1
25-036
FloatForce®+ Mixing Mechanism Trial at Kennecott
Copperton Concentrator
Joshua Cole
Rio Tinto, Salt Lake City, USA
Joshua Dettamanti
Rio Tinto, Salt Lake City, USA
Rabia Abbasi
Rio Tinto, Salt Lake City, USA
Joshua Sovechles
Metso, Burlington, Canada
Christian Cardoso
Metso, Burlington, Canada
Guillermo Bermudez
Metso, Burlington, Canada
Martta Hirsi
Metso, Espoo, Finland
ABSTRACT
The implementation of technological advancements in
flotation is key to optimize performance in mining opera-
tions. Consequently, flotation cell’s performance is highly
dependent on the effectiveness of the mixing mechanism.
A more efficient flotation mixing mechanism is likely to
improve metallurgical performance and optimize energy
consumption, which is the motivation for Metso’s journey
to develop the latest iteration of FloatForce ®. Looking to
test the new design at plant scale, Metso approached the
Kennecott Copperton concentrator, which is continuously
looking for different venues to improve metallurgical per-
formance. In this context, a test campaign was conducted
to implement this new flotation mixing mechanism in
their rougher circuit during 2024. The industrial trial con-
sisted of several sampling campaigns assessing different
operational parameters for comparison purposes around a
300m3 flotation cell. The effect of the new flotation mixing
mechanism on the cell’s power draw was also studied. The
results of this trial at Kennecott are presented in this paper.
Overall new flotation mixing mechanism, FloatForce+ was
seen to perform as well as the original FloatForce.
INTRODUCTION
Flotation is a crucial mineral processing technique that
enables the efficient separation of valuable minerals from
gangue, playing a vital role in upgrading low-grade ores
(Wills and Finch, 2016). Mechanical flotation cells, which
have been an industry standard since the inception of flo-
tation, rely on mixing mechanisms—typically rotor-stator
assemblies—to ensure solids suspension, disperse air, and
create the conditions necessary for effective bubble-parti-
cle interactions (Gorain et al., 2000 Gupta et al., 2006).
Within these systems, the rotor generates turbulence to sus-
tain particle suspension and air dispersion, while the stator
modulates flow to establish a stable environment for min-
eral recovery and froth removal.
Achieving efficient flotation requires five key functions:
maintaining solids suspension, dispersing gas into bubbles,
maximizing bubble-particle collision and attachment,
stabilizing the pulp-froth interface, and ensuring effec-
tive froth removal (Harris, 1976 Mesa and Brito-Parada,
2019). In a flotation cell, these tasks are distributed across
three hydrodynamic zones: the turbulent zone (where the
rotor facilitates mixing), the quiescent zone (promoting
bubble-particle separation from the main flow), and the
froth zone (where enriched froth is collected). The rotor-
stator assembly is critical in optimizing these zones, with its
design directly influencing the efficiency of each function.
With energy consumption representing up to 68%
of the total life-cycle cost of large flotation cells, innova-
tions in rotor design are imperative for enhancing flotation
performance while reducing operational costs (Rinne and
Peltola, 2008). In response to these demands, Metso has
introduced the FloatForce+, an advanced rotor designed to
25-036
FloatForce®+ Mixing Mechanism Trial at Kennecott
Copperton Concentrator
Joshua Cole
Rio Tinto, Salt Lake City, USA
Joshua Dettamanti
Rio Tinto, Salt Lake City, USA
Rabia Abbasi
Rio Tinto, Salt Lake City, USA
Joshua Sovechles
Metso, Burlington, Canada
Christian Cardoso
Metso, Burlington, Canada
Guillermo Bermudez
Metso, Burlington, Canada
Martta Hirsi
Metso, Espoo, Finland
ABSTRACT
The implementation of technological advancements in
flotation is key to optimize performance in mining opera-
tions. Consequently, flotation cell’s performance is highly
dependent on the effectiveness of the mixing mechanism.
A more efficient flotation mixing mechanism is likely to
improve metallurgical performance and optimize energy
consumption, which is the motivation for Metso’s journey
to develop the latest iteration of FloatForce ®. Looking to
test the new design at plant scale, Metso approached the
Kennecott Copperton concentrator, which is continuously
looking for different venues to improve metallurgical per-
formance. In this context, a test campaign was conducted
to implement this new flotation mixing mechanism in
their rougher circuit during 2024. The industrial trial con-
sisted of several sampling campaigns assessing different
operational parameters for comparison purposes around a
300m3 flotation cell. The effect of the new flotation mixing
mechanism on the cell’s power draw was also studied. The
results of this trial at Kennecott are presented in this paper.
Overall new flotation mixing mechanism, FloatForce+ was
seen to perform as well as the original FloatForce.
INTRODUCTION
Flotation is a crucial mineral processing technique that
enables the efficient separation of valuable minerals from
gangue, playing a vital role in upgrading low-grade ores
(Wills and Finch, 2016). Mechanical flotation cells, which
have been an industry standard since the inception of flo-
tation, rely on mixing mechanisms—typically rotor-stator
assemblies—to ensure solids suspension, disperse air, and
create the conditions necessary for effective bubble-parti-
cle interactions (Gorain et al., 2000 Gupta et al., 2006).
Within these systems, the rotor generates turbulence to sus-
tain particle suspension and air dispersion, while the stator
modulates flow to establish a stable environment for min-
eral recovery and froth removal.
Achieving efficient flotation requires five key functions:
maintaining solids suspension, dispersing gas into bubbles,
maximizing bubble-particle collision and attachment,
stabilizing the pulp-froth interface, and ensuring effec-
tive froth removal (Harris, 1976 Mesa and Brito-Parada,
2019). In a flotation cell, these tasks are distributed across
three hydrodynamic zones: the turbulent zone (where the
rotor facilitates mixing), the quiescent zone (promoting
bubble-particle separation from the main flow), and the
froth zone (where enriched froth is collected). The rotor-
stator assembly is critical in optimizing these zones, with its
design directly influencing the efficiency of each function.
With energy consumption representing up to 68%
of the total life-cycle cost of large flotation cells, innova-
tions in rotor design are imperative for enhancing flotation
performance while reducing operational costs (Rinne and
Peltola, 2008). In response to these demands, Metso has
introduced the FloatForce+, an advanced rotor designed to