Flot Master With Video Mar 8 CD Version

8/18/2019 Flot Master With Video Mar 8 CD Version

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AGENDA• MECHANICAL DESIGNS

• SALES BENEFITS

• MIXING

• AIR HOLD UP

• POWER

• AIR CONTROL

• CASE STUDY-FREEPORT

• INSTALLATIONS

• COMPETITION OVERVEIW


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TYPES OF FLOTATION CELLSPYRAMID COLLUMNS

WEMCO SMARTCELLS

WEMCO 1+1

AGITAIR CELLS


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BASE METALS

COPPER

LEAD

ZINC

INDUSTRIAL MINERALS

POTASH

PHOSPHATE

CLAYS

PRECIOUS METALS

GOLD

PLATINUM AND PALLADIUM

SILVER

COAL

IRON OR

MAJOR FLOTATION APPLICATIONS


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Elevated Rotor

• Self-induced air

• Easy Restart under Load• Non-plugging design

• Lower Maintenance Cost

• Rotors can be Inverted• Fine ubble !roduction


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Disperser/

Stator

• !rovides "pti#u#

!article $ ubbleContact

• !rovides %uiescent

Separation Region• Easy #aintenance


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DisperserHood

• &issipates !ulp

Energy• Establis'es Surface

Stability


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Standpipe and Crowder Plate

• Internal Chamber to

Provide Self -inducedAeration

• Support for ood

• Increa!e Froth "obilit#

• $educe! Froth Tran!portTime


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Hybrid Draft Tube and FalseBottom

Managed circulation

• Maintains SolidsSuspension

• Reduces s'ortcircuiting


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Me!anism"ssembly

$otor bein%

in!talled in &'&


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(E"CO SmartCell

New Design Features


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Radial #aunders and $ertial Ba%es


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&&' Me!anism wit!

dia(onals


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)mproved Me!anism

Desi(n

*EMC+ Flotation*EMC+ Flotation


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Me!anism "ssembly• Maximum Design

Clearances

• Individual Mechanism

Can be Removed without

Shutting Down the Entire

Row

• Lowers Oerating costs

• Maximi!es "roduction

#ime


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Me!anism "ssembly

$otor bein%in!talled in &'&


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Circular )o* La#out


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Circular Connection )o*

•Shortens Row Length

•Decreases The Number ofRequired Dart Valves

•Can Be Changed off Line

•Provides Linear lowControl

•Can Be Changed !uic"l#

Benefits


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Internal Dart Valves

in%ed +art!

• allow tanks close together

• minimum moving parts

• low maintenance


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RECTANGULAR DISCHARGE AND CONNECTION BOXES


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Plu% Flo, $ . $ o /& - e-0T1

0limpel $ . $ o / & - 2&-e-0T340T 1

(ell "i*ed $ . $ o /0T 4 & ' 0T1

Flotation ,inetis


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RESIDENCETIME


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0limpel $ . $ o / & - 2&-e-0T

340T 1

T- $e!idence Time

(ariables)

• +e!i%n volume

• Mixing • Air hold up

• Power

Flotation ,inetis


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0%

20%

40%

60%

80%

100%

120%

0 5 10 15 20 25

$T

R e c o v e r # %

&

Plug Flow

Well Mixed

Klimpel

Flotation ,inetis


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MIXING


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RTD "-"#.S)S

"ctave Levenspiel* C'e#ical Reactor "#niboo+* !age ,-,* .//,


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$evie, $e!ult! of CO+ELCO $e!idence Time

Te!tin% at Chu5uicamata


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#drod#namic! 2$T+3

0'e C'ilean Co##ission of Nuclear Energy&eter#ined ot' Li1uid and Solid R0&s

Li5uid $T+ Te!t!--0racer r 2

Solid Tracer Te!t!--0racer 3ctivated Na4

• Solid Sa#ple 5Co#posite6

• Solid Sa#ple 57.88 Mes'6• Solid Sa#ple 5- .88 79: Mes'6

• Solid Sa#ple 5- 9: Mes'6


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#drod#namic! 2$T+ Solid!3

Chilean Commi!!ion of Nuclear Ener%# $eport--Pa%e 67


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#drod#namic! 2$T+3

Evaluatin% $e!idence Time +i!tribution!

