Celdas Flotacion Outotec Modulo

Outotec Flotation cPlant
Product Overview
Agenda
1. 2. 3. 4.
cPlant Basic Benefits and Modules Layout &
Principles value Configurations
proposition
5. 6. 7. 8.
Gas Installation on Maintenance Case Study
Recirculation site
system
Flotation cPlant, Product Overview

Outotec All rights reserved
Flotation cPlant Basic Principles
Flotation plant for capacities ranging from

100K TPY to 2.500K TPY
Made into sea container sized frames
Containers used as support elements
Preinstalled pipelines into modules
Pipes between modules with fast
couplings
Preinstalled electric cable trays and cables
Blower/compressor module(s)
Analyzer modules
Conditioner modules
Pump sump modules with pumps
MCC modules (Motor Control Cabinet)
Control room module
Automation room module
Reagent plant

cPlant module basic principles
Module
can contain one or several containers
to form a functional unit Flotation module
can be a skid mounted functional unit Pumping unit
can contain more than the basic equipment Flotation module
contains preinstalled piping, support structures, cabling, instrumentation etc.
Container
Is a standard container sized transfer unit of cPlant Drive container for C44
Can contain preinstalled and tested equipment Blower
Can be simply a cargo unit for skid mounted equipment Pumping unit

Agenda
1. 2. 3. 4.
proposition
5. 6. 7. 8.
Recirculation site
system

Flotation cPlant - Benefits
95% of the plant installation work can be done at Workshop

Effective fabrication and installation in time wise and in costs wise in perfect
environment
Pre-commissioning could be executed inside in the Workshop
Easy Site Installation
30% faster installation time than with competitors solutions
30% less installation labor force compared with typical flotation plant installation
Small footprint minimizes civil work and foundation materials needs by 20%
Site warehousing of Containers is very simple compared to conventional delivery
Easy to transport
Logistics of Containers is 10% more simple compared to conventional plant
delivery
Possibility to transfer the plant to next site after mine closing

Outotec cPlant Value Proposition
Value proposition
Short lead time for production and low CAPEX investment /
Fast-track projects with savings in means of time, costs, quality and operation
Features Benefits
High quality modules and fast installation
Prefabricated and ready to install modules
with low labour need at site
Easy to transport and fast delivery (product

Reduced capital expenditure
instead of project)
Standard modules Expansions are easy and reliable to estimate
Proven Outotec Flotation Technology Maximize gains

Agenda
1. 2. 3. 4.
proposition
5. 6. 7. 8.
Recirculation site
system

Sample Process Flowsheet
Blower
MCC
Reagent
Preparation
Reagent
Dosing
Control Room
Automation
room
Analyzer

Main Modules
Outotec cPlant
cPlant Additional Modules
Pumping module
cPlant Flotation cells Modules
Blower module
C11 Flotation module
MCC module
C6 Flotation module
Reagent Preparation
C3 Flotation module
Reagent Dosing
C1.5 Flotation module
Conditioner
Launder module
Control Room
Automation room
Analyzer

3.
Modules

Includes two containers

Drive container
Tank container
Cell volume 11 m3
Rotationally cast polyethylene tanks and
launders
Available configurations:
C11-4: 4 cells/shafts in 40 foot container
No intermediate steps inside module
available
Step between modules (600 mm)
Feed and discharge boxes included as
a separate structure
FloatForce 500 mechanism

Level control with discharge dart box or pinch valve

Electric actuators
Belt drive, 15 kW (TC e10)
Preinstalled flotation air and launder water piping, cabling, instrumentation
and electrical equipment in drive container
Piping connections with fast couplings
Power and control connections with fast couplings

Drive container Launder water piping Air piping

Cable trays
Air Control
Electric cabinet Drive unit
Level Sense
Froth master
Support frame

Tank container
Dart assembly
Feed box
Discharge box
Tank
Froth outlet FloatForce
Launder Support frame

C11 Cell unit
Launder
Tank
*) Outotec standard wear tests shows practically no wear at all on polyethylene

Modelling of Flow Patterns inside the new cell design

free surface
shaft
rotor
tank wall vortex breaker stator
Modelling of flow made in Outotecs Research Center in Pori

Modelling of Flow Patterns inside the new cell design
Velocity at y=0, angle= 45o Velocity, at z=0.2, 1, and 2 m

