Flotation technologies

Outotec is the world leader in flotation technology. We

set new standards for superior flotation performance:
mixing, aeration and froth recovery for every
flotation task. Our solutions are tailor-made for each
customer, including flotation packages with support
services, modular process sections and even whole
concentrators for base and precious metals and
industrial minerals.
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Flotation technologies for maximizing
metallurgical performance and availability
Our Flotation concept:
n Performance driven tailoring
n Flexibility in operation
n Responsive controls
n High availability
n Easy and safe maintenance
n Commitment throughout the
life span of the operation
Advantages
n Case-proven metallurgical
superiority
n Minimized capital expenditure
through optimum cell size
and minimal footprint
n Minimized operational cost
through ef cient hydro-
dynamics, robust designs
and advanced materials.
Time-proven, innovative and efficient solutions
Our Flotation offering is based in the earlier mining and concentrator
operations of the Outokumpu corporation. Development of in-house
otation cells started in the 1960's to satisfy the need for more ef cient,
more reliable and easy-to-use equipment. This development has led to
many innovative products and processes. For decades, we used to call
these otation technologies with the well-known brand name OK.
Outotec continues to offer you the same competitive advantage
with otation technology that has evolved through decades of continuous
R&D and experience. Forty years in business prove our commitment to
customers as well as the operational reliability and performance of our
equipment.
Our automation and analyzer solutions offer operators the
perfect tools to enhance otation performance. In addition, our froth
management technology and particle-size-speci c otation lead the
eld for optimizing recovery in every application. We are ready to serve
you at any time in whichever corner of the world you operate.
Flotation cell to match your application
Flotation is a technology with over 100 years of history, yet now the
development in our offerings is more rapid than ever. To yield maximum
pro ts in applications with various particle sizes, we have specialized
designs for each in the otation cell. The heart of the cell is the
mechanism which creates the bubble-particle interactions, and equally
important criterion is ef cient froth recovery.
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FreeFlow -mechanism for enhanced mixing of

coarse and medium-size particles

The energy-saving FreeFlow mechanism keeps the

slurry in motion without excessive turbulence. Coarse
particle contact with air bubbles is maintained by
strong and gentle mixing to permit maximum recovery
by minimizing bubble-particle detachment.

MultiMix -mechanism provides high kinetic energy

for fine and medium size particles

The MultiMix -mechanism maximizes bubble and

particle contact in the shear zone between the rotor
and stator. The strong shear forces produce suf cient
energy for nes to break through the water lm
energy barrier on the air bubbles.
New FloatForce mechanisms underway
To excel on the proven OK-mechanism in MultiMix
and FreeFlow con gurations, a whole family of
new FloatForce mechanisms is launched. This
new technology is not only available in new Outotec
otation technology deliveries, but also for existing
installed OK, SkimAir and TankCell equipment.
Optimum aeration at any altitude
The forced air otation principle ensures optimum
aeration at any operating altitude. Our blower systems
are always designed to the speci c site conditions.
Easy start-up under full load
The unique, downward-tapering rotor enables fast
start-up under load after a scheduled or unscheduled
shut-down.
Froth management leads to high recovery with
optimal grade
Another otation challenge is to keep the froth in
constant motion to ensure high recovery or to make
maximum concentrate grade. Our otation units
feature patented froth crowders to exibly manipulate
the froth and keep it in continuous motion.
Special launder designs
High-capacity internal launders, double launders
or exible high capacity radial launders recover the
concentrate quickly, thereby reducing drop-back,
especially of the coarsest particles.

Chile

Successful site tests and TankCell installations have proven that the cells are easy to operate. Control
tools, especially the air control, are very good and the metallurgy is excellent. Operating and maintenance
costs are also low. Heavy-duty manufacturing of all otation units and top-quality components are highly
appreciated.
Assistance and services used most often include training of operators and maintenance staff,
proposals for inspections and preventive maintenance activities as well as spare parts recommendations.
We also make suggestions for process improvements. Our customers appreciate that we work as partners
with them and give them the service they need. We know the process and can really assist them.
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TankCell flotation units

superior performance
TankCell units as unit reactors meet all the requirements set for superior flotation performance.

They are easy to operate, low on power and air consumption and allow for a flexible layout. Further,

the TankCell family comprises the widest size range on the market.

Maximum return on investment

We have a simple goal to maximize your return on investment. Our design

philosophy is to provide you with the best long-term investment. As operators,
we understand the value of every 1% in throughput, grade and recovery.
Over the lifetime of the Outotec otation units, operating costs
have proven time and again to be by far the lowest. High reliability and low
maintenance enable trouble-free operation, contributing to a rapid return
on investment.
Our otation units are built to last. Components and electrical
equipment are selected for maximum operating life. For instance, our
rotors and stators have proven to be the most wear-resistant available.
The wide range of available cell sizes permits plant design to be compact,
economical and efcient, without fear of short circuiting, even for todays
high-tonnage operations. Fewer units mean substantial savings in
construction costs, piping, cables, instrumentation and auxiliary equipment.