Levenspiel;s I#portant !ara#eters

Loo+ for)

• Short Circuiting --

C'aracteri


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#drod#namic! 2$T+3

Co#parison of .:8* .,8* > .,8 cubic #eter cells at .:*888 tpd

'bserved (ean Retension Time

2

3

4

5

6

7

Liquid Solids

)*ll+

Solids

),-.+

Solids

)/001,-.+

Solids

)/00+

( i n u

t e s

Dorr 'liver

'uto"um2u

34(C'


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Hydrodynamis RTD0

'bs5 Theor# 'bs56Theor#% & 'bs5 Theor# 'bs56Theor#% & 'bs5 Theor# 'bs56Theor#% &

Liquid 5.3 5.2 101.9 3.2 5.6 57.1 6.2 5.6 110.7

*ll Solids 3.2 5.0 64.0 3.1 5.6 55.4 5.1 5.7 89.5ine Solids 3.4 5.2 65.4 2.6 5.5 47.3 5.5 5.5 100

7nterm5 Solids 2.9 5.3 54.7 3.0 5.6 53.6 5.0 5.5 90.9

Coarse Solids 3.9 5.1 76.5 3.1 5.2 59.6 5.2 5.8 89.6

*verage Solids 8.5/ .950 :-5.

34(C''uto"um2uDorr 'liver

Com2arison of 'bserved and Theoretical (ean Residence Times% (in5

Tracer Test

?Early Curve 5Early "bserved Mean Residence 0i#e wit'Respect to 0'eoretical6 Means Stagnant Fluid=@ "ctaveLevenspiel* C'e#ical Reactor "#niboo+* !age ,-,* ./2/


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Anal#!i! of cell! b# Octave Leven!piel

T!"e M!#ei!l $o%&li'e &u#o(umpu W)M*&

+i,uid 15 48 0

-ll .olid/ 37 39 0Fie .olid/ 38 53 0

#emedi!#e 42 40 0

*o!/e .olid/ 45 40 0

*verage Solids 9/ 9, 0

Stagnant Vessel raction% &

• No Evidence of S'ort Circuiting in Ae#co

• No Evidence of Stagnant 3reas in t'eAEMC" S#artCell

• Significant Stagnant 3reas in lown Cells

ased on tests on large cells in C'ile in .///


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Wemco Smartcells provide up

to 50 more residence time

than !orce air cells


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POWER


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Power Consumption

0'e Rotor)

• 3ir 3spiration

• ubble For#ation and

&ispersion

• ubble$!article

Contact

Flotation !ri#arily "ccurs in and 3round t'e Rotor


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3verage Flotation Cycle B 58n49f 3428n4 9p3 . 9p49f

9P is a Function of

t'e !ower Input=reater !ower Input

results in a Dig'er 9P

and an Increased

!robability of Flotation=


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CFD Modelin( of *EMC+® 121

Pulp Reynolds number


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REYNOLDS NUMBER VS RECOVERY

0%

25%

50%

75%

100%

10 100 1000 10000 100000

eold/ ume

2 e " o ' e 3

l!// /pee/ u!# p!#i"le/

Courtesy of Prof Laurindo Leal Filho-Brazil


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*verage Power 7n2ut%"3

Dorr1'liver 120.1'uto"um2u 124.2

34(C' 184.6 :175;

C"&ELC" !ower Measure#ents

Higher Power Input Makes Money!Higher Power Input Makes Money!


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AIR HOLD UP


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CONVENTIONAL SIZINGAIR HOLD UP

WEMCO – 10-15

FO!CE" #$! -%%-%&

4L T4N74NT4 (4*S;R4(4NTS


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4L T4N74NT4 (4*S;R4(4NTS


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F+RCED ")R *EMC+


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Fl t ti ,i ti


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0limpel $ . $ o / & - 2&-e-0T340T 1

0 - Flotation $ate Con!tant

8ariable!

• Mineralogy

• !article si


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"M)R" ModelConept of t!e bubble surfae

area 3u4

surface (S) area ()

"M)R" M d l


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"M)R" Model

t higher air"flow

rates# $%M&'

machines producedhigh alues of Sb#

aeraging *+

higher than those

predicted by theMIR model,

&orrelation of Model Predictions with Measured -alues

of .ubble Surface rea /lu0

30

40

50

60

70

80

90

30 40 50 60 70 80 90

.> pedi"#ed

. 5 > m e ! / u e d

&u#o(umpu

?!#e,uip

W)M*&> low !i

W)M*&> ig !i


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Relations!ip of Bubble Surfae"rea Flu4 to Super5ial 6as

$eloity

&onsistent bubblesi1e for $%M&'

machines results in a

linear relationship,


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Relations!ip of Bubble Surfae "rea

Flu4 to Super5ial 6as $eloityFored7air Ma!ines8 a #o(arit!mi

Relations!ip

.ubblecoalescence in

forced"air

machines will

result in a

ma0imum flu0alue,


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AIR VOLUMEAND

CONTROL


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'uto"um2u 34(C' Dorr 'liver

Number of Tests @, @. @A

*ir Rate% (,6(in5

*verage /.5A /.5A /-5A

(aBimum -05: -05- /@58

(inimum /05@ /05- /05: 4levation

Summar# of *ir 7nta"e Conditions

-@,0 meters

15.8 m!m"#

R$#%&-'(.'-1(.'