C6 Flotation module
Includes
External drive support structure
Tank container
Cell volume 6 m3
Rotationally cast polyethylene tanks and launders
Available configurations:
C6-4: 4 cells/shafts in 40 foot container (2+2)
C6-3: 3 cells/shafts in 30 foot container (1+2, 2+1)
C6-2: 2 cells/shafts in 20 foot container (1+1)
One intermediate step inside module (300 mm)
Feed and discharge boxes included inside
container frame
Alternatively pinch valve for level control
FloatForce 400 mechanism

C6 Flotation module
Intermediate feed box possible

Belt Drive, (TC e5)
and electrical equipment in drive support structure

Main Structure and Components
C3 Flotation module
Includes
Container structure to support the cell units
Skid mounted cell units
Cell volume 3 or 1.5 m3
Rotationally cast polyethylene tanks and launders
Drive, mechanism and tanks are skid mounted
More variations possibe to suit the process needs
Different sizes are possible to install inside one module
Multiple intermediate steps possible within container frame
Feed and discharge boxes included inside container frame
FloatForce mechanism

Main Structure and Components
C3 Flotation module
Level control with pinch valve

Electric actuators
Intermediate feed box possible
Belt or gearmotor driven
and electrical equipment in drive support structure

Launder module
Modular construction froth collection launders

Includes support structure
Standard design
Polyethylene piping
Simple and fast connection couplings to cell launder

cPlant Flotation Cell Material
Flotation cell tanks and launder are made of polyethylene (PEH) by

rotationally casting
According to standard wear tests made in Outotec reasearch center for
polyethylene plastic it is very resistant for abrasive slurries
PEH piping is widely used for slurry transportation in flotation plants. And also as
lining material.
Polyethylene is also known for good resistance for chemical corrosion
Currently there is working reference for flotation machines manufactured of

polyethylene tanks and using Outotec Float Force flotation mechanisms
Application: flotation of silica sands
Customer has been running the plant for several years without
significant wear in place or need to repair their cells.

cPlant Automation Levels (Modules)
Basic Controls includes

Application modules to enable basic controls of cPlant depending of provided modules and instruments included.
Basic controls are made with basic process control automation Proscon.
Launder Water control to adjust water flow to flotation.
Air control to keep air flow in setpoint per cell levels.
Cell Level control to keep slurry level in cell at its setpoint.
Sump Level control to keep sump level in its fluctuation range.
Smart Level includes
Smart level introduces control applications to enable controls of froth speed and to speed up cell level controller
reaction time to sudden changes of slurry. These controls are made in ACT server. To make Smart level controls
possible, basic controls are required.
EXACT Level improve cell level controller reaction time to slurry flow changes.
Froth Speed Control to enable control of froth speed based on froth cameras.
Analyzer Level
Courier analyzer with sampling system
Advanced level
Advanced level introduces Grade recovery optimation which is made based on to analyzer results. The possibility
to use GRO is depending of process and has to be discussed with Outotec spelialist before its offering. Advanced
level requires Basic controls, Smart Level and Analyzer level.
25 11/9/2015 Internal | Presentation name, Author

ACT Proscon 2100S
Application Modules Application

Module
Application
module
ADVANCED LEVEL
Grade Elemental Analyzes

Recovey
Optimization
Speed Targets
SMART LEVEL ANALYZER LEVEL
Froth information
EXACT Froth Speed
level Control Courier
Elemental
Analyzer
Setpoints Setpoints
BASIC LEVEL Setpoints
Air Flow Reagent

Level Control Level Control Level Control Air Flow Reagent
Reagent
Level Control
Launder Level Level
Sump Control Level Control
Cell Level Control Control
Air Control Control
Dosing
Water Control Control Control
Control
Sampling
Froth Camera System
cPlant Flotation Process

26 11/9/2015 Internal | Presentation name, Author
3.
Modules
cPlant Additional Modules

Additional Modules
Pumping module
Modular skid mounted design

Transferable in standard container
Pump tank and pumps on a same structure
Several pump sizes or brands can be mounted on same base frame
Includes closing valves, drain and flushing nozzles
Instrumentation for level control
The whole unit can be changed for service or only the pump can be easily
dismantled from the skid
Initially three different sizes planned for cPlant

Additional Modules
Blower module
Flotation air blower installed in 20 foot container

Factory installed and tested ready to operation functional unit
Plug and play type of design
Includes all needed components
Only electric power needed
Comes with local PLC or can be controlled from plant DCS
Two sizes
Model 151A.06
Model 077A1.06
Main difference in capacity

Additional Modules
MCC module
Standard 40 foot container including

Transformer
MCCs
Cable trays and cabling
Necessary heating and/or cooling built in
Expandable
FAT tested
Scalable to suit the project needs
Supply voltage according to project specifications

