XXXI International Mineral Processing Congress 2024 Proceedings/Washington, DC/Sep 29–Oct 3 2829
particles in a low-shear environment ideal for coarse par-
ticle recovery. After attachment, both fine and coarse valu-
able minerals rise in the NovaCell ™ and are collected in
two product streams. A froth concentrate is collected at the
top of the cell, as in existing froth flotation technologies.
A secondary collection device, an internal cone, captures
additional coarse valuable particles unrecoverable through
the froth zone. The design of the particle collection and
separation phases of the cell enables this innovative tech-
nology to achieve high recoveries across a wide particle size
range.
For existing and future porphyry copper mines, the
NovaCell ™ targets the following benefits:
• 10 to 20% increase in metal production – by main-
taining mineral recoveries at coarser flotation feed
grind sizes, it would allow mines to operate at higher
throughput rates and reduce the capital investment
required to debottleneck the comminution circuit.
• 5 to 10% increase in copper recoveries – by recov-
ering fine and coarse copper particles typically lost
by conventional flotation technologies, the recovery
efficiencies could be improved, with less metal con-
tent reporting to the tailings storage facility (TSF).
• 15% reduction in carbon emissions – by maintain-
ing mineral recoveries at coarser flotation feed sizes,
it would allow mines to reduce the energy consump-
tion in comminution circuits without losing copper
recovery.
• Increase in dry tailings disposal – by adopting coarser
flotation feed grind sizes, which enables mines to
implement mechanical dewatering technologies and
adopt dry tailings disposal. This also reduces the
amount of waste being sent to TSF, which extends
the life of the facility.
In this paper, we discuss three case studies where the
NovaCell ™ potential benefits are evaluated with samples
from mines in Canada, Chile, and Australia. In all cases,
the NovaCell ™ metallurgical results were compared to con-
ventional flotation technology, i.e., mechanically agitated
float cell.
CASE STUDY 1—INCREASED METAL
PRODUCTION
In the first case study, fresh ROM ore from an operating
mine in Canada was evaluated. The mine is a low-grade
porphyry copper deposit, with minor molybdenum.
Currently, the flotation feed grind size (P80) varies between
325 and 350 µm, and the final product copper recovery
varies between ~82% and ~70%, respectively. At the flota-
tion feed grind size (P80) of 350 µm, the plant throughput
rate can be increased by ~11%. However, given the signifi-
cant reduction in copper recovery (of 12%), the circuit is
generally operated at the flotation feed grind size (P80) of
325 µm.
The objective of the test work was to investigate
whether at the flotation feed grind size (P80) of 350 µm, the
NovaCell ™ could significantly improve the final product
copper recovery above the current levels. This would pro-
vide potential benefits of increased metal production and
increase the likelihood of dry tailings disposal.
The material delivered for testing was received as
rocks and was crushed and ground to a particle size (P80)
of 350 µm. Sub-samples submitted for chemical analysis,
indicated head grades of 0.19% Cu and 49 ppm Mo. Note,
the copper grade of the feed sample was lower than the
typical plant feed grade of 0.25% Cu.
Case Study 1—Sample Characteristics and Flotation
Conditions
Table 1 shows the size-by-size copper and molybdenum
assays of the feed ore, and the feed distributions of solids,
copper and molybdenum. Copper shows the highest distri-
bution in the finer size fractions, with ~83% of the copper
in the –212 µm size fractions. Similarly, for molybdenum,
~86% was in the –212 µm size fractions.
Table 1. Case study 1 sample characteristics
Particle Size,
µm
Copper
Feed
Grade, %
Molybdenum
Feed
Grade, ppm
Feed Distributions
Mass Copper Molybdenum
–600 +425 0.07 20 14% 5% 5%
–425 +300 0.10 23 11% 6% 5%
–300 +212 0.13 23 8% 6% 4%
–212 +106 0.19 25 13% 13% 7%
–106 +53 0.26 33 10% 14% 7%
–53 0.23 80 44% 56% 72%
Total 0.19 49 100% 100% 100%
particles in a low-shear environment ideal for coarse par-
ticle recovery. After attachment, both fine and coarse valu-
able minerals rise in the NovaCell ™ and are collected in
two product streams. A froth concentrate is collected at the
top of the cell, as in existing froth flotation technologies.
