coarse and fine particle flotation, with less energy and

jord.com.au

Coarse and fine particle flotation, with less energy and water consumption

JRD011_NovaCell 8pp FA2.indd 1JRD011_NovaCell 8pp FA2.indd 1 9/9/21 12:25 pm9/9/21 12:25 pm

Jord International ( Jord), together with Laureate Professor Graeme Jameson, have developed a sustainable mining technology called the NovaCell™. The NovaCell™ recovers valuable particles from 1µm to 1mm, whilst requiring less milling energy and minimal water addition than conventional technologies.

• NovaCell™ provides optimal conditions for both coarse and fine particle flotation recovery in one device.

• The efficient design significantly reduces the total milling energy required for selective flotation recovery.

• The process flowsheet is simple, with no need for an upfront fines removal plant.

• Jord offers flexible delivery options, including modular plants with trial assembly.

Introducing NovaCell™

For more information, contact Sherwin MorganPhone +61 467 061 121Email [email protected]


Efficient Flotation DesignThe NovaCell™ has a novel configuration, which produces the best hydrodynamic conditions for both fine and coarse particle flotation recovery. Feed material entering the NovaCell™, is distributed across downcomers where particles and tiny bubbles collide in the high-shear zone ideal for fine and ultrafine particle recovery. Material exiting the downcomers enters the fluidised bed, where partially loaded bubbles surround particles in a low-shear environment ideal for coarse particle recovery. Both fine and coarse valuable minerals rise in the NovaCell™ and are collected as two separate streams. A high-grade flotation concentrate is collected at the top of the cell, whilst coarser valuable particles that may detach are collected in an inverted cone. The coarse valuables are then removed by a separation device, such as a screen or cyclone for further processing.

Figure 1 illustrates the typical NovaCell™ plant. The classification circuit is represented by a cyclone. Depending on the process requirements, this may be in combination with a screen.

Figure 1: Process schematic of NovaCell™ plant

AIR

NEW FEED

FROTH CONCENTRATE

TANKPUMP

PROCESS WATER

BLOWER

LEGENDAir/Water streamsFeed & recycle streamsProduct streamsTailings streams

CYCLONE

NOVACELL

PUMP

OVER FLOW TAILINGS

UNDERFLOW TAILINGS

CYCLONE UNDERFLOW


Technology BenefitsLower Energy Consumption – The NovaCell™ can process coarse feed material, reducing the energy consumption in the milling circuit by up to 40%. Coarse particles, that have insufficient buoyancy to be recovered in the froth concentrate, are collected over the screen or cyclone. Results suggest that even particles with relatively low mineral liberation (~5%) are recovered.

Improved Recoveries – The NovaCell™ produces a significant recovery improvement across the complete particle size range. The particles recovered to the product streams are also high in valuable mineral content, confirming selective recovery.

Reduced Environmental Impact – The NovaCell™ produces a coarse tail for disposal, enabling the use of modern tailing management strategies, such as dry stacking. It also uses a recycle stream to fluidise the bed, reducing its water consumption and impact on tailings dams.

Lower Capital Investment – The NovaCell™ process flowsheet is simple because there is no need for an upfront fines removal plant. The NovaCell™ has a froth layer to selectively recover fines, thus the full process flow can be treated. Having fines in the system also minimises wear on the components.


ApplicationsCoarse Gangue (Waste) Rejection – By recovering both fine and coarse particles efficiently, the NovaCell™ can be installed in the milling circuit. This allows clients to reject a significant portion of the feed early on, whilst still maintaining good recoveries. As a result, mine operators can reduce energy consumption, target higher mill throughputs, and/or install smaller downstream equipment.

Tailings Scavenging – By recovering both fine and coarse particles efficiently, the NovaCell™ can be installed on a rougher scavenger tailings stream. This allows clients to improve overall plant recovery and produce a ‘cleaner’ tailing with less acid-generating potential for disposal.

Suitable Commodities – NovaCell™ technology can be applied to precious metals, base metals, coal and industrial minerals. We test all types of commodities and the technology has a unique ability to separate and recover a range of particle sizes, even for ore types with low levels of mineral liberation.

