Modelling and Simulation of a Coarse Particle Flotation Technology
Year: 2026
Type: article
Abstract: Coarse particle flotation technologies have emerged to overcome the limitations of conventional flotation circuits, whose performance decreases for coarse fractions. Metso’s Coarse Particle Flotation (CPF) technology takes an approach based on feeding directly into the froth zone, where particle collection and froth transport processes occur. Currently, there are no models that link operating variables with the metallurgical performance of this technology. This work presents a model for the Metso’s CPF cell based on the two phenomena that occur simultaneously in the froth zone: particle collection and the transport of particle–bubble aggregates by the froth. The collection process is modelled using a rectangular distribution for flotation kinetics and a residence time distribution based on three perfectly mixed reactors in series: two small reactors and one large. The transport of the froth is represented as a function of froth stability, froth transport distance, and gas residence time. The model was calibrated using laboratory experimental data from copper ore, showing a maximum absolute error in Cu recovery of 2.9%. The main results showed recoveries of approximately 70% for the 300–425 μm class and approximately 50% for the +425 μm class. The size analysis showed a systematic decrease in recovery with particle size, with critical behavior at low froth depths and low superficial gas velocity. A sensitivity analysis confirmed consistent model responses to changes in the main operating variables.
Source: Minerals
DOI: 10.3390/min16090883
Institutions: Universidad Técnica Federico Santa María, Metso (Finland)
Language: English
Subfield: Filtration and Separation
Field: Chemical Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $2,896
OpenAlex ID: W7204872547