New DELKOR BQR flotation cell with MAXGen mechanism undergoing commissioning

New DELKOR BQR flotation cell with MAXGen mechanism, core to process solution for recovery of valuable minerals from tailings stream, with proven DELKOR high-rate thickeners and horizontal vacuum belt filters helping to reduce tailings water loss, commissioned in India.

DELKOR process solution for cement, flotation cells with MAXGen mechanism, horizontal belt filters, and high-rate thickeners
DELKOR process solution for cement client included flotation cells with the MAXGen mechanism (top left and center), horizontal belt filters (top right) and high-rate thickeners (bottom).

The first commercial application of the DELKOR BQR flotation cell equipped with the MAXGen mechanism is currently being commissioned on a project where the technology will be applied to maximize limestone recovery. The flotation cells were ordered by one of India’s leading cement producers, as part of a contract covering the supply of flotation, thickening and filtration equipment for one of its cement works in India.

DELKOR BQR flotation cells, equipped with the MAXGen mechanism, achieve superior process performance in maximizing recovery. DELKOR BQR flotation cells achieve optimum operation through improved particle-bubble interaction, faster flotation kinetics and precise froth level controls.

The order comprises design, engineering, supply and supervision of erection and commissioning of:

  • 2 banks of DELKOR flotation cells, with each bank comprising 3 x BQR flotation cells for single stage roughing flotation
  • Reagent preparation and dosing system
  • 2 x DELKOR high-rate thickeners
  • 2 x DELKOR horizontal belt filters
  • Slurry holding tank agitator
  • Various other ancillaries

The order was received following the development of a process solution by DELKOR India to reduce the high levels of limestone and water that the plant was losing in the tailings discharged from the limestone washing plant into the tailings pond. Besides the loss of valuable minerals, the water loss meant that the tailings ponds were filling up at an unacceptably fast rate, while also contributing to water scarcity. 

The process solution was developed based upon extensive laboratory and pilot scale test work by specialists at our Bengaluru lab center, which demonstrated the advantages of the MAXGen mechanism in optimizing recovery of limestone from the washing plant tailings. In addition, bench scale tests with high-rate thickeners and a vacuum belt filter demonstrated the potential for water recovery. The resulting process flowsheet includes flotation, dewatering and filtration equipment. The flotation plant will thus minimize limestone loss into the tailings, while the dewatering equipment will provide between 85 and 90% water recovery. The tailings cake generated from the flotation plant will be dry enough to be stacked, after filtering, for use as mine backfill.

As a result of this environmentally-friendly solution, both the mine and tailings pond life will be significantly increased, with the water that is recovered being re-used in the process immediately, thus reducing the fresh/make-up water requirement in the plant.

Ramesh Mahadevan, Regional Managing Director – DELKOR, had this to say upon commissioning, “The commitment and time our process team invested in demonstrating the advantages of the MAXGen mechanism in terms of grade, recovery and power consumption, were without doubt a deciding factor in winning this important contract. This is an environmentally friendly and important project for us and a key reference for DELKOR and our BQR flotation cell with MAXGen mechanism for the future. This project only serves to show that, It pays to talk to a specialist!”

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