/ Equipment service
Flotation equipment
We restore flotation machine performance and upgrade aeration units without replacing the entire cell bank.
- 015 unit types
- 02Site visits: KZ & CIS
- 0312-mo warranty
/ Equipment
Types of units we work with
Mechanical flotation machines
Cells, impellers, stators, shafts, drives and air supply systems.
Pneumomechanical machines
Aeration units, air distribution and mechanical section.
Flotation cells
Tanks, lining, overflow elements and froth removal.
Aeration systems
Air ducts, valves, flow meters and distribution elements.
Drives
Motors, gearboxes, couplings, shafts and bearings.
/ Technical audit
Aeration unit geometry matters more than replacing worn parts
Impeller and stator wear can change the geometry of the aeration unit, so servicing a flotation machine is more than just replacing worn parts.
Process parameters
- Cell volume
- m³
- Slurry feed
- m³/h
- Slurry density
- kg/m³
- Solids content
- %
- Air Flow
- m³/min
- Impeller Speed
- rpm
- Motor Power
- kW
- Pulp Level
- mm / %
What we check
Shaft and impeller
- shaft
- impeller
- stator
- bearing unit
- coupling
- gearbox
- motor
Cell
- fastenings
- lining
- cell condition
Aeration unit geometry
- Impeller Diameter
- Stator Clearance
- Impeller–Stator Position
- Shaft Runout
- RPM
- Motor Current
Aeration
- air flow rate
- pressure
- air distribution between cells
- condition of air ducts
- valves
- flow meters
- clogging of elements
- aeration stability
/ Audit result
After the inspection the customer receives
- 01
List of identified defects
- 02
Technical condition assessment
- 03
List of units requiring repair or replacement
- 04
Upgrade recommendations
- 05
Preliminary spare parts list
- 06
Proposed scope of work
- 07
Technical proposal
/ Repair
Partial repair and overhaul
Partial repair
Possible work during flotation machine repair.
- shaft repair
- bearing replacement
- restoring fits
- drive repair
- impeller replacement
- stator replacement
- cell repair
- lining replacement
- repair of froth removal devices
- restoring the air supply system
Overhaul
An overhaul involves in-depth fault detection with restoration or replacement of worn main units.
- 01
Disassembly and fault detection
Determining the actual condition of parts and units.
- 02
Restoration
Machining, repair or manufacture of parts.
- 03
Replacement
Installation of new components where restoration is technically or economically unjustified.
- 04
Assembly and adjustment
Restoring geometry, adjusting mechanisms and drives.
- 05
Testing
Testing of equipment systems.
- 06
Commissioning
Installation supervision and commissioning, depending on the scope of work.
Aeration diagnostics
Impeller and stator wear can alter the geometry of the aeration assembly, so servicing is not limited to replacing worn parts.
We diagnose
- air flow rate
- pressure
- air distribution between cells
- condition of air ducts
- valves
- flow meters
- clogging of elements
- aeration stability
Possible work
- Restoring air distribution
- Valve replacement
- Flow meter repair
- Cleaning clogged elements
- Air duct repair
- Balancing air supply across cells
The effect of an aeration upgrade on process performance is determined by analysing the flotation circuit and the equipment's operating mode.
/ Upgrade
Improving the efficiency of existing equipment
Flotation equipment upgrades can have different goals, from stabilising aeration to automating the monitoring of process parameters.
Improving aeration stability
Changing or restoring air distribution.
Slurry level stabilisation
Installing or upgrading level measurement and control.
Air flow control
Air control for individual cells.
Drive upgrade
Replacing the motor, gearbox or control system where technically justified.
Automation
Monitoring of level, air, drive load and other process parameters.
Important: the effect of an upgrade on process performance, including recovery, is determined by analysing the flotation circuit, feed characteristics and equipment operating mode — specific percentages are not stated without process testing.
/ Automation
Aeration and slurry level control
Automation enables real-time monitoring of air flow per cell, slurry level and drive load.
Aeration control loop
- Air supply
- Distribution across cells
- Pressure monitoring
- Slurry level control
- Flow control
Automation equipment
- PLC
- HMI
- VFD
- level sensors
- air flow meters
- pressure sensors
- control cabinet
Integration with the plant DCS
- Modbus RTU
- Modbus TCP
- PROFINET
- Ethernet/IP
What the operator sees on the HMI
AIR SYSTEM
NORMAL- Header Pressure
- XX kPa
- Cell 01
- X,X m³/min
- Cell 02
- X,X m³/min
- Cell 03
- X,X m³/min
- Cell 04
- X,X m³/min
/ Installation supervision
Installation supervision
Technical supervision of equipment installation by specialists, checking correct assembly, installation and connection of main units.
- site readiness check
- installation control
- equipment position control
- connection check
- drive installation control
- piping connection control
- recommendations to the installation contractor
- preparing equipment for commissioning
/ START-UP
Commissioning
- 01
Installation check
- 02
Electrics and instrumentation check
- 03
Drive check
- 04
Idle run
- 05
Algorithm tuning
- 06
Start-up under load
- 07
Parameter adjustment
- 08
Handover of equipment to the customer
If provided for in the contract, training of the customer's staff.
/ Spare parts
Spare parts and consumables
- Impellers
- Stators
- Cell linings
- Bearing units
- Couplings
- Valves and air flow meters
- Level sensors
- Froth removal devices
- Drive elements
- Control cabinet components
/ What to choose
Repair, upgrade or replacement?
Repair
When the equipment's original performance needs to be restored.
Goal: return the equipment to working order
Upgrade
When existing equipment is working or repairable, but its throughput, automation or operating characteristics need to change.
Goal: improve the existing system
Replacement
When remaining service life, structural condition or restoration cost make further repair economically unjustified.
Goal: replace the equipment with a new solution
/ How we work
How we handle a request
- 01
Request
We receive the problem description and documentation.
- 02
Analysis
We study the equipment and input data.
- 03
Audit
If needed, we inspect the equipment.
- 04
Solution
We define the scope of repair or upgrade.
- 05
Work
We carry out the agreed set of work.
- 06
START-UP
We test and adjust the equipment.
- 07
Operation
We hand over recommendations and the required documentation.
We work with equipment from other manufacturers
We carry out technical audits, repairs and selection of compatible components for flotation equipment from various manufacturers after identifying the model and technical parameters.
Completed projects
Examples of completed inspection, repair and upgrade work are in the Projects section.
View projects/ Not sure where to start?
Send the equipment data and we will define the scope of work
The equipment passport, problem description, photos and technical parameters help engineers prepare a preliminary technical assessment.