A secondary collection device, an internal cone, captures
additional coarse valuable particles unrecoverable through
the froth zone. The design of the particle collection and
separation phases of the cell enables this innovative tech-
nology to achieve high recoveries across a wide particle size
range.
For existing and future porphyry copper mines, the
NovaCell ™ targets the following benefits:
• 10 to 20% increase in metal production – by main-
taining mineral recoveries at coarser flotation feed
grind sizes, it would allow mines to operate at higher
throughput rates and reduce the capital investment
required to debottleneck the comminution circuit.
• 5 to 10% increase in copper recoveries – by recov-
ering fine and coarse copper particles typically lost
by conventional flotation technologies, the recovery
efficiencies could be improved, with less metal con-
tent reporting to the tailings storage facility (TSF).
• 15% reduction in carbon emissions – by maintain-
ing mineral recoveries at coarser flotation feed sizes,
it would allow mines to reduce the energy consump-
tion in comminution circuits without losing copper
recovery.
• Increase in dry tailings disposal – by adopting coarser
flotation feed grind sizes, which enables mines to
implement mechanical dewatering technologies and
adopt dry tailings disposal. This also reduces the
amount of waste being sent to TSF, which extends
the life of the facility.
In this paper, we discuss three case studies where the
NovaCell ™ potential benefits are evaluated with samples
from mines in Canada, Chile, and Australia. In all cases,
the NovaCell ™ metallurgical results were compared to con-
ventional flotation technology, i.e., mechanically agitated
float cell.
CASE STUDY 1—INCREASED METAL
PRODUCTION
In the first case study, fresh ROM ore from an operating
mine in Canada was evaluated. The mine is a low-grade
porphyry copper deposit, with minor molybdenum.
Currently, the flotation feed grind size (P80) varies between
325 and 350 µm, and the final product copper recovery
varies between ~82% and ~70%, respectively. At the flota-
tion feed grind size (P80) of 350 µm, the plant throughput
rate can be increased by ~11%. However, given the signifi-
cant reduction in copper recovery (of 12%), the circuit is
generally operated at the flotation feed grind size (P80) of
325 µm.
The objective of the test work was to investigate
whether at the flotation feed grind size (P80) of 350 µm, the
NovaCell ™ could significantly improve the final product
copper recovery above the current levels. This would pro-
vide potential benefits of increased metal production and
increase the likelihood of dry tailings disposal.
The material delivered for testing was received as
rocks and was crushed and ground to a particle size (P80)
of 350 µm. Sub-samples submitted for chemical analysis,
indicated head grades of 0.19% Cu and 49 ppm Mo. Note,
the copper grade of the feed sample was lower than the
typical plant feed grade of 0.25% Cu.
Case Study 1—Sample Characteristics and Flotation
Conditions
Table 1 shows the size-by-size copper and molybdenum
assays of the feed ore, and the feed distributions of solids,
copper and molybdenum. Copper shows the highest distri-
bution in the finer size fractions, with ~83% of the copper
in the –212 µm size fractions. Similarly, for molybdenum,
~86% was in the –212 µm size fractions.
Table 1. Case study 1 sample characteristics
Particle Size,
µm
Copper
Feed
Grade, %
Molybdenum
Feed
Grade, ppm
Feed Distributions
Mass Copper Molybdenum
–600 +425 0.07 20 14% 5% 5%
–425 +300 0.10 23 11% 6% 5%
–300 +212 0.13 23 8% 6% 4%
–212 +106 0.19 25 13% 13% 7%
–106 +53 0.26 33 10% 14% 7%
–53 0.23 80 44% 56% 72%
Total 0.19 49 100% 100% 100%
