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.
Future of Flotation_White@2x
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Our Expert-Driven Solutions

Augmented Actions With AI-Driven Sensor Technology and Expert Domain Knowledge.

Froth Sensor
Pulp Sensor
Grade Sensor
Bubble Sizer

Smart Sensors

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

Froth Sensor Flotation

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 Bubble Sizer

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)
  • Gas Holdup (Eg)
  • Superficial Gas Velocity (Jg)
  • Bubble Rise Velocity (Ug)
  • Pulp Colour

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Pulp Sensor Flotation

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 AnalyzerTM

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

APC for Flotation

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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

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Monitoring & Diagnostics

Drive concentrator excellence with a solution that combines real-time data analytics and expert advisories to boost recovery and grade.

APC Support & Monitoring
Monitor APC utilization and performance. Online APC support and case management system. Available for froth, pulp, grade and reagent.
Control Loop Performance Monitoring
Detect and diagnose poorly performing controllers to ensure base-layer stability.
Online Mass-Balance + Mass-Pull performance
Live mass-balance and mass-pull tracking delivers real-time insights into circuit performance.
Data Investigations & Expert Recommendations
Data Science Services. Custom data-driven investigation for process troubleshooting. Available for plant wide deep-dives.
Froth States
Real-time froth state detection for cell availability (% time in froth production state) and pulping froth.
Sensor Health Monitoring
Sensor data health monitoring and tracking dashboard. Monitors: Froth-, Pulp-, and Grade Sensor Health.
Online Froth State Advisories
Automated online froth state advisories providing real-time actionable recommendations to detect root causes and rectify undesired conditions timelessly.

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