Quick Takeaways
- Cell sizing is a circuit problem, not a single-machine decision.
- Residence time targets drive total required flotation volume.
- Rougher-cleaner-scavenger duties need separate sizing logic.
- Pilot data greatly improves sizing confidence.
Step 1: Calculate total flotation volume
Use slurry flow and target residence time per stage to determine total volume. This prevents under-sizing that later hurts both recovery and grade stability.
Step 2: Split duties by stage
Do not size all banks the same way. Rougher banks prioritize recovery, cleaner banks prioritize grade, and scavenger banks prioritize value recovery from tails.
Step 3: Lock operating envelope
Check grind size, pH regime, and reagent strategy with metallurgy team before final procurement. Mechanical selection without process envelope usually creates rework.
FAQ
Can I size flotation cells using only throughput t/h?
Not reliably. You also need slurry density, residence time targets, and stage-by-stage process requirements.
Should cleaner stage use the same cell size as rougher?
Often no. Cleaner duty is different and may require different volume and control strategy.
What is the main risk of under-sizing?
Under-sized banks usually cause unstable froth behavior, lower recovery, and reduced concentrate quality consistency.
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