Search for a command to run...
New intensified flotation technologies have emerged to enhance fine and ultrafine particle recovery. However, their modelling remains challenging, as it requires defining the effective collection volume, residence time, and internal recirculation, factors not included in conventional models, while also facing operational complexity and the limited availability of key hydrodynamic and kinetic data. This study presents the development of a flotation model for the Concorde Cell technology, which separates the flotation process into three stages: collection zone, separation tank, and froth transport. The collection zone was represented as a plug-flow reactor with a rectangular rate of constant distribution; the separation zone as a perfect mixer with a detachment efficiency factor; and the froth recovery as a function of froth stability, residence time, and transport distance. Water recovery and gangue entrainment were also modelled to estimate concentrate grades. The model was tested and calibrated using experimental results from tests conducted in a Concorde Cell Lab Unit. A case example is presented for a semi-batch exhausting test performed with minerals from a copper concentrator plant. Good agreement between simulated and experimental results demonstrated the robustness and flexibility of the model. Additionally, the results showed collection rate constants significantly higher than those typically reported for conventional flotation cells (more than 100 times higher for Cu), due to the smaller collection volume and shorter residence time in the Concorde Cell. The calibrated model was then applied to simulate an industrial operation, where sensitivity analyses showed consistent responses to variations in operating conditions. Overall, the proposed model provides a practical tool for predicting the metallurgical performance of intensified flotation cells, supporting the integration of this new technology into modern concentrator flowsheets for the development of hybrid circuits.