1
24-067
Optimizing Froth Zone in Larger Flotation Cells Through
Innovative Spider Crowder Upgrade
G. Bermudez
Metso Canada, Burlington, ON, Canada
A. Jalili
Metso Canada, Burlington, ON, Canada
C. Cardoso
Metso Chile, Santiago, Chile
ABSTRACT
Bigger flotation cells can result in larger froth surface areas
and longer froth transport distances, this has been credited
to impact froth recovery. Thanks to recent advancements,
the newer flotation machines can be designed with differ-
ent launder and crowder arrangements to enhance froth
management. Nevertheless, lower head grades, complex
ores and even larger mechanical flotation cells can lead to
insufficient froth collection, even if the cell is equipped
with the most recent flotation advancements like the center
launder design. Aforementioned issue can become critical
at the end of the flotation row. Increased crowding has been
proven to be a solution to overcome inadequate froth recov-
ery. However, scaling-up crowders for larger flotation cells
can rise challenges, particularly in terms of structural limits
and design for service. This paper presents the development
journey for the Spider Crowder Upgrade, an advancement
to improve froth collection in large flotation cells that are
already equipped with center launders.
INTRODUCTION
Flotation is key mining operation to separate valuable
materials from gangue to facilitate obtention of necessary
metals that are highly demanded for current global needs,
such as electrification and manufacturing. Consequently,
this has surged the growth of concentrator plants to fulfill
the aforementioned. This trend can be noticed at the flota-
tion circuits, where cells have increased to volumes larger
than 600 m3.
Some benefits that these larger flotation machines have
brough include the possibility to process higher through-
puts, reduced installed footprint and energy consumption
optimization. Nevertheless, they also have resulted in new
challenges, like the need for newer maintenance strategies
and difficult froth management.
Bigger cells have reported poor froth collection and
low coarse particles recovery, thus hampering metallurgical
performance. This effect has been attributed to its legacy
design including suboptimal froth zone parameters, like
large froth surface area and long transport distance.
Froth zone parameters relative to flotation tank vol-
ume growth has been plotted by Corona et al. (2021) in
Figure 1 for Metso´s flotation cells installations. As detailed
in the graph, there is a correlation between cell´s volume
and froth transport parameters, such as Froth Surface Area
(FSA), Froth Transport Distance (FTD) and Lip Length
(LL). When these factors grew significantly, different
arrangements of launder and crowders were trailed to miti-
gate this effect.
According to Mesa and Brito-Parada (Mesa and Brito-
Parada, 2019b) it is highlighted that the available lit-
erature on the design of different inserts for froth control
24-067
Optimizing Froth Zone in Larger Flotation Cells Through
Innovative Spider Crowder Upgrade
G. Bermudez
Metso Canada, Burlington, ON, Canada
A. Jalili
Metso Canada, Burlington, ON, Canada
C. Cardoso
Metso Chile, Santiago, Chile
ABSTRACT
Bigger flotation cells can result in larger froth surface areas
and longer froth transport distances, this has been credited
to impact froth recovery. Thanks to recent advancements,
the newer flotation machines can be designed with differ-
ent launder and crowder arrangements to enhance froth
management. Nevertheless, lower head grades, complex
ores and even larger mechanical flotation cells can lead to
insufficient froth collection, even if the cell is equipped
with the most recent flotation advancements like the center
launder design. Aforementioned issue can become critical
at the end of the flotation row. Increased crowding has been
proven to be a solution to overcome inadequate froth recov-
ery. However, scaling-up crowders for larger flotation cells
can rise challenges, particularly in terms of structural limits
and design for service. This paper presents the development
journey for the Spider Crowder Upgrade, an advancement
to improve froth collection in large flotation cells that are
already equipped with center launders.
INTRODUCTION
Flotation is key mining operation to separate valuable
materials from gangue to facilitate obtention of necessary
metals that are highly demanded for current global needs,
such as electrification and manufacturing. Consequently,
this has surged the growth of concentrator plants to fulfill
the aforementioned. This trend can be noticed at the flota-
tion circuits, where cells have increased to volumes larger
than 600 m3.
Some benefits that these larger flotation machines have
brough include the possibility to process higher through-
puts, reduced installed footprint and energy consumption
optimization. Nevertheless, they also have resulted in new
challenges, like the need for newer maintenance strategies
and difficult froth management.
Bigger cells have reported poor froth collection and
low coarse particles recovery, thus hampering metallurgical
performance. This effect has been attributed to its legacy
design including suboptimal froth zone parameters, like
large froth surface area and long transport distance.
Froth zone parameters relative to flotation tank vol-
ume growth has been plotted by Corona et al. (2021) in
Figure 1 for Metso´s flotation cells installations. As detailed
in the graph, there is a correlation between cell´s volume
and froth transport parameters, such as Froth Surface Area
(FSA), Froth Transport Distance (FTD) and Lip Length
(LL). When these factors grew significantly, different
arrangements of launder and crowders were trailed to miti-
gate this effect.
According to Mesa and Brito-Parada (Mesa and Brito-
Parada, 2019b) it is highlighted that the available lit-
erature on the design of different inserts for froth control