Outotec TankCell
The cylindrical TankCell excels in performance
as a rougher, scavenger or cleaner and currently
leads the world in otation technology. We use
our knowledge of froth crowding and froth transport
characteristics to adapt the basic design to the
demand of different otation duties.
Superior mixing and minimized short circuiting
The cylindrical TankCell operates as an ideal mixer
and maximizes the number of collisions between the
mineral particles and air bubbles, as well as reduces
short circuiting.
Optimized aeration and froth recovery
TankCell units have an optimized froth surface area
based on the mineralogy and kinetics in each case.
They are designed to handle maximum carrying rates
and lip loadings for the speci ed task.
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Flexible plant layout, minimized footprint
The wide range of proven cell sizes from 5 m to
300 m and the symmetrical design allow a exible
layout. Internal dart valves minimize the footprint.
Availability
With large cell size, the reliability of single equipment
becomes critical. Countless hours of uid dynamics
analyses and mechanical engineering have allowed
us to build ever larger cells with extremely high
reliability.
Our otation cells are designed and built
with availability being a key criterion. They tolerate
uctuating feeds and even oversize material without
blocking up. Mechanical components are carefully
sized to minimize vibration and loading; wear parts
provide easy and safe maintenance.
Advanced cell controls
The TankCell is easy and responsive to operate
with the basic level of instrumentation and controls.
However, a circuit with a smaller amount of larger
cells lends itself nicely to more sophisticated controls.
FrothMaster
The on-line FrothMaster froth image analysis and
advanced controls further enhance the operation of
the cells. Froth motion and bubble analysis coupled
with higher-level controls for air feed, froth depth
and reagents provide a unique way to optimize the
concentrate mass pull and grade.
The FrothMaster high quality live video feed
and easy readouts provide the operator an accurate
feel of the process continuously.
EXACT level
In real life, periodic and uncontrolled plant surges
and large uctuations in the otation feed are not
uncommon. The EXACT level control solution is
designed to monitor upstream processes and feeds a
compensation signal to the cell level controller before
disturbances interfere otation performance.
The EXACT level is based on feed forward
control principles and unique automatic tuning
functionality. It is tailored to a project speci c
owsheet and requires no extra instrumentation.
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SkimAir flotation units

profit-makers in the grinding circuit
Outotec is known as a forerunner in bringing new technologies to the market. No one comes close when it comes to

understanding and utilizing particle dynamics and froth management. Our otation approach focuses on exibility

and circuit optimization. Our various types of otation mechanisms have proved capable of handling all kinds of
otation processes. Reliability and ease of use are the keys to our continued success.

Flash Flotation

In conventional Flash Flotation, we look for grade. The Outotec SkimAir

otation unit is used as a stand-alone cell in a one-stage process for producing
a high-grade concentrate.

Flash Roughing

Flash Roughing is recovery-driven. SkimAir operates using Dual Outlet

Technology, which has world-wide patent coverage, to produce a lower-grade
concentrate at a high recovery. Flash Roughing can comprise two stages: the
SkimAir unit is used as the rougher, and a special TankCell is closely linked
as the cleaner.
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Flash Roughing owsheet.

Outotec SkimAir This creates extra capacity and improved control

Flash Flotation or Flash Roughing by the SkimAir
otation unit takes place in the grinding stage.
Minimal overgrinding
The SkimAir unit oats the valuable liberated
particles from the circulating load of the grinding
process while still relatively coarse. These liberated
particles are not ground further and do not enter the
main otation process as slime particles with poor
recovery.
in the existing otation process. A lower-grade
concentrate with high recovery can be obtained and
blended with the higher grade SkimAir concentrate
to increase the overall plant recovery.
Increased mill throughput
Along with otation improvements, the grinding mill
throughput can be increased due to the controlled
high density of the SkimAir under ow.
Improved dewatering

Improved overall recovery Dewatering improves because the nal concentrate

P80 is coarser due to the elimination of nes.
SkimAir recovers considerable amounts of valuable
minerals, resulting in a more stable feed to the
conventional otation circuit.

Australia

Outotec is number one in Australia due to the development, successful testing and installation of large
TankCell units. The largest Flash Flotation SkimAir cells have also been developed and successfully
installed for the Australian market.
Our locally-based technical and engineering team, operating with ISO 9001 certication, can quickly
respond to customers and engineering companies. This applies to bid requests as well as solving on-site issues.
Our quotations have general arrangement drawings in electronic form for further processing as initial plant
layouts.
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All under control

Outotec offers the widest range of flotation solutions available to meet all application needs. Each flotation

unit can be delivered complete with a customized package of our automation or on-stream analyzers.

