The flotation circuit is one area on a mineral processing plant that can significantly impact revenue. It is therefore critical that this process is controlled to reach its optimum. Typically control on a flotation circuit is reactive as assays give operators and engineers feedback on metal recovery, losses and, product grade. Operational parameters are then adjusted in response to these assays, which may be outdated and no longer representative of what is actually happening live on the flotation circuit. As these assays do not relate to the performance of individual cells but to the unit process as a whole, it is difficult to see if a particular cell is performing poorly. This can lead to loss from tailings not meeting product specification and therefore significant loss of revenue.

By implementing the Fluorite Release of the Flotation App, operations are optimized adding much-needed transparency and insight on process performance with Virtual Sensors – giving you previously unmeasurable data for variables like individual cell recovery, gas hold-up and air bubble diameter. From inputs such as feed flow rate and other known parameters, the brains.app Material Model can be configured to provide visibility on individual cell performance. This means that poor performing cells can easily be identified, and problems quickly rectified, minimizing losses to tailings. This optimizes the circuit’s performance and maximizes revenue by maximizing recovery whilst maintaining grade.

The brains.app Platform releases are updated and deployed frequently (usually twice per year) - with 2020 having seen the releases of Erythrite and Fluorite. The Graphite Release will be deployed in early 2021. This continuing development always keeps the Platform and Apps operating well and delivering maximal value to mining operations around the world.

The Graphite Release of the Flotation App include real-time predictions of mass pulls, as well as grade and recovery.