Sensor-Based Sorting at the Forefront of Physical Separation '26

Not so long ago, MEI's physical separation conferences typically opened with sessions on pre-concentration, most often centred around heavy medium separation (HMS). Today HMS barely earns a mention. The spotlight has shifted decisively toward pre-concentration by sensor-based electronic sorting, reflecting the rapid evolution of this technology.

We’re therefore delighted to welcome the two leading players in this field, Steinert and TOMRA, as sponsors of Physical Separation '26, to be held in Cape Town.

Steinert, a long-standing supporter, was a sponsor of both Physical Separation '24 and Comminution '25, and confirmed its ongoing involvement some time ago (posting of 6 January 2025). We’re now especially pleased to announce the participation of TOMRA in next year’s event.

TOMRA is a Norwegian company best known for its cutting-edge sensor-based sorting systems, originally developed for recycling and reverse vending machines. Over the years, TOMRA has become a major force in the mineral processing industry through its subsidiary TOMRA Mining, which specialises in sensor-based sorting technologies tailored to mining operations.

TOMRA offers a versatile portfolio of sensor technologies, each designed to target specific mineral sorting needs:

• X-ray Transmission (XRT): Differentiates materials based on atomic density; ideal for diamonds, gold, and base metals.
• Near-Infrared (NIR): Identifies materials based on surface chemistry; used for industrial minerals like quartz.
• Laser Sorting: Distinguishes materials by reflectivity and texture; particularly effective for minerals such as calcite.
• Colour Sorting (VIS): Separates particles based on visible colour differences; used in gem and industrial mineral applications.

TOMRA's latest innovation is CONTAIN, a major development in AI-powered ore sorting, engineered to reveal what traditional sorting can’t, by detecting inclusion-type ores like tin, tungsten, nickel, sulfides, and REE that often remain hidden deep inside. It visually classifies rocks based on the probability of subsurface mineral inclusions, transforming uncertainty into precision, and waste into value.

TOMRA Mining has made significant achievements in mineral processing over the past year. A standout achievement was its role in commissioning the world’s largest lithium ore sorting facility at Pilbara Minerals’ Pilgangoora mine in Western Australia. Part of the P680 Expansion Project, the plant processes more than 1,000 tonnes of ore per hour. By combining TOMRA’s XRT and colour sorting systems, the operation effectively removes barren material at the front end, boosting lithium recovery and product quality. This pre-concentration strategy is projected to reduce downstream energy consumption by 8-15 GWh per year, while also cutting water and reagent use.

Another milestone came in August 2024, when Lucara Diamond Corp. recovered a colossal 2,492-carat diamond at its Karowe Mine in Botswana using TOMRA’s advanced XRT sorters (posting of 29 August 2024). This remarkable find ranks as the second-largest diamond ever discovered, surpassed only by the 3,106-carat Cullinan diamond found in 1905. Impressively, it is the largest diamond ever recovered directly from run-of-mine ore, a testament to the precision and robustness of TOMRA’s sorting systems.

It’s fantastic to have TOMRA and Steinert, the two global leaders in sensor-based sorting, on board for Physical Separation '26, alongside our other current sponsor, Mineral Technologies. Their presence highlights the growing importance of cutting-edge technologies in modern mineral processing.

#PhysicalSeparation26

July Cornish Mining Sundowner and a potential tungsten resource in Cornwall

 What a relief to see a fine turnout of around 25 at last night's Cornish Mining Sundowner at Falmouth's Chain Locker, having had the lowest turnout ever a month ago. And good to see so many staff and former students from Camborne School of Mines (CSM).

Linda Shimmield founded the CSM Association (CSMA) in 1989 to foster the alumni network and maintain the CSM identity. She served as secretary until 1996 and we were pleased to welcome the current secretary, Nicola Wilton, to her first sundowner.

Linda and Nicola

We only occasionally see Charlie Northfield, who graduated in mineral processing in 1980, as he is based in Malaysia. He is General Manager at the Selinsing Gold Mine, in Pahang State, approximately 158 km north of Kuala Lumpur and was on leave in his native Devon. It was good to catch up with Charlie, and to welcome a guest to the sundowner, Matthew McLeod, Mining Manager at the Gold and Minerals Co. Saudi Arabia. 

