Chapter 20

Current trends in flotation applications are reviewed, focusing on the implications of increased cell sizes and automation of circuits. The study evaluates the significance of laboratory and pilot plant investigations in determining design criteria and project feasibility. As flotation practices evolve, the industry anticipates a shift towards managing lower grade feeds and complex mineralogy. Notable developments include an anticipated surge in iron ore flotation plants as non-magnetic taconites begin to outpace magnetic counterparts, although high-intensity wet magnetic separation may mitigate this trend. Moreover, the demand for phosphate production is expected to rise, with changing mineral composition playing a crucial role. The sulfide sector remains stable, with large-scale operations predominantly focused on copper and molybdenum concentrates. The pilot plant program emerges as a fundamental step in design, encompassing key activities such as extensive testing of ore types, establishing reagent variability, and detailed circuitry analysis. Despite its benefits, there are inherent risks, including the potential for overconfidence in managing mineral variations and operational challenges. The insights gained from these pilot studies ultimately inform pre-engineering estimates of plant costs and support management decisions regarding project viability.