Major Copper Mine in Chile
A case study demonstrating how Flotation real-time monitoring and optimization enhanced metal recovery by 1%, a value of $38M
Customer Challenge
Low Columnar Cells Performance
A complex flotation circuit consisting of over 100 cells, encompassing rougher and second cleaner stages, faced challenges of instability stemming from significant variability in ore feed.
The absence of per-cell process visibility and control contributed to diminished recovery rates.
How We Helped
Real-time Virtual Sensors per Column Cell
We incorporated real-time Hydrodynamic and Kinetic Virtual Sensors (VS) for each cell.
Optimizer tool for Air Flow and Froth Depth recommended setpoints.
Additionally, we carefully configured a comprehensive Control and Alerts panel tailored to site-specific needs.
The Outcome
Improved Circuit Overall Recovery by 1%
New virtual Hydrodynamic and Kinetic sensors across 125 flotation cells, providing optimizer-guided suggestions for air flow and froth depth adjustments.
Potentially yield a 1%recovery boost, translating to annual gains of $38M USD, while also facilitating swift identification of underperforming cells.
Enhanced visibility allowed quicker operational response, minimizing downtime and unplanned shutdowns.
Discover how Flotation Optimization can be applied to your operation