Additional Modules
Reagent Preparation
Reagent Dosing
Containerized reagent plant

At the moment outsourced
Adjustable according to the project specifications
Used reagents according to the flotation process
Capacity
Automation level
Scope from equipment only to turn key package
Example PAX
And MIBC

Additional Modules
Conditioner
Containerized OKTOP C conditioner module

Tank in containerized form
Mixer, drive and bridge assembled at site
Volume 5 to 25 m3
Mixer up to 5,5 kW

Additional Modules
Analyzer and sampling
Containerized analyzer package

Samplers located in Flotation cell Modules
Equipped with
Multiplexer
Courier Multiplexer
Sample return pumping
Courier
Sample return

Additional Modules
Control Room
Automation room
Containerized automation and control room

Equipped with project needs
Automations system
Operator workstations
Automation workstation
Accessories according to project
specifications Control room
Lighting
Heating
Ventilation
Automation room
Technical room

Agenda
1. 2. 3. 4.
proposition
5. 6. 7. 8.
Recirculation site
system

Layout & Configurations
Layout design simple and fast due to modular design

Modules are placed in defined grid
3D module library will be available
Possible to combine with larger Tank Cells for larger capacity needs



cPlant example
Rougher flotation cells
Conditioner
cPlant example
Control room
Automation room
MCC container
Reagent containers
Cleaner cells Multiplexer

Courier
Return pumping
Reagent storage
cPlant example
Flotation air blower container

Combined TC- and C-Flotation Plant for
Molybdenum Rougher Circuit with TC-
Flotation machines
Dewatering Plant
Reagent Plant
Cleaning Circuit with Cplant

Gas Scrubbing Flotation machines

Agenda
1. 2. 3. 4.
proposition
5. 6. 7. 8.
Recirculation site
system

Gas Re-circulating System
For Molybdenum Flotation
Liquid ring compressor supplies the pressurised gas to the sealed flotation
cells
Exhaust gas lines are used to collect the flotation gas from the launders of
cells
Gas lines are connected to the suction side of the liquid ring compressor
thus forming a closed loop
Re-circulating gas is bled continuously to balance the gas system (due to
the fluctuating of pulp level, temperature etc) and directed to the stack
Water locks are designed to prevent gas releasing from or incoming to the
GRS due to the fluctuation of pressure
O2- (and H2S if necessary) content of the re-circulating gas is/are monitored
to control N2 addition

Schematic description

Outotec Gas Scrubbing

Unit
Liquid Ring
Compressor

Main Equipment
Liquid ring compressor
One duty + One stand-by
OKTOP Packed bed gas scrubbers by Outotec
Material Fibre-reinforced Plastic with PE-lining
Water lock system for over and under pressure
Two units made of Fibre-reinforced Plastic
Stack
Made of Fibre-reinforced Plastic
Nitrogen Generation unit
98 % N2 and inert gases

Agenda
1. 2. 3. 4.
proposition
5. 6. 7. 8.
Recirculation site
system

Installation on site
In plant delivery battery limit typically from top of the concrete

Outotec supplies specifications and guide drawings for foundation design
Containers are attached to foundation column with clamp locking devices for easy
installation or replacement
Special JIG can be used to align the foundation columns
Lifting tools for container handling is needed
Autolocking special spreaders
Container bottom lift slings
Containers are attached to each other with clamp locking devices
Piping and electrical connections with fast couplings

Structural considerations
The flotation modules are self supporting steel structures supported

by the corner blocks of the container frame on concrete columns.
In the FEM strength analysis the most severe seismic conditions
have been taken into account with tanks in full operation condition.
The structural steel calculations has been made according to seismic
conditions of UBC4, ground acceleration of 0,4 g, and cells in full
operation condition.

