2828 XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3
INTRODUCTION
It is well documented that by 2030, there will be insuf-
ficient copper supply to balance the demand for copper.
In May 2022, RFC Ambrian conducted a copper market
analysis and concluded that the deficit will be significant.
We will need to increase the supply from existing opera-
tions, as well as bring new projects online. However, the
challenge remains that ore bodies are becoming more dif-
ficult to process. Mudd and Jowitt (2018) assessed copper
deposits globally and agreed that the average copper grades
are declining over time. Northey et. Al (2013) showed as
ore grades decrease, both greenhouse gas (GHG) emissions
and energy intensity increase. Thus, continuing to apply
conventional technologies to meet the copper demand will
result in higher carbon emissions. The way forward is to
accelerate the adoption of new innovative technologies
that deliver both efficient production and reduce energy
consumption.
The NovaCell ™ is a novel froth flotation machine
that delivers high copper recoveries at relatively coarse
flotation feed grind sizes. To date, two laboratory studies
have demonstrated the NovaCell ™ benefits. Jameson and
Emer (2019) found that for a porphyry copper ore, the
NovaCell ™ obtained 100% recovery at particle sizes up
to 300 µm. Morgan and Jameson (2022) observed similar
results for a low-grade porphyry copper deposit. At a flo-
tation feed grind size (P80) of 300 µm, the NovaCell ™
improved copper recovery when compared to the existing
plant recovery. The review of Anzoom et al., (2023) on
coarse particle flotation (CPF) technologies indicated that
the NovaCell ™’s ability to recover coarse valuable particles
is significant.
The benefit of CPF i.e., coarsening the flotation feed
grind size, is that it reduces the energy consumption in the
comminution circuit, which allows for higher throughput
rates and/or reductions in carbon emissions. Morgan et
al., (2023) presented the Pinto Valley mine copper recov-
ery study, which demonstrated the potential impact of
NovaCell ™ at coarser flotation feed grind sizes. The pre-
dicted benefits were a 20% increase in plant production
and a 15% reduction in carbon emissions per ton of copper
product produced.
Figure 1 presents the process schematic of the
NovaCell ™ circuit. Feed material entering the NovaCell ™
plant is combined with recycled tails. The combined stream
is pumped and distributed to downcomers where particles
and tiny bubbles collide in the high-shear zone ideal for fine
and ultrafine particle recovery. Material exiting the down-
comers enters the fluidized bed (shown as the shaded area in
Figure 1). In this region, partially loaded bubbles surround
Figure 1. Process schematic of the NovaCell™ circuit
INTRODUCTION
It is well documented that by 2030, there will be insuf-
ficient copper supply to balance the demand for copper.
In May 2022, RFC Ambrian conducted a copper market
analysis and concluded that the deficit will be significant.
We will need to increase the supply from existing opera-
tions, as well as bring new projects online. However, the
challenge remains that ore bodies are becoming more dif-
ficult to process. Mudd and Jowitt (2018) assessed copper
deposits globally and agreed that the average copper grades
are declining over time. Northey et. Al (2013) showed as
ore grades decrease, both greenhouse gas (GHG) emissions
and energy intensity increase. Thus, continuing to apply
conventional technologies to meet the copper demand will
result in higher carbon emissions. The way forward is to
accelerate the adoption of new innovative technologies
that deliver both efficient production and reduce energy
consumption.
The NovaCell ™ is a novel froth flotation machine
that delivers high copper recoveries at relatively coarse
flotation feed grind sizes. To date, two laboratory studies
have demonstrated the NovaCell ™ benefits. Jameson and
Emer (2019) found that for a porphyry copper ore, the
NovaCell ™ obtained 100% recovery at particle sizes up
to 300 µm. Morgan and Jameson (2022) observed similar
results for a low-grade porphyry copper deposit. At a flo-
tation feed grind size (P80) of 300 µm, the NovaCell ™
improved copper recovery when compared to the existing
plant recovery. The review of Anzoom et al., (2023) on
coarse particle flotation (CPF) technologies indicated that
the NovaCell ™’s ability to recover coarse valuable particles
is significant.
The benefit of CPF i.e., coarsening the flotation feed
grind size, is that it reduces the energy consumption in the
comminution circuit, which allows for higher throughput
rates and/or reductions in carbon emissions. Morgan et
al., (2023) presented the Pinto Valley mine copper recov-
ery study, which demonstrated the potential impact of
NovaCell ™ at coarser flotation feed grind sizes. The pre-
dicted benefits were a 20% increase in plant production
and a 15% reduction in carbon emissions per ton of copper
product produced.
Figure 1 presents the process schematic of the
NovaCell ™ circuit. Feed material entering the NovaCell ™
plant is combined with recycled tails. The combined stream
is pumped and distributed to downcomers where particles
and tiny bubbles collide in the high-shear zone ideal for fine
and ultrafine particle recovery. Material exiting the down-
comers enters the fluidized bed (shown as the shaded area in
Figure 1). In this region, partially loaded bubbles surround
Figure 1. Process schematic of the NovaCell™ circuit