Revolutionizing coarse particle flotation Part I – A comprehensive exploration method for the HydroFloat™ technology

The development of coarse particle flotation technologies marks a significant milestone in the evolution of the mineral processing industry due to the expansion of the upper particle size limitation associated with conventional flotation technologies as defined by the well-known “Elephant Curve”. As the industry strives to process lower-grade ores with higher tonnages for financial reasons, the significance of processing coarse particles through coarse particle flotation technologies like the HydroFloat™ unit becomes increasingly critical. This approach offers substantial benefits by potentially reducing energy consumption within grinding circuits, making it a key solution in enhancing efficiency and cost-effectiveness. Despite these advantages, a significant limitation of existing fluidized bed flotation testing is the high sample requirements, with Eriez's 150-mm diameter HydroFloat™ unit demanding 15–20 kg per test and over 100 kg for comprehensive evaluations toward a single ore type. To address this challenge, a unique 82-mm diameter laboratory scale HydroFloat™ unit was designed by Eriez for testing purposes. This study outlines the design of a standard test method tailored for the small-scale unit, aimed at reducing sample requirements while ensuring reproducibility and scalability for metallurgical testing and circuit design. The proposed methodology was statistically evaluated through experimental test designs, demonstrating its reliability with significantly lower sample requirements around 2 kg per test. The findings from this study deepen the understanding of HydroFloat™ technology and serve as a crucial guide for practitioners aiming to enhance the efficiency and effectiveness of coarse particle flotation technologies.