IInstallation on site

Clients scope in plant delivery

Installation of conditioner

Installation of 1st bank tank containers

Installation of 1st bank mechanism containers

Installation of 1st bank platform frame

Installation of MCC, Automation Room and Control Room

Containers
Installation of Pump Tank Containers

Installation of Launder Containers

Installation of 2nd Bank Containers including Blower and

Analyzer Containers
Installation of Reagent Storage and Reagent Preparation Containers

Agenda
1. 2. 3. 4.
proposition
5. 6. 7. 8.
Recirculation site
system

Maintenance
C11 Flotation Module
Equipment is designed to be maintained
as a whole unit.
Drive container + stator wear parts
Tank container
Maintenance is done in designated
maintenance area or in Outotec
workshop.
Maintenance area is equipped with
suitable tools, lifting equipment and
service stand.
Replacement of wear parts for C11-4
include:
Stator wear parts
Rotor
Level control
Tanks
Drive components (bearing unit, belts,
pulleys, shaft)

Maintenance
Replacement of mixing mechanism on a service rig
Lift the drive container as a whole set to a service rig
Maximum lift for the C11-4 drive container is 15 tons.
Replace the rotors in maintenance area
Stator wear parts replaced inside tank at the same time
In case maintenance is done off-site, one tank module should be kept as a
spare part on-site

Maintenance
Replacement of mixing mechanism one by one
It is also possible to service the rotor
mechanism one at a time by lifting
them separately through drive
container
Stator can be serviced by accessing
the cell from manhole access (dia 600
mm) by removing the feed or
discharge box or discharge valve

Agenda
1. 2. 3. 4.
proposition
5. 6. 7. 8.
Recirculation site
system

Case Study 250.000 TPY
Comparison between a
conventional plant delivery and a
cPlant delivery in terms of costing
and delivery time is presented
Plant located in Northern Africa
Project considered to be executed
in 3 phases in order to reduce extra
risk provisions and contingencies
Delivery includes from Concept
engineering to commissioning (EPC
Basis)
Generic Polymetal Copper Zinc
flotation plant
Capacity of 250.000 tpy

Design Basis
New Capacity: 250.000 t/y

Utilization rate: 95%
ROM Ore Mineralogy:
Pyrite - FeS2 10%
Chalcopyrite CuFeS2 2,5%
Sphalerite ZnS 8%
Galena PbS 1,5%
Non Sulphide gang 78%
Head Grades
Copper % 0,8
Zinc % 5,5
Lead % 1

Option 1 Conventional delivery - Flowsheet
Zinc Flotation
Copper Flotation

Option 1 - Main Equipment
Flotation cells
2 Cu 2nd Cleaner flotation machines OK-1.5-2R
2 Cu 3rd Cleaner flotation machines OK-1.5-2R
3 Zn Rougher flotation machines TC-10
3 Zn Scavenger flotation machines TC-10
4 Zn 1st Cleaner flotation machines OK-3-2R
2 Zn 2nd Cleaner flotation machines OK-3-2R
Blowers
Pumps & Pump Sumps
Reagent Plant
Conditioners
Instruments
Automation module
Proscon
Courier 6x
Samplers

Option 2 cPlant Deliver - Flowsheet
Zinc Flotation
Copper Flotation

Option 2 Main equipment
Flotation cells cPlant Modules

1 Cu 1st Cleaner flotation machines C-1.5-4
1 Cu 2nd Cleaner flotation machines C-1.5-2
1 Cu 3rd Cleaner flotation machines C-1.5-2
1 Zn Rougher flotation machines C-11-3
1 Zn Scavenger flotation machines C-11-3
1 Zn 1st Cleaner flotation machines C-3-4
1 Zn 2nd Cleaner flotation machines C-3-2
Blower Module
Pumps & Pump Sumps Modules
Reagent Plant Modules
Conditioners modules
Instruments
Automation module
Proscon
Courier 6x
Samplers
MCC Modules & Electrical equipment

Cost Comparison
Price Breakdown
Conventional cPlant Conventional Plant Delivery : 12.64M
Price Conventional % From Total Price cPlant % From Total
2% 3% 2% 4% Conceptual Study
Conceptual Study 210 000,00 1,66 % 210 000,00 2,11 % Basic Engineering
Basic Engineering 476 000,00 3,76 % 385 000,00 3,88 % 8%

