Flotation Challenges

Today's mineral processing operations face critical challenges that impact safety, efficiency, and profitability.

Sub-Optimal Recovery

Despite stable operations, recovery remains below target due to limited visibility into key drivers, resulting in lost value and reduced plant efficiency.

Below Lip Cell Losses

Ore trapped in below lip cells bypasses the recovery process, reducing circuit efficiency and contributing to avoidable losses.

High Variable Mass Pull

Fluctuating mass pull causes circuit instability, complicates control, and leads to inconsistent concentrate quality and recovery performance.

Sliming, Pulping & Boiling

Excess fines and turbulent pulp conditions reduce flotation selectivity, hinder reagent performance, and lower recovery rates.

Unstable Froth

Froth conditions vary across cells and shifts, making it difficult to maintain selectivity and control, ultimately impacting product quality and throughput.

Grade Penalties

Inconsistent concentrate grade, often caused by delayed detection or poor control, results in financial penalties and product rework.

Stone Three's Flotation Optimization Solution delivers up to

3 - 5% Recovery Improvement

Boost My Flotation Recovery

Smart Sensors

We offer comprehensive sensor-based solutions, with AI-driven technology, tailored to different operational needs and scales.

Stone Three AI-powered froth sensor measuring real-time froth velocity, height, stability, bubble size, and colour in a flotation cell to optimize recovery and concentrate grade at mineral processing operations globally.

Froth Sensor

Provides accurate, real-time measurement of froth performance in the flotation cell, helping concentrators optimize froth velocity and height to ensure consistently high-performing flotation cells.

  • Froth Velocity Over Lip
  • Froth Height Above Lip
  • Froth Stability
  • Froth Bubble Size
  • Froth Colour
Stone Three offline bubble sizer measuring bubble size distribution, gas holdup, and superficial gas velocity in flotation pulp for on-site mineral processing diagnostics and circuit optimization.

Offline Bubble Sizer

The offline bubble sizer is a compact pulp measurement equipment for on-the-go measurements of bubble size distribution.

  • Sauter Mean Diameter (D32)
  • Superficial Gas Velocity (Jg)
  • Portable Sensor

Click Here to  Download Software

Stone Three's industry-first online pulp sensor delivering real-time bubble size distribution and rise velocity measurements below the froth level in a flotation cell, enabling unprecedented visibility into flotation circuit performance.

Online Pulp Sensor

A one-of-a-kind in-pulp sensor that delivers accurate, real-time measurements of bubble size distribution and rise velocity within a flotation cell, offering,  insights below the froth level.

  • Sauter Mean Diameter (D32)
  • Gas Holdup (Eg)
  • Superficial Gas Velocity (Jg)
  • Bubble Rise Velocity (Ug)
  • Pulp Colour
Stone Three MicroTrace grade analyzer providing real-time slurry grade measurements in flotation concentrate, feed, and tails streams with no nuclear sources and no ongoing calibration, reducing grade penalties at global mining operations.

Grade Analyzer

Stone Three MicroTraceTM provides real-time slurry grade measurements, enabling operations to automate responses to grade fluctuations, maintain consistent recovery, and reduce the risk of grade penalties.

  • No-Nuclear Sources.
  • No Ongoing Calibration
  • Accuracy within 3% in tails at 04g/t
  • Repeatability 0.04ppm over an hour.
  • Measurement in Conc/Feed & Tails Streams

The world's first in-pulp sensor delivering real-time bubble size distribution and rise velocity measurements below the froth level.

See The Online Pulp Sensor

Advanced Process Control

An automated, adaptive, and performance-driven solution that uses predictive models and sensor data to dynamically adjust key variables in the flotation circuit – maximizing recovery, improving reagent efficiency, stabilizing froth and pulp conditions, and enhancing overall plant performance

Flotation APC

A real-time, model-based system that continuously monitors and adjusts key flotation variables – such as air flow, reagent dosage, pulp level, and froth pull – to maximize recovery, improve concentrate grade, and stabilize operation. APC uses advanced algorithms and live plant data to optimize performance beyond manual control capabilities..

Phase 1: Stabilization

Stabilization is the first step in implementing APC in flotation operations. This phase focuses on establishing consistent operations and reducing variability.

  • Stabilize Feed & Froth Levels
  • Control Conc Pump Box Flow
  • Stabilize Froth Pull per Cell
  • Balance Grade & Recovery

Phase 2: Optimization

Optimization is the second step in implementing APC in flotation operations. This phase focuses on ensuring sustainable results.

  • Automatic Frother CCC Control
  • Collector & Depressant Dosing Automation

SmartROC™

Stone Three's SmartROC™ combines expert process knowledge with AI-powered machine learning to deliver remote visibility and actionable insights across your operation, reducing downtime and driving consistent plant performance.

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