15.8 m!m"#

R$#%&-'(.)-1(.*

&omponent /unction&omponent /unction


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&omponent /unction&omponent /unction

0'e 3#bient 3ir Inta+e i! the point ,here ambient air

i! dra,n into the flotation air control a!!embl#;

*EMC+ Fl t ti*EMC+ Flotation


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"anual or Automatic Air Control

• di'idu!l *ell/ *!?e Fied Tued #o"e!/e Me#!llugi"!l

Pe


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FO!CE" #$!WEMCO


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E4ess air (ives poor frot!

surfae


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• Lo, air-no flo,

• E*ce!! air -poor !urface

• Small ran%e of air control

FO$CE AI$ "ACINE

T,&$/$- S0&2# P&2 C&23 O40 '((1


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• Lo, air-


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A'en t'e !ercent Solids C'anges* AEMC"S#artCells are Self 3dusting

34(C' *ir 7nta"e

10

13

16

19

22

30 35 40 45 50 55

Tails & Solids

*

i r 7 n t a " e %

S m , 6 m

i

om!lied #o 142 PM o#o peed

C'D4LC' Re2ort% *22endi -


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ME'#LL(!)*


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"etallur%ical Performance 2Ca!tro3

1 :$o &li'e; 2 :&u#o(umpu; 3 :W)M*&;

/ )Dorr 'liver+ 69.4 72.5 73.9- )'uto"um2u+ 67.6 72.8 77.0

, )34(C'+ 68.0 71.3 71.8

*logorithm

Predicted Co22er Recover#% &

Cell Conditions

&r= Castro;s !rediction Indicates t'at t'eAEMC" S#artCell !roduces t'e Dig'est

Recovery at all Conditions Investigated=


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(E"CO &6> "6 CELLS AT EL TENIENTE

-1( 4&//6

7118 m

R&49&2: )';


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Head to Head testsEl 0eniente--88.

• Partici2ants Outo?umpu--7 * &6>m6 . @> m6

(E"CO--7 * &&Bm6 . 7 m6

• (ulti2le Cell Tests )9 Cell Rows

• Short Test Cam2aign )/ (onth+

• Simultaneous '2eration• eed Distribution Verified

• Sam2ling% *uto

• (etallurgical and Residence Time Tests

• Determine Row lotation $inetics

• *nal#e Recover# b# Particle Sie

• (ineralogical 4valuation• Data *nal#sis

• Data *vailabilit#

WEMCO HAD 1.5 ; BETTER RECOVERY ON THE COARSE SIZE

OVERALL (.' ; AT 1'


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WEMCO- W2/=>6 /&$=&2 "# ?/0$0"#WEMCO- W2/=>6 /&$=&2 "# ?/0$0"#

Elevated rotor4di!per!er

• )etter availabilit#

• Po!itive Froth removal

"a*imum po,er input

• )etter mi*in% and ?inetic!

• i%he!t $etention Time

• i%he!t )ubble Flu*

Self adDu!tin% Air

Lo, chemical con!umption

)e!t "etallur%#


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C#+E +'("*


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I#=602: P2@/&m•+a, Mills ause u.sets

•Cylones o/erflo ros toflotation

•Lar,e ells sand u.


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C!ile7 '90 1:; ubi meter ells


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+versi


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Coarse ro>s from *EMC+ 1:; m= Cell in C!ile

S"6 MillS"6 Mill


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S"6 MillS"6 Mill

?psets?psets

3emco Cells *ug ::

3ithout Beveled

Bottoms

'$ cells (a# :: in Chile


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(emco! Solution

Improved h#drod#namic!


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CASE ST+Y


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7@>> ft6 (emco SmartCell!

CASE ST+Y


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Installation of beveled botto#s

CASE STUDY

*EMC+*EMC+


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SmartCell +e!i%n Feature!

• eveled 0an+ otto#

• Dybrid &raft 0ubes

• Radial Launders• (ertical affles

• 3ir Control

• I#proved Mec'anis#

&esign

FlotationFlotation


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(E"CO SmartCell

New Design Features


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fter installation of

beeled bottoms thesanding was eliminated

.eeled bottom

installed on

$emco 23** cell

CASE STUDY


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Cell Power

0

50

100

150200

250

Cell1Beveled bottoms in *% C% D

C o n s u m e d P o

w e r

) = 2 +

ow -

ow ?

