Top 5 Common Mistakes in Flotation Systems

Flotation is a critical separation method used in ore beneficiation. However, many operations suffer from inefficiencies due to recurring errors in flotation plant design and operation. Here are the top five common mistakes:

1. Improper Pulp Density Adjustment
   Operating with pulp that is too diluted or too dense disrupts particle-bubble interaction and reduces recovery rates.
2. Inadequate Aeration Control
   Over or under-aeration negatively impacts froth stability and selectivity in mineral separation.
3. Neglecting Reagent Optimization
   Using outdated dosages or unsuitable reagents causes poor selectivity and increased operational costs.
4. Uncalibrated Level Control Systems
   Incorrect froth height affects residence time and leads to inconsistent product quality.
5. Lack of Maintenance on Critical Equipment
   Components like impellers, stators, and air injectors require periodic checks to avoid performance loss.

💡 With Minevate’s technical analysis services, you can avoid these common pitfalls and improve your flotation efficiency by up to 40%.