Outotecs range of otation equipment

n TankCell for rougher, scavenger and cleaner otation
n SkimAir for conventional Flash Flotation or Flash Roughing
in the grinding circuit
n Conventional otation for rougher, scavenger and cleaner otation

Flotation package with support services

We deliver otation systems to meet your specic requirements;

automation and analyzers can be included. We provide supervision
services for installation, commissioning and start-up, and training of plant
personnel is an essential part of the package. Comprehensive after-sales
service and consultation are proof of our commitment to your continuous
operational performance. Each delivery focuses on maximizing the use of
local resources.
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Operator interface

We also offer a unique control solution for otation

units the FrothCon. As a stand-alone control panel
positioned on the deck of the otation cell, it replaces
conventional eld controllers and performs a variety
of additional functions. It can be linked to the Outotec
family of analyzers and any plant process control
system.
The PLC based FrothCon has easy to use
graphical displays to follow control loop status, trends
and to adjust set points for otation air and slurry levels.
By connecting one of the Outotec Courier
analyzers through a process control system or directly
Modular process sections
to FrothCon, the operator can access process assay
information online. Naturally also the FrothMaster
Sub-assembled process sections are cost-effective
signals can be accessed on the FrothCon. It provides a
and fast to bring into operation. These modules are
ready-made solid basis for a high-level control, such as
practical for transportation, and easy to assemble and
the Outotec Proscon advanced process control system.
install in the eld; customized automation, sampling
arrangements and analyzers are included. Supervision
Service across the globe
services and training complete the package.

Our rst class equipment is backed up by rst class

Top safety
people.
We provide rapid service to help you achieve
We set new standards for superior otation
high availability and optimized production rates. We have
performance: aeration and mixing, froth manipulation
highly-trained personnel dedicated to serve you on all
and recovery for every otation task. Operational
continents and geographical areas where mining and ore
safety is one of the primary design criteria and it
beneciation are taking place.
also applies to the choice of components. All units
carry the CE mark. Reducing environmental impact is
always the starting point in the design of all Outotec
systems. Our equipment is designed for the highest
operational cleanliness.

Link to high-level automation

We can assist you in every step of your automation

development, based on our highly recognized
achievements in process control and automation.

The CIS countries

Outotec has had long experience of modernizing existing plants in the CIS. The company has also delivered
complete new plants, comprising equipment for otation, thickening and ltration as well as related automation
and analyzers. Years of experience in this market have facilitated timely deliveries and smooth co-operation.
Our designers and specialists all have plant metallurgical backgrounds from similar ore processes.
We have a long tradition in equipment manufacturing, which is complemented by easy railway transportation
from Finland to the CIS.
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100
50
0 Fraction size, microns
Case study: superior size-by-size recovery of TankCell.
Market leader
Outotec is the technology and market leader. Our
commitment to clients and their needs, continuous
R&D and proven ability to commercialize novel
technologies and improvements have resulted in us
holding a majority share of the market.
The best, all the time
We have experience beyond others. Our client plant
audit services have contributed to optimized plant
performances. From the 1970's onwards, Outotec has
developed solutions for many speci c otation tasks,
from base metals to oil sands separation.
In the independently organized comparative
studies between competing otation technologies,
Outotec has always been reported to be superior in
terms of metallurgical performance.
3
2.5
1.5
0.5
0
0 5
Tankcell
Proven to be
Other
superior
The chart above illustrates the difference in recovery
between TankCell and competing technology in actual
plant operation. The size-by-size results show that in
some size fractions the increase in recovery was over
20 percentage units. Based on four cell comparative
test, the client decided to retro t the competing
technology. The total plant recovery was improved
as a consequence, and the payback time for the
improvement was very short.
Most efficient technology available
TankCell is known to have the fastest otation kinetics
available; this has been proven by fullscale tests in
South America, Canada, Europe and Australia. In the
otation kinetics case study depicted below, Outotec
TankCell was able to make the required gangue
reduction from the feed with 10 minutes' retention
time, which is much faster than competitors' 15 minutes'
retention time.
Case study: fast kinetics of TankCell.
Tankcell
Target reduction below one
Other
10 15
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We offer you a long-term partnership through local presence,

supported by a global network of professionals. We provide

flotation packages, modular process sections or whole

concentrators.

Canada

We value the Outotec otation units because they suit the specic purpose and have a metallurgically bene-
cial design, meeting or exceeding metallurgical expectations in terms of grade and recovery. Operation is
trouble-free. Compared with competitor units, the Outotec units operate at low power consumption.
As a company, our expertise in recommending the cells, cell sizes and cell placement is recognized,
along with our design and application competence. Similar application references, quality of after-sales
performance and on-site service are highly appreciated by our customers.
 3007EN. Pinta/Libris, Helsinki, Finland. July 2007
Outotec, formerly Outokumpu Technology, is a worldwide technology
leader in minerals and metals processing, providing innovative and
environmentally sound solutions for a wide variety of customers in
minerals processing, iron and steel, aluminum and non-ferrous metals
industries. Outotec Oyj is listed on the Helsinki Stock Exchange.

otation@outotec.com
www.outotec.com

Copyright 2007 Outotec Oyj. All rights reserved.

Outotec and More out of ore! are registered trademarks of Outotec Oyj.