With Matt and Charlie

Matthew was brought up in Falmouth and he was visiting his family who live in the Truro area. His son is a miner at South Crofty, working on the shaft refurbishment. Matthew graduated from Camborne School of Mines as a mature student in 2012 and then worked in Canada for a short time before returning to Cornwall to be with his family. He spent some time at South Crofty, working for Cornish Minerals as a shift boss and briefly as a temporary mine captain on the shaft refurbishment before he was offered a position in Saudi Arabia by John Webster, a 1980 CSM graduate, who is now CEO of Gold and Minerals Co. Their first project is likely going to be five to seven open pits in the desert. It will be a 30mt a year project and will be making use of TOMRA Ore Sorters, for which they are currently preparing a second, larger test batch, initial testing reducing ore handling by about 50%. They also have ongoing labwork at GSL, now an Alfred H. Knight company, near Truro, to develop the processing of the sulphide part of all the deposits.

I was pleased to hear about the TOMRA sorters, which will also likely be used in the new processing plant for the resurgent South Crofty. TOMRA recently signed up with MEI as a sponsor for next year's Physical Separation '26 in Cape Town.

The resurgence of mining in Cornwall has seen South Crofty's return as a viable tin mine, with hopes of restarting tin production by the end of 2027, along with work on Cornish Lithium's hard rock and brine projects.

But Cornwall isn't all about tin and lithium. A new mining revolution is underway in Cornwall with the start of drilling for a critically important metal. Tungsten is known for its strength and durability and was historically a key component of light-bulbs. It has the highest melting point of all metals and is now used in everything from industrial cutting tools to aerospace and defence. 

Drilling is underway underground at the Redmoor Tungsten-Tin-Copper Project in Callington, East Cornwall. The company behind the mine, Cornwall Resources Limited says it is exploring for resources of tungsten, tin, and copper in its Tamar Valley licence areas, with a focus on Redmoor.

Dennis Rowland, CRL project manager, said: "This is an important moment for the company, for Cornwall, and for the UK. The drilling now underway is the first exploration drilling at Redmoor since 2018 and aims to enable the accelerated development of a potentially important new domestic source of critical minerals. We are excited to highlight through this drill programme the potential of Redmoor as a strategically important, high-grade, polymetallic tungsten resource right here in the UK".

Last night showed that the sundowner is alive and well, and I look forward to the next one, at the Chain Locker on Thursday August 21st from 5.30pm.

Flotation '25 Programme Released: The Strongest Line-Up Yet

I have known Jim Finch, Emeritus Professor at McGill University, Canada, for nearly 50 years. Over that time, we’ve developed a close and productive working relationship. Jim is a natural consultant to MEI’s flotation conferences and served as my co-editor for the 8th (and probably final) edition of Wills’ Mineral Processing Technology.

Jim and I signing books in Phoenix at the 2016 SME Meeting

Signed copies of the new edition will be awarded as prizes for the best oral and poster student presentations at Flotation '25, which takes place this November.

And what a conference it’s shaping up to be, featuring around 110 oral and 100 poster presentations. Jim and I spent a great deal of time working on this packed programme, and Jim finally remarked: "The programme looks excellent- nice grouping of topics, and such a range."

We are extremely satisfied with the groups and the breadth of topics covered across the four days. The schedule, now published on the conference website, reflects the ongoing evolution of flotation and its expansion into a wider array of commodities.

Day 1 opens with a keynote lecture, “From comminution to flotation: bridging the gap”, delivered by Chris Greet of Magotteaux, Australia. The rest of the day will explore flotation circuit design and the increasing role of AI and digital twins in operational management.

Day 2 focuses on flotation reagents, starting with Liza Forbes (JKMRC, Australia), who will present her keynote, “Beyond reagent trials – new directions in flotation chemistry research.”

