Flotation machine monitoring

Flotation cells: the heart of mineral recovery

Flotation machines are key assets at base-metal concentrators. They separate valuable minerals (copper, molybdenum, lead, zinc, gold) from gangue by differences in surface wettability.

Flotation performance depends directly on equipment condition: aeration intensity, impeller speed, seal integrity. Any deviation from the optimal regime cuts metal recovery and revenue.

Critical monitoring points

Impeller shaft bearings

The impeller shaft operates in harsh conditions: submerged in pulp, exposed to corrosion, vibration and hydraulic loads.

SDT340 checks bearing condition through contact points on the bearing housing. Multi-month trends support planned bearing replacement instead of emergency stops.

Flotation drive gearboxes

Many cells use gearboxes to set impeller speed. They run under constant load in high humidity and vibration.

SDT340 monitors:

• Input and output shaft bearings
• Gear mesh (pitting, scuffing)
• Noise level (changes indicate degradation)

Mechanical shaft seals

Face seals on the impeller shaft work in aggressive pulp. SDT340 detects early seal degradation by characteristic ultrasonic signatures before visible leakage.

Aeration system

Air lines and spargers are checked with SDT270 for leaks. Leaks reduce aeration pressure and disturb the flotation regime.

Lubrication with LUBExpert

On concentrators with dozens or hundreds of cells, systematic LUBExpert use delivers:

• Precise grease dosing per bearing
• No over-lubrication (pulp contamination)
• Documented grease consumption
• Shorter planned lubrication rounds

Artesis EMCM for flotation drives

Artesis EMCM is installed in motor control centers and continuously monitors all cell drives in a section. It detects:

• Rising load (impeller blockage, aeration faults)
• Motor bearing defects
• Abnormal operating modes

A central dashboard shows the entire flotation fleet on one screen.

Business impact

Concentrators running SDT + Artesis programs for flotation cells report:

• 55–70% fewer unplanned flotation outages
• Stabilized flotation process parameters
• 1–3% higher metal recovery by holding optimal regimes
• ~35% lower spare-parts spend on bearings and seals