Detail Engineering
11 % Flotation Equipment
Detail Engineering 1 343 000,00 10,62 % 362 000,00 3,65 %
Auxiliaries
Flotation Equipment 2 484 000,00 19,64 % 2 404 000,00 24,21 % 14 % Reagents Plant
20 % EPC Site Supervision
Auxiliaries 3 211 500,00 25,40 % 3 186 000,00 32,08 %
Site Work
2%
Reagents Plant 1 115 000,00 8,82 % 882 000,00 8,88 % 9% Buildings
Commisioning & Start-up
EPC Site Supervision 198 000,00 1,57 % 249 000,00 2,51 % 25 %
Transport
Site Work 1 829 000,00 14,46 % 996 000,00 10,03 %
Buildings 1 043 000,00 8,25 % 560 000,00 5,64 %
Commisioning &
Start-up 305 700,00 2,42 % 298 000,00 3,00 %
cPlant Plant Delivery : 9.93M
Transport 430 175,00 3,40 % 398 000,00 4,01 % 4%
4% 2% Conceptual Study
3%
12 645 375,00 9 930 000,00 4% Basic Engineering
Detail Engineering
6%
Cost per phase Flotation Equipment
Auxiliaries
Conventional delivery cPlant Delivery 10 %
24 % Reagents Plant
Phase 1 - Concept + Basic 2%
EPC Site Supervision
Engineering 749 329 479 652 9% Site Work
Phase 2 - Equipment supply &
Buildings
Detail Engineering 7 057 368 6 189 523
Commisioning & Start-up
Phase 3 - Material Supply, 32 % Transport
construction and commisioning 4 838 678 3 260 826
Total 12 645 375 9 930 000

Project execution schedule comparison
Conventional Delivery
1 month shorter conceptual and basic
engineering phase with cPlant
Predesigned and standardized plants and
modules
Preselected manufacturers, partners and
implementation methods.
1 month shorter equipment supply and
detail engineering phase with cPlant
Due to productized design manufacturing
can start immediately after order
Flotation cells manufactured utilizing cPlant Delivery
molds.
Modules delivered as products
2 month shorter Construction and
commissioning phase with cPlant
Modules are plug and play
Minimized installation work on site
Construction on site minimized to concrete
slab and light building (As required by
customer)

Conclusions
Short lead time for production and low CAPEX investment, as well as fast-
track projects with savings in means of time, costs, quality and operation
can be achieved in minerals processing projects by this new modularized
approach. This is thanks to prefabricated modules delivered for quick on site
erection. These modules are easy to transport to site and have fast delivery
times (product instead of project). The modules are standardized, hence are
easy to replace or upgrade in time, securing a sustainable operation of a
minerals processing plant. Furthermore, all metallurgical features from
conventional flotation plants can be replicated in this new modular flotation
plant design.


Celdas Flotacion Outotec Modulo

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Outotec Flotation cPlant

Flotation cPlant, Product Overview

Flotation plant for capacities ranging from

Flotation cPlant, Product Overview

Flotation cPlant, Product Overview

Flotation cPlant, Product Overview

95% of the plant installation work can be done at Workshop

Flotation cPlant, Product Overview

Easy to transport and fast delivery (product

Standard modules Expansions are easy and reliable to estimate

Proven Outotec Flotation Technology Maximize gains

Flotation cPlant, Product Overview

Flotation cPlant, Product Overview

Flotation cPlant, Product Overview

Flotation cPlant, Product Overview

cPlant Flotation cells Modules

Flotation cPlant, Product Overview

Includes two containers

Flotation cPlant, Product Overview

Level control with discharge dart box or pinch valve

Flotation cPlant, Product Overview

Drive container Launder water piping Air piping

Electric cabinet Drive unit

Flotation cPlant, Product Overview

Froth outlet FloatForce

Launder Support frame

C11 Cell unit

*) Outotec standard wear tests shows practically no wear at all on polyethylene

Modelling of Flow Patterns inside the new cell design

tank wall vortex breaker stator

Modelling of flow made in Outotecs Research Center in Pori

Flotation cPlant, Product Overview

Modelling of Flow Patterns inside the new cell design

Velocity at y=0, angle= 45o Velocity, at z=0.2, 1, and 2 m

Flotation cPlant, Product Overview

Flotation cPlant, Product Overview

Intermediate feed box possible

Flotation cPlant, Product Overview

Flotation cPlant, Product Overview

Level control with pinch valve

Flotation cPlant, Product Overview

Modular construction froth collection launders

Flotation cPlant, Product Overview

Flotation cell tanks and launder are made of polyethylene (PEH) by

Currently there is working reference for flotation machines manufactured of

Flotation cPlant, Product Overview

Basic Controls includes

25 11/9/2015 Internal | Presentation name, Author

Application Modules Application

Grade Elemental Analyzes

SMART LEVEL ANALYZER LEVEL

BASIC LEVEL Setpoints

Air Flow Reagent

cPlant Flotation Process

cPlant Additional Modules

Flotation cPlant, Product Overview

Modular skid mounted design

Flotation cPlant, Product Overview

Flotation air blower installed in 20 foot container

Flotation cPlant, Product Overview

Standard 40 foot container including

Flotation cPlant, Product Overview

Containerized reagent plant

Flotation cPlant, Product Overview