Flotation ACE is an Advanced Process Control solution designed to stabilize froth level control across the flotation circuit — including rougher, rougher-scavenger, scavenger, cleaner, and flash flotation cells. The core objective is to maintain stable cell froth levels, enabling consistent control of percent mass pull and a controllable split of mass pull between flotation banks, ultimately increasing metal recovery.

The BrainWave® model predictive controller provides closed-loop control of flotation cell froth levels, automatically compensating for the strong interaction dynamics between adjacent cells. Feed forward capabilities are used to minimize level disturbances, and a custom decoupling strategy manages flow changes between adjacent cells as a function of cell level difference.

Where a froth vision system is available at site, Flotation ACE can extend into Froth Characteristics Control. By monitoring froth bubble size, color, velocity, and breakage rate, the system adjusts cell airflow, reagent dosing, and froth depth to achieve optimal froth characteristics — further improving circuit stability, mass pull precision, and metal recoveries.