotation machine RCS Flotation is a mineral...

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