ote outotec flotation technologies eng web

8/12/2019 OTE Outotec Flotation Technologies Eng Web

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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.

Benefits

Case-proven metallurgical superiority

Minimized capital expenditure through

optimum cell size and minimal footprint Minimized operational cost through

efficient hydro-dynamics, robust designs

and advanced materials

High availabily throught easy and safe

maintanances

OutotecFlotation technologies


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002 Outotec Flotation technologies

Flotation technologies for maximizing

metallurgical performance and availability

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 flotation cells

started in the 1960's to satisfy the need for more

efficient, more reliable and easy-to-use equipment.

This development has led to many innovative products

and processes. For decades, we used to call these

flotation technologies with the well-known brand

name OK.

Outotec continues to offer you the same competitive

advantage with flotation 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 oper ators

the perfect tools to enhance flotation performance.

In addition, our froth management technology and

particle-size-specific flotation lead the field for

optimizing recovery in every application. We are ready

to serve you at any time in whichever corner of the

world you operate.

Our Flotation concept:

Performance driven tailoring

Flexibility in operation

Responsive controls

High availability

Easy and safe maintenance

Commitment throughout the life span of

the operation


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Outotec Flotation technologies 003

Chile

Successful site tests and TankCellinstallations 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 flotation 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.

Flotation cell to match your application

Flotation is a technology with over 100 years of

history, yet now the development in our of ferings

is more rapid than ever. To yield maximum profitsin applications with various part icle sizes, we have

specialized designs for each in the flotation cell. The

heart of the cell is the mechanism which creates the

bubble-particle interactions, and equally important

critetrion is efficient froth recovery.

New Outotec FloatForcemechanisms

To replace and excel on the proven OK-mechanism in

MultiMix and FreeFlow configurations, a whole family

of new FloatForce mechanisms has been launched.

The FloatForce mechanism maximizes bubble and

particle contact in the shear zone between the rotor

and stator. The strong shear forces produce suf ficient

energy for fines to break through the water film

energy barrier on the air bubbles.

To complement metallurgical performance, the

FloatForceis also more energy-efficient than anything

before. The mechanism keeps the slurr y in motion

without excessive turbulence. Coarse par ticle contact

with air bubbles is maintained by strong and gentle

mixing to permit maximum recover y by minimizing

bubble-particle detachment.

This new FloatForcemechanism is not only

available in new Outotec flotation deliveries, but also

for existing installed OK, SkimAirand TankCell

equipment to replace MultiMix and FreeFlow

mechanisms.

Optimum aeration at any altitude

The forced air flotation principle ensures optimum

aeration at any operating altitude. Our blower systems

are always designed to the specific 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 flotation challenge is to keep the froth in

constant motion to ensure high recovery or to make

maximum concentrate grade. Our flotation units

feature patented froth crowders to flexibly manipulate

the froth and keep it in continuous motion.

Special launder designs

High-capacity internal launders, double launders

or flexible high capacity radial launders recover the

concentrate quickly, thereby reducing drop-back,especially of the coarsest particles.


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Outotec TankCellflotation units

superior performance

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 under-

stand the value of every 1% in throughput, grade andrecovery.

TankCellunits 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.

Over the lifetime of the Outotec flotation units,

operating costs have proven time and again to be by

far the lowest. High reliability and low maintenance

enable trouble-free oper ation, contributing to a rapid

return on investment.

Our flotation 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 efficient, 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.


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Outotec TankCelleSeries

The cylindr ical TankCell excels in performance as a

rougher, scavenger or cleaner and currently leads theworld in fl otation technology. We use our knowledge

of froth crowding and froth transport characteristics

to adapt the basic design to the demand of dif ferent

flotation duties.

The wide range of proven cell sizes from 5 m to

500 m and the symmetrical design allow a flexible

layout. Internal dart valves minimize the footprint

Superior mixing and minimized short circuiting

The cylindr ical TankCell with the FloatForce

mechanism operates as an ideal mixer and maximizes

the number of collisions between the mineral

particles and air bubbles, as well as reducing 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 r ates

and lip loadings for the specified task.

Availability and Efficiency

With large cell size, the reliabilit y of single equipment

becomes critical. Countless hours of fluid dynamics

analyses and mechanical engineering have allowedus to build ever larger cells that with extremely high

reliability.

Our flotation cells are designed and built with

availability being a key criterion. They tolarate

fluctuating 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.

The new eDrive has beed built will all of the above

criteria. As a result, it combines ease of maintenance,

top-notch efficiency and compact design.


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Outotec 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 flotation approach focuses on flexibility

and circuit optimization. Our various types of flotation mechanisms have proved capable of handling all kinds of

flotation processes. Reliability and ease of use are the keys to our continued success.


OutotecFlash Flotation

In conventional Flash Flotation, we look for grade. The

Outotec SkimAirflotation unit is used as a stand-

alone cell in a one-stage process for producing a

high-grade concentrate.

Outotec Flash Roughing

OutotecFlash 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 thecleaner.


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Australia

Outotec is number one in Australia due to the development, successful testing and installation of large

TankCellunits. 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 certification, 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.

Outotec Flash Roughing flowsheet.

Outotec SkimAir

OutotecFlash Flotation or Flash Roughing by the SkimAir flotation unit takes place in the grinding stage.

Main customer benefits of Outotec SkimAir:

Minimal overgrinding

The Outotec SkimAirunit floats the valuable

liberated particles from the circulating load of thegrinding process while still relatively coarse. These

liberated particles are not ground fur ther and do not

enter the main flotation process as slime par ticles

with poor recovery.

Improved overall recovery

SkimAir recovers considerable amounts of valuable

minerals, resulting in a more stable feed to the

conventional flotation circuit. This creates extra

capacity and improved control in the existing flotationprocess.