Day 3 continues the reagent theme, kicking off with Jim Finch’s keynote, “Frothers: from fundamentals to practice.” Later that morning, the spotlight will shift to innovations in flotation machines, both mechanical and pneumatic. Leading manufacturers will be present in the exhibition during the extended coffee and lunch breaks to discuss these developments in depth.

On Day 4, we turn to the processing of critical metals such as lithium and rare earth elements, topics rarely addressed in earlier conferences but now taking centre stage. The morning begins with Charlotte Gibson, of Queen’s University, Canada and her keynote, “Lithium mineral flotation: the past, present, and future.” The day concludes with sessions on flotation fundamentals, control, and simulation, followed by the presentation of student prizes.

This 12th MEI flotation conference promises to be the most exciting in the series. As always, there will be ample opportunities for networking during long breaks, evening sundowners, and the informal conference dinner at the Gold Restaurant in central Cape Town. The event ends with a farewell function in the hotel gardens, with rumours of a special birthday celebration.

Registration is now open, so be sure to book your flights and accommodation early.

#Flotation25

Momentum Builds for Comminution '27 as Industry Leaders Rally Early Support

Comminution '27 is just 21 months away! It’s hard to believe it’s been only three months since the highly successful Comminution '25 ended in Cape Town. The event attracted 237 delegates from 29 countries and received outstanding feedback from attendees,  a clear testament to the strength of MEI’s comminution conference series.

Looking ahead to Comminution '27, excitement is already building. The event has had a strong start, with 13 of the 22 sponsors from Comminution '25 already confirming their return, nine of these re-committing during the conference itself (posting of 28 April 2025).

The latest sponsors to sign on are Magotteaux, Derrick, Molycop, and Sino Grinding -  a warm welcome back to each of them!

We’re always pleased to share good news from our long-time sponsors. Russell Mineral Equipment (RME), a regular supporter of MEI’s comminution events, consistently brings a large team from Australia. We were especially proud to hear that RME Founder and Director, Dr. John Russell, received the prestigious Austmine 2025 Champion of Innovation Award at the Industry Leaders and Awards Dinner, held on 21 May 2025 during the Global Resources Innovation Expo.

MEI's Jon Wills with John Russell at Comminution '25

Austmine is Australia’s premier industry association for the Mining Equipment, Technology and Services (METS) sector. The Champion of Innovation Award is a lifetime achievement honour, recognising individuals who have significantly shaped the METS sector. 

John Russell founded RME in 1985 in Toowoomba, Queensland, with a mission to mechanise the mill relining process, improving safety, reducing reline times, and enhancing mine profitability. Today, RME operates in 64 countries with 13 international sales and service centres, employing over 450 people worldwide.

Congratulations to John and the entire RME team on this well-deserved recognition. We look forward to welcoming you once again in 2027.

Comminution '27 promises to be another landmark event for mineral processing professionals worldwide. Abstract submission is now open, and there are fantastic opportunities available for sponsorship and exhibiting. Don’t miss your chance to be part of what will surely be another must-attend industry gathering.

#Comminution27

New book: Liberation Based Energy Efficient Sulfide Flotation Circuits

I met Bill Johnson for the first time at the SME Annual Meeting in Denver in 2017, where he was inducted into the International Mining Hall of Fame.  Later in the year he was in Cape Town to present a keynote lecture at Flotation '17. In 2020 I interviewed him for the blog.

In over 50 years in minerals processing, Bill has made outstanding advances to the treatment of complex ores. He pioneered the use of the paradigm of size-by-size mineral liberation-class behaviour, and is a masterful user of this approach to drive major improvements to mineral processing plant design and performance. He was pivotal to the development of flowsheets and new processes for McArthur River, Mount Isa, Hilton and George Fisher, and has provided highly skilled technical support for a global array of operations. culminating in the development of the IsaMill technology and the Jameson Cell.

His educational and training experience includes teaching undergraduates and supervising postgraduate research together with running “in house” courses on advanced topics for technical staff. Bill is a respected mentor and widely known for his success in developing the professional skills of many minerals processing engineers during his time in the corporate sector and academia.

