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Molycop's history spans 100 years of operation.

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Molycop's network of manufacturing facilities, distribution centres and regional sales offices service over 400 mines across 40 countries.

FloatStar

Mintek’s FloatStar suite of control modules distributed by Molycop use smart process control to overcome design-related limitations and maximise circuit performance.

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Features

Maximise circuit performance
Handle control of pH
Modular, customisable solutions
Implement with little or no additional instrumentation

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Overview

Flotation is a complex process that is affected by multiple factors. These factors may be inherent in the circuit design, or in how the flotation plant is operated. Mintek’s FloatStar suite of control modules, distributed by Molycop, uses smart process control to overcome design-related limitations and maximise circuit performance during operation.

The FloatStar control module is designed to be implemented with little or no additional instrumentation. This modular approach ensures a customised solution designed to each plant’s specific objectives. This approach allows for phased implementations that are useful both in assessing the benefit of the system and in allowing plant personnel to be introduced to any changes in operation gradually.

The FloatStar Level Stabiliser

The FloatStar Level Stabiliser has been successfully implemented in flotation circuits globally, consistently demonstrating its ability to reject disturbances and rapidly track setpoints.

Controlling flotation levels can be challenging due to the interconnected nature of the system. The control actions of one bank can influence others, and if not managed properly, disturbances can propagate throughout the circuit. Effective level stabilisation requires more than just local controllers – it demands a system that can handle the interdependencies across the entire flotation process.

Additional stabilisation

The control of pH is required in a number of areas in the mining industry, including in flotation reagent control systems. There are several difficulties in controlling pH:

Non-linearity of the pH curve
Silting up of the base (typically CaOH) feed-valve
Compensating for changing feed conditions.

The FloatStar pH controller is designed to handle all of these control difficulties.

Optimisation

The FloatStar Level Stabiliser ensures circuit stability and rapid setpoint tracking, creating a solid foundation for flotation optimisation.

The FloatStar Flow Optimiser manages circulating loads and mass pull within the flotation circuit, key parameters that significantly impact circuit performance, including grade and recovery. By stabilising these factors, the system helps maintain consistent and optimal performance throughout the flotation process.

Process monitoring

Controllers must maintain optimal performance not only under initial installation and tuning conditions but also across varying and fluctuating plant environments.

The FloatStar Performance Monitor continuously tracks controller performance, providing diagnostic insights to identify when and why controllers are underperforming, helping to maintain peak efficiency.

Typical Uses

The FloatStar suite of control modules is used by metallurgists and plant operators to enhance the efficiency of the flotation process. Operators use FloatStar to optimise variables such as air flow, reagent addition and froth levels, thereby improving recovery rates, reducing reagent consumption and maintaining consistent concentrate quality.

Benefits

Maximise circuit performance.
Increase recovery.
Accurate grade control.
Optimise reagent usage.

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FloatStar – Flotation Control & Optimisation

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The FloatStar suite of control modules utilises advanced process control to overcome design-related limitations and maximise circuit performance during operation.

Innovation

At Molycop, we see innovation as a way to find solutions to some of the mining industry’s greatest challenges. We aim to improve on today so we can deliver better for tomorrow.