The Chilean Copper Commission (Cochilco) has announced that demand for raw materials used in metal production is projected to grow by 10.5% in 2025, while supply is expected to decline by 3.4%. Chile, a global leader in the copper market, could significantly benefit from this rising demand. However, Cochilco estimates that non-ferrous metallurgy enterprises will operate with minimal profits. The issue lies in the rapid decline in ore quality, which consequently increases production costs.
In the 19th century, the world primarily mined high-grade ores with approximately 10% copper content. By the end of the first quarter of the 20th century, this figure dropped to 5%. Today, ore with just 0.1% copper is considered industrially viable. As a result, improving the efficiency of ore processing has become a critical priority.
In 2024, researchers from Empress Catherine II St. Petersburg Mining University completed the patenting process for the flotation complex "Smart Flot." A laboratory model was created, which went on to win the grand prize at the International Innovation Exhibition "HI-TECH." Moreover, its innovative electrode unit was successfully tested at a Russian mining and beneficiation company during the flotation of copper ores. The results confirmed the efficiency of the development, with concentrate quality improving by 10% and reagent consumption decreasing by approximately the same percentage.
In addition to complex copper ores, the "Smart Flotation" machine can effectively process polymetallic ores, gold-bearing ores, and refine iron concentrates. Tatiana Alexandrova, Doctor of Technical Sciences, Corresponding Member of the Russian Academy of Sciences, and Head of the Department of Mineral Processing, explained the innovation to Forpost:
«Here’s how a traditional flotation machine works: air is introduced into a liquid-filled tank, creating foam. Hydrophobic material adheres to the air bubbles and floats, while hydrophilic material, such as sand, sinks. For the first time, we’ve developed an apparatus that combines classical flotation with magnetic separation. Today, the quality of ores leaves much to be desired; they contain numerous minerals, including iron. Iron, in particular, interferes with the flotation of valuable components like copper.
Our machine is equipped with a magnetic block. If the ore contains iron, the magnets retain it in the chamber, preventing it from hindering the flotation process. This improvement addresses the apparatus design, but we have also automated the control of the technological process».
One of the co-authors, Candidate of Technical Sciences Artem Romashev, elaborated on the digital component of the development:
«Machine vision visually controls the foam layer—where valuable components float—by analyzing the color of the bubbles. Data from the camera is processed in real-time, and the computer adjusts reagent dosages and frothing intensity.
Another digital solution we employed is electrochemical monitoring. Using electrodes selected according to the type of raw material, we obtain real-time data on the electrochemical composition of the pulp [a mixture of water and rock in mining]. The software, based on mathematical models, provides flotation operators with recommendations on altering specific parameters to maintain the optimal state of the process.».
Currently, the authors are verifying the apparatus under various operating conditions and training the neural network. Simultaneously, consultations are being held with industry representatives interested in enhancing the efficiency of mineral processing.
The researchers' development can be implemented at beneficiation plants of companies like Apatit, Polyus, and Polymetal. In the near abroad, KAZ Resources, which announced a new strategic project to build a mining and beneficiation plant in East Kazakhstan’s Ulan district in November 2024, could be a potential adopter.
Regarding potential stakeholders from distant foreign countries, companies from China and the African continent are primary prospects. For instance, Anglo American Platinum Limited, the world leader in primary platinum mining based in South Africa, is actively seeking effective enrichment technologies, yet their current machinery lacks an efficient online control system.
Certain aspects of this technology are applicable beyond the mining industry, such as in industrial wastewater treatment.
