Floatation circuit13 May 2026 19:58
1. Flotation is the only process that upgrades spodumene to 6%+ Li₂O
Crushing and milling only liberate the minerals — they do not create a high‑grade product.
Spodumene has to be selectively floated away from:
- quartz
- feldspar
- mica
- iron-bearing minerals
If the flotation stage fails, the concentrate ends up too diluted, often 2–4% Li₂O instead of 6–7%.
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2. Spodumene flotation is technically difficult
Spodumene is a hard-to-float mineral because:
- It has similar surface chemistry to quartz and feldspar.
- It requires precise pH control (usually 9.5–10.5).
- It needs specialised collectors (fatty acids, amines) and temperature conditioning.
- It is sensitive to slimes, water chemistry, and reagent dosage.
If any of these are wrong, recovery collapses or the concentrate becomes contaminated
3. Circuit design errors cause chronic underperformance
PREM’s original flotation circuit never produced consistent, market‑spec concentrate.
According to reports:
- The unit “failed to produce spodumene concentrate consistently and to market specifications” since installation.
- It caused missed production targets, funding issues, and offtake delays.
Typical design problems that force redesign include:
- Incorrect cell sizing or residence time
- Poor froth handling
- Inadequate air control
- Wrong impeller/rotor design
- Poor reagent conditioning
- Bad slurry flow or level control
- Inadequate desliming or classification
Any one of these can prevent achieving 6% Li₂O.
4. PREM replaced the entire flotation plant because the old one was fundamentally flawed
PREM discarded the original flotation unit and purchased a new Xinhai-designed flotation plant, because:
- The old circuit could not reach required grade.
- The new circuit is “well established and proven in comparable operations.”
- New flotation cells were installed, aligned, levelled, and connected under manufacturer supervision.
- The new circuit is central to PREM’s plan to finally produce on‑spec concentrate.
🧪 Why achieving 6% Li₂O requires circuit modification
To reach 6% Li₂O, a flotation circuit must deliver:
✔ High spodumene recovery
✔ High rejection of quartz/feldspar
✔ Stable froth
✔ Correct reagent chemistry
✔ Proper residence time and cell configuration
If the circuit is not optimised, the concentrate will be:
- Too low grade (<5% Li₂O)
- Too contaminated (Fe, Al, Si)
- Too inconsistent for offtake contracts
This is why PREM had to redesign, replace equipment, and re‑engineer the flotation flowsheet
🧩 Summary: Why flotation must be redesigned to hit 6%
| Key Factor | Why It Matters |
| Selective separation | fOnly flotation can separate spodumene from quartz/feldspar to reach 6%+ |
| Complex chemistry | Requires precise pH, reagents, temperature |
| Circuit design sensitivity | Wrong cell sizing/airflow kills grade |
| PREM case study | Old circuit failed →
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