CASE STUDY

CASE STUDY


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Cell Power

0

50

100

150

200

250

Cell1Beveled bottoms in *% C% D

C o n s u m e d P

o w e r

) = 2 +

ow -

ow ?

ow *

ow $

CASE STUDY

FREEPORT CASE STUDY


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*ir low Rates 9.00 ft, cell) -1 A $1 ?e'eled o##om/;

0

400

800

1200

1600

-B1 -B4 ?B4 ?B5 $B1 $B4 $B5

Row6Cell

* i r l o w

) a c

f m

Beveled BottomFREEPORT CASE STUDY


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Metallurgical results of t'e Cu$3u plant #odifications

G arr# Sie,ertH $ou%her Flotation Improvement! at P;T; Freeport Indone!ia!>&H Otta,aH CanadaH pa%e! 6-@

!rocess (ariable 2 #ont's prior

to #odifications

.. #ont's following

#odifications

(ariance

Cu roug'er feed assay GH .=8/ .=89 -:= H

Cu roug'er tail assay GH 8=.9: 8=.8, -.=4 HCu roug'er concentrate assay GH .,=4 .4= -.9=, H

Cu rou%her recover# /M1 B; B; ;7 M

Cu roug'er #ass yield GH :=2, ,=:J .= H

3u roug'er feed assay Ggpt .=,: .=.4 -9.= H

3u roug'er tail assay Ggpt 8=4J 8=.48 -49=9 H

3u roug'er concentrate assay Ggpt .2=/ .=4 -94=: H

Au rou%her recover# /M1 B7;B B;6 &; M

FREEPORT CASE STUDY

.49 HI:9 &'8&%84R4'R


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4I5S 6R7% -S &%55 P'SI4I'8

0

0.2

0.4

0.6

0.8

1

1.2

Feed *ell 3 T!il *ell 4 T!il *ell 5 T!il *ell 6 T!il *ell 7 T!il *ell 8 T!il *ell 9 T!il *ell 10 T!il Fi!l T!il

Cell

> r a d e C u &

+ie C1

+ie C2


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$2+'#LL#'$O2+


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"atue #i$au %50& ' ()0 cu*ic meter cells


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)ATE IKA -"A+E IN CINA


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,enneott7';0 :;;; ubi foot ells,enneott7';0 :;;; ubi foot ells

O/er 30 reo/ery

Collahua!i


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"TP+


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H

"TP+


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F!#2C$+CO $ M#"E!#-ME4$CO


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+ourtes, o! Minera -scondida and "echtel +orporation

E!condida Pha!e I8 E*pan!ion ProDect


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) - W&m4 1+1 15(( ?0 4&//6 7'm'

8- E"m4 .'


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,enneott7';0 :;;; ubi foot ells,enneott7';0 :;;; ubi foot ells

O/er 30 reo/ery


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(E"CO &6> "6 CELLS AT EL TENIENTE

-1( 4&//6

7118 m

R&49&2: )';


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&>m6 (E"CO SmartCell



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ESCON+I+A PASE 7

9 WEMCO 160 CUBIC METER CELLS

)nstallation)nstallation

#ist#ist


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Com2an# Sie1ft, !t# Location

F!l"oidge i"(el 4500 59 *oll!u!/i> *ile

Feepo# doe/i! 4500 36 ! D!!

!l/o> 1500E/ !d &K "ell/ 3000 48 doe/i!

T%Kee"o## 3000 50 !l# +!(e *i#

Pelp/ $odge Mie/ 4500 8 *io Mie/

ew Mexi"o

)/"odid!%?GP 5650 94 *ile

*odel"o 5650 1 *u,ui

*odel"o 4500 4 )l Teie#e> *ile

+o/ Pel!me/ 4500 48 *ile

Pelp/ $odge 4500 16 +! *!d!l!i!

*ile

#ist#ist


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WEMCO-2 "# 2%2&66WEMCO-2 "# 2%2&66

$otor en%a%ement

• &>M to 6>M

$otor !i:e• Lar%er %ive! better

mi*in% and ?inetic!

$otor !ubmer%ence• 7@ M to &>> M

@> cubic meter cell

TAN DIMENSIONS


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TAN DIMENSIONS

5.1 m


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10 67- 1187 66 %50 67- 1739 66

Documents

Flot Master With Video Mar 8 CD Version