Bill Johnson is a Principal Consultant with Mineralis who has recently published what will be a very important book Liberation Based Energy Efficient Sulfide Flotation Circuits (Including Regrinding and Cleaner Flotation Technology Improvements since 1970).

In this book Bill distills his 50 years of internationally recognised experience in the treatment of complex ores into one publication. He discusses the significant developments in regrinding and cleaning technologies that have taken place from 1970 to 2020 and provides some future directions for primary grinding, roughing, regrinding and cleaning in sulfide flotation circuits to decrease the energy required for grinding in the total system. The decreased energy consumption can be achieved by performing the final stages of liberation of the valuable sulfide minerals mainly in regrinding where the tonnages of solid being processed are lower than in primary grinding.  

He uses data and real-world examples to effectively communicate the complexities of the sulfide mineral flotation process. Also included are discussions on the importance of the chemical conditions inside a regrinding mill and the relationships between these chemical conditions and the separation performance of the associated cleaner system.

Ample examples from industry are included to assist the reader, along with over 160 references. A must volume for anyone involved with sulfide mineral flotation.

Mineral Technologies to sponsor Physical Separation '26 in Cape Town

Next year’s Physical Separation ’26 will be the 9th in this popular conference series and the second to be held in Cape Town, South Africa, once again at the beautiful Vineyard Hotel. The 2024 event drew 80 delegates from 17 countries, and we look forward to building on that success.

Physical Separation ’26 will showcase the latest developments in all physical separation techniques used in mineral processing. We are therefore pleased to announce that Mineral Technologies will be sponsoring an MEI Conference for the first time, joining our current sponsor, Steinert.

Mineral Technologies is a globally respected leader in fine mineral separation, particularly in the processing of mineral sands -including ilmenite, rutile, zircon, and garnet- as well as iron ore, chromite and other industrial minerals.

The company specialises in gravity and magnetic separation technologies, offering equipment such as spirals, magnetic and electrostatic separators, and custom flowsheet design. Its state-of-the-art metallurgical testing facility in Queensland underpins its engineering expertise.

Founded over 80 years ago, Mineral Technologies is part of the Downer Group, an Australian company known for delivering integrated services across multiple industries. With a global footprint, Mineral Technologies maintains operations and offices in North and South America, Africa, India, and Southeast Asia.

We warmly welcome Mineral Technologies to Physical Separation ’26 and look forward to their active involvement in the conference (#YourMineralsMatter).

Abstract submission is now open. Please submit short abstracts by October 31st. Physical Separation ’26 will be immediately followed by Mineral Processing Circuits ’26, also at the Vineyard Hotel.

#PhysicalSeparation26

June Summary: activity in Falmouth and sad news from Egypt

Early in the month it was good to have Sunday Lunch with Tim Napier-Munn and his wife Goeorgie, who were visiting Falmouth on an extended holiday from their home in Brisbane.

Now semi-retired Tim is a former Director of the JKMRC in Brisbane and was my co-editor of the 7th edition of Mineral Processing Technology. He was the first person that I interviewed for MEI's In Conversation series.

Lunch overlooking the Penryn River, Falmouth

Three days later I was at the UK Mining Conference in Falmouth, and caught up with a few familiar faces, including my old friend Alan Butcher. We go back a long way since we were both lecturers at Camborne School of Mines in the 1990s, before he moved to Australia in 1998 to aid with the development of QEMSCAN automated mineralogy with CSIRO. In 2003 he became part of Intellection Pty Ltd, incorporated specifically to bring QEMSCAN to market. During his 5 years with Intellection Alan and I organised three annual conferences on automated mineralogy in Brisbane, which evolved into MEI's current process mineralogy series. Alan is now Chief Scientist and Technical Director with Hafren Scientific Ltd, UK and is an advisor to MEI's Process Mineralogy '26 and Critical Minerals '26.

With Alan Butcher in Falmouth

And another three days later Falmouth was gridlocked due to the weekend's Sea Shanty Festival and a Cornish Gig Regatta on a beautiful Saturday at Gylly Beach.