Coarse Gangue (Waste) Rejection Adding NovaCell™ to EXISTING circuit

COARSE GANGUE REJECTION - ADDING NOVACELL TO EXISTING CIRCUIT

NovaCell

Viper

Final Product

Final Tails

ROM Ore

COARSE GANGUE REJECTION - ADDING NOVACELL TO NEW CIRCUIT

NovaCell Circuit

Viper

Final Product

Final Tails

ROM Ore

TAILINGS SCAVENGING - ADDING NOVACELL TO EXISTING CIRCUIT

NovaCell

Viper

Final Product

Final Tails

ROM Ore

Coarse Gangue (Waste) Rejection Adding NovaCell™ to NEW circuit

Tailings ScavengingAdding NovaCell™ to EXISTING circuit


Proven ResultsJord uses laboratory-scale NovaCell™ equipment at the University of Newcastle in Australia to conduct testwork on different ore types. The results are used to confirm expected plant performance and to optimise process conditions. Testing can also be conducted onsite. We work with clients to address their needs for feed variability, operations and maintenance.

The NovaCell™ technology has been tested on a range of complex ore types, including particles with only ~5% mineral liberation. The results prove that the technology is producing high recovery efficiencies across all size fractions and is selectively recovering coarse and fine mineral-rich particles to both product streams. This is a breakthrough in flotation equipment technology.

Figure 2 presents the copper and gold recovery by size results, and demonstrates a consistently high recovery performance across the full range of particle sizes.

Cu AuParticle Size (µm)

Rec

over

y %

100 100010

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Figure 2: Recovery by size results for copper and gold


5.0

0.0

10.0

15.0

20.0

25.0

30.0

Particle Size (µm)

Particle Size (µm)

Cop

per

Rec

over

y (%

)C

oppe

r U

pgra

de R

atio

Froth+Screen Froth Screen

Froth+Screen Froth Screen

Figure 3: Cu recovery by size results for froth and screen products

Figure 4: Copper upgrade ratio for froth and screen products

10%

0%

20%

30%

-600+500

-600+500

9.4

24.9

7.5

5.13.4

7.2

0.9 0.4 0.4 0.6

6.86.7

16.8

15.114.0

12.5

9.58.6

0.3 0.3

14.5

10.0

12.4

28.2

-500+425

-500+425

-425+300

-425+300

-300+212

-300+212

-212+150

-212+150

-150+106

-150+106

-106+53

-106+53

-53

-53

40%

50%

60%

70%

80%

90%

100%

Figure 3 illustrates the copper recovery by size results for the flotation concentrate and screen product streams. The screen results indicate the expected performance of the classification system at full-scale.

Figure 4 presents the copper upgrade ratio (i.e. concentrate assay/feed assay) for both product streams, and indicates that the particles recovered to the flotation concentrate are significantly higher in valuable mineral content.


ContactSherwin Morgan Shaun Wait Phone +61 467 061 121 Phone +61 418 582 776 Email [email protected] Email [email protected]

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About JordJord designs, manufactures, commissions and services custom process plant and systems. For nearly 50 years, the Jord Group has served the global energy and resource process industries. From its Australian headquarters, Jord has delivered $5 billion of bespoke plant and systems to over 130 countries around the world. Visit www.jord.com.au for more information.

Our Research and Development ProgramAt Jord, we live by the motto ‘ideas engineered’. Jord heavily invests in research and development initiatives with a goal to commercialise new minerals beneficiation technologies for more efficient and more effective liberation of ore. Our goal is to unlock new technologies that provide step-change improvements to current processes in the industry. It’s about using less energy, using less water, and removing environmental challenges with a particular focus on tailings management.

Jord sponsors the Australian Research Centre (ARC) Centre of Excellence and works closely with the University of Newcastle to research, test and produce new technologies at scale in partnership with our customers. Under an embedded partnership agreement, a small team of Jord staff work at the university every day. This enables real-time collaboration with academics and involvement in experimentation to drive commercially viable results, rather than just theoretical results.

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Flexible Delivery ModelsJord has 50 years of experience in modular design, manufacture and installation of process plants. The business is supported by a well-established global network of fabrication alliances in strategic locations around the world. We can deliver the NovaCell™ technology as equipment supply or as a full turn-key solution, depending on your requirements. The NovaCell™ components are designed to international engineering standards, and produced in a clean and controlled workshop environment with Quality Assurance and Quality Control protocols in place. We also offer a trial assembly to mitigate installation risks.


coarse and fine particle flotation, with less energy and

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