A sensor for monitoring flotation recovery

Minerals and coal need to be beneficiated from ore/crudes before being sold into the market.

Among the prevalent beneficiation methods, froth flotation is widely employed for fine and ultrafine sized fractions of ore.

Monitoring and diagnosis of flotation performance are increasingly more dependent on real-time measurements, than plant personnel, especially in remote areas where most mining and processing operations are located.

There is a pressing need to develop a low-cost and accurate diagnostic tool to monitor the flotation performance in real time, enabling instant control of the operational variables to maximise flotation efficiency.

The technology

Researchers at The University of Queensland (UQ) have developed a novel, low-cost sensor for real-time monitoring of flotation performance in mineral and coking coal processing plants.

The sensor operates by measuring the drag force exerted by overflowing froth on a cantilever beam when immersed in the froth. This drag force is directly correlated with flotation efficiency, particularly the mass pull (flotation recovery), a key performance indicator.

The sensor offers a standalone solution for online process monitoring and provides immediate feedback for operational optimisation and control.

Improved flotation performance through real-time monitoring has the potential to increase hourly yield of coal and minerals, thereby enhancing operating margins across the mining sector.