Water treatment technologies: Development and implementation of an automated laboratory flotation cell for mineral processing and performance analysis

Abstract

• Development of an automated laboratory flotation cell integrating advanced control technologies for enhanced mineral processing. • Implementation of real-time monitoring and precise adjustment of air flow, agitation speed, reagent dosage, and froth level using programmable logic controllers (PLCs). • Systematic design approach leveraging Model-Based Systems Engineering (MBSE) to ensure scalability, interoperability, and operational efficiency. • Demonstrated potential for improving mineral recovery rates, reducing energy consumption, and achieving consistent flotation performance. • Establishment of a replicable framework for future innovations in automated mineral processing systems, bridging gaps between research and industrial applications. This study presents the development and implementation of an automated laboratory flotation cell aimed to improve the efficiency and performance of mineral processing operations. Traditional flotation systems require extensive manual intervention to optimize key parameters such as air flow, reagent dosage, and agitation rate. By automating these processes, the study introduces a precise control mechanism that minimizes human error, improves operational consistency, and enhances mineral recovery rates. The system integrates advanced control technologies, including programmable logic controllers (PLC), sensors, and human-machine interfaces (HMI), allowing real-time monitoring and adjustment of critical process variables. A model-based systems engineering (MBSE) approach was employed to design the flotation cell, ensuring seamless integration of hardware and software components. The results demonstrate that the automated flotation cell achieves precise control of operational parameters, providing consistent and repeatable conditions for flotation testing. This precision offers significant potential for improving mineral recovery efficiency, reducing energy consumption, and enhancing process stability. By addressing key limitations of traditional systems, this advanced automation technology is poised to make a substantial contribution to both research initiatives and practical applications in mineral processing.