Hydrodynamic Improvement of Flotation Machines and Alternative Machine Selections Beyond Mechanical Cells: A Comprehensive Review

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This paper offers a comprehensive review of the development and evolution of flotation machines beyond traditional mechanical cells. Given the limitations of mechanical cells in handling ultrafine and coarse materials and producing high-grade products, theoretical analyses have suggested several strategies to optimize machine design for enhanced flotation performance. The review encompasses more than 60 flotation machines categorized into five major types and identifies the most industrially promising models in each category. Reactor-separator systems, particularly the Jameson™ Cell and StackCell™, have been widely adopted in fine particle flotation operations. Among cyclonic machines, the FCSMC has shown remarkable success in Chinese mineral processing plants for fine particle collection. Fluidized-bed technologies, especially HydroFloat®, NovaCell™, CoarseAIR™, and RFC™ systems, are emerging as game-changers for coarse particle recovery. Flash flotation machines like SkimAir® have proven particularly valuable for early recovery of liberated particles. Flotation columns equipped with advanced sparging systems, such as Microcel™ and columns with lance-type spargers, continue to dominate cleaning circuits where high concentration grades are required. Insights derived from this review present opportunities to reconsider flow sheet designs and operational strategies in mineral processing, aiming to develop flexible process chains that maximize economic benefits while minimizing environmental footprint.