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 flotation improvements, the grinding mill

throughput can be increased due to the controlled

high density of the SkimAir underflow.

Improved dewatering

Dewatering improves because the final concentrateP80 is coarser due to the elimination of fines.


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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.


Outotec's range of flotation equipment

TankCell for rougher, scavenger and

cleaner flotation

SkimAir for conventional Flash Flotation or

Flash Roughing in the grinding circuit

Conventional flotation cells for rougher, scavenger

and cleaner flotation

Modular Process Sections

Sub-assembled process sections are cost-effective

and fast to bring into operation. These modules are

practical for transportation, and easy to assemble and

install in the fi eld; customized automation, sampling

arrangements and analyzers are included. Supervision

services and training complete the package.

Service across the globe

Our first class equipment is backed up by first class

people. We provide rapid service to help you achieve

high availability and optimized production rates. We have

highly-trained personnel dedicated to serve you on all

continents and geographical areas where mining and ore

beneficiation are taking place.


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Top safety

Operational safety is one of the primary design criteria

and it also applies to the choice of components

All units carr y the European 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.

OutotecFrothMaster Froth Image Analysis and

Control

The on-line OutotecFrothMaster froth image analysis

and advanced controls fur ther enhance the operation

of the cells. Froth motion and bubble analysis coupled

with higher-level controls for air feed, f roth 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.

Outotec CellStation Operator Interface

We also offer a unique control solution for flotation

units the CellStation. As a stand-alone control panelpositioned on the deck of the flotation cell, it replaces

conventional field 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 CellStation has easy to use graphical

touch screen display to follow control loop status, trends

and to adjust set points for flotation air and slurry levels.

EXACT level

In real life, periodic and uncontrolled plant surges

and large fluctuations in the flotation 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 flotation performance.

The EXACT level is based on feed forward control

principles and unique automatic tuning functionality. It is

conveniently embedded into the CellStation as a plug-

in, and requires no extra instrumentation.

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 flotation, thickening and filtration 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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Proven to

be superior

100

50

0

Fraction size, microns

Tankcell

Other

Case study: superior size-by-size recovery of Outotec TankCell.

3

2.5

2

1.5

1

0.5

00 5 10 15

Tankcell

Other

Targetreductionbelowo

ne

Case study: fast kinetics of Outotec TankCell.

Market leader

Outotec is the technology and market leader. Our

commitment to clients and their needs, continuous

R&D and proven abilit y to commercialize novel

technologies and improvements have resulted in usholding 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 specific flotation tasks,

from base metals to oil sands separation.

In all of the independently organized comparative

studies between competing flotation technologies,

Outotec has always been reported to be superior in

terms of metallurgical performance.

The chart above illustrates the dif ference 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 retrofit the competingtechnology. 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 flotation kinetics

available; this has been proven by fullscale tests in

South America, Canada, Europe and Australia. In the

flotation kinetics case study depicted below, Outotec

TankCell was able to make the required ganguereduction from the feed with 10 minutes' retention

time, which is much faster than competitors' 15 minutes'

retention time.

Canada

We value the Outotec flotation units because they suit the specific purpose and have a metallurgically bene-

ficial 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.


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Outotec services

improve your

process

performance

Outotec's comprehensive technology transfer package

can be completed with expert services and support. Our

customer service operates through a global network of

local units that offers not only assistance meeting the

customers' needs but also a commitment to providing

advanced customer support whenever needed.

Our service experts provide punctual spare parts

logistics, maintenance and training, as well as

assessment and consulting services that generate acompetitive advantage for you.

We can tailor services efficiently to your specific needs,

when considering the necessary operational and

maintenance services already from the beginning of

the project. As your trusted service partner, Outotec

ensures an optimized operation for the entire lifetime

of your plant.

Equipment services

Obtaining all spare parts and maintenance from the

same organization as process and equipment design

ensures that your plant runs optimally. We make

sure that you receive only the highest quality parts,

consumables and upgrades, that can be seamlessly

integrated into your plant.

Plant and process support services

Outotec's advanced plant and process assessment,

ef-X Efficiency Explorer, indentifies the areas for

potential improvements, e.g. equipment, automation

systems, metallurgical processes and complete plants.

What is more, we can make it much easier for you to

fulfill current and future legislation, by ensuring that

your plant and processes are running as efficiently as

possible, and that maintenance is being carried out

proactively. New Virtual Experience Training enhances

users knowledge and skills to manage the dynamic

environment of operating a flotation circuit and the

entire concentrator plant.

Total service package from Outotec:Equipment services

Spare parts and spare parts management

Equipment inspections and maintenance

Training

Process support services

Process assessment

Process control analysis

Plant services

Plant assessments

Operation and maintenance support ser vices

Upgrades and modernizations

Shutdown maintenance services

Benefits of Outotec services

Critical original spare parts in stock

Process and equipment know-how

Minimize downtime and unscheduled

stoppages

Maximum operating performance


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[email protected]

www.outotec.com

Copyright 2011 Outotec Oyj. All rights reserved.

Outotec develops and provides technolog y solutions for the sustainab le use of Earths natural resources.

As th e glo bal le ad er in mi ner al s an d me tal s proc essing te ch no lo gy, Out ot ec has dev elo ped ov er dec ade s

sev er al br ea kth ro ug h te ch no log ies . The co mp an y al so of fe rs inn ov at ive sol uti on s fo r th e ch em ic al

industry, industrial water treatment and the utilization of alternative energy sources. Outotec shares are

listed on the NASDAQ OMX Helsinki.

Finland,

November2011.

ote outotec flotation technologies eng web

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