During 2002, design and development of the world's largest flotation cell was completed. The cell is the mineral industry's first 257 m3 flotation cell, and represents a major development in the design of larger flotation cells, with a 50 per cent increase in cell volume over the widely installed 160 m3 WEMCO SmartCellTM flotation machine. It is anticipated, in the next few years, world-class copper sulfide concentrators will incorporate 257 m3 flotation cells in their rougher-scavenger flotation circuits.
The prototype 257 m3 cell, No 250 SmartCellTM flotation machine is installed in Minera Los Pelambres' existing rougher flotation circuit. The machine is located in front of the first cell in Row 1 and is followed by nine No 130 SmartCellTM flotation cells. The unit has been in operation since April 2004, and has proven itself in this duty. A key to the successful development of the equipment has been the emphasis placed on fundamental hydrodynamic scale-up criteria. Hydrodynamic factors include superficial gas velocity, water (pulp) circulation through the draft tube, and pulp mixing (distribution) characteristics.
This paper will review the scale-up criteria of the No 250 flotation cell, and a case study will be presented on the in-plant testing of the equipment. The case study will document the metallurgical and hydrodynamic performance of the machine. It will also illustrate the economic benefits derived by incorporating larger flotation cells in a modern copper sulfide concentrator.