Amanda with Gig rowers on Falmouth's Gylly beach

Just four days later, I was in my office tuned in to Jon’s biweekly three-hour show on ARA City Radio Luxembourg. During the broadcast he mentioned that John Fogerty, one of the founding members of the iconic 1960s band Creedence Clearwater Revival,would be performing at the Glastonbury Festival the following week. He then played his favourite CCR track, Bad Moon Rising, a song I can’t help but associate with the cult classic horror film An American Werewolf in London.

Hearing it also reminded me how Jon is carrying on a family tradition. Fifty-five years ago, my old friend Pete Love and I ran a discotheque in Chingola. Among our vinyl collection was Proud Mary, my personal favourite CCR hit. We had dreams of striking it rich with that disco, but alas, we never quite had the DJ flair that Jon clearly does!

Zambia 1970 and Luxembourg 2025

Jon’s next show airs on Wednesday at 9:00 AM BST. Tune in if you're into alternative and indie music, it's always a great listen.

I've spent a lot of time in my office this month, working on the provisional programme for Flotation '25, aided by our consultant Prof. Jim Finch. 

Due to the record number of abstracts received this was hard work, but rewarding as we are now drafting a superb programme for November and registration is now open.

Four days ago, I received the sad news of the passing of Professor Tawfik Refaat Boulos, a distinguished Egyptian mineral technologist affiliated with the Central Metallurgical Research and Development Institute (CMRDI) in Helwan, Cairo. Over the course of his long and impactful career he made significant contributions to mineral processing, particularly in the beneficiation of industrial minerals such as silica sand, feldspar, phosphate and talc. In 2020, Professor Boulos mentioned that he had retired, though he continued to serve as a consultant research professor at CMRDI.

I first met Professor Boulos in 1981, when I was invited to CMRDI to provide guidance on their fledgling pilot plant. During my week-long visit, I was warmly welcomed and taken to see the sights of Cairo, including the Pyramids at Giza. The hospitality extended further with a generously arranged trip to Luxor and Aswan in Upper Egypt, complete with airfare and accommodation, an unforgettable experience.

Fourteen years later, Professor Boulos, then serving as Professor of Mineral Technology at CMRDI, hosted Barbara and me during a goodwill visit to Cairo (posting of 23 April 2020). This visit, which included visits to cultural sites in both Upper and Lower Egypt, underscored his commitment to fostering international academic collaboration.

During that memorable trip, we had the pleasure of sharing a delightful meal with Tawfik and his wife Brenda, overlooking the Nile. We hold fond memories of their warmth and hospitality, and of the time we spent in their fascinating country 30 years ago.

Cairo 1995

UK Mining Conference in Cornwall 2025: Insights from a day in Falmouth

The annual UK Mining Conference in Cornwall was held in Falmouth, Cornwall, from June 11 to 12, 2025 at the Princess Pavilion and Gyllyngdune Gardens. Organised by Jay One Events, the conference has established itself as a key gathering for professionals in the mining, investment, and energy sectors, with a strong focus on sustainable practices and the UK’s critical mineral supply chain.

This year’s event saw a record attendance of over 440 delegates from 15 countries. As the Princess Pavilion can accommodate only 320 people, additional relay screens were set up outside in a marquee and within the exhibition area to accommodate the overflow.

The Princess Pavilion

The overflow marquee

The conference attracted professional and private investors, brokers, financial institutions, supply chain consultants, government representatives, trade associations, as well as mine operators and explorers. It's not the kind of event I typically cover, but since it was taking place so close to home, I called in for the first day and spent some time speaking with attendees. As a result, I won’t be reporting on the 40 presentations, but rather sharing insights gathered from conversations on the ground. 

Mineral processors were very sparse on the ground, but I did manage to catch up with a few. The first was Neil Rowson, who I last saw at Physical Separation '19, also in Falmouth. He is an Emeritus Professor of the University of Birmingham, having spent over 25 years at Birmingham focusing on metal recovery, from mining to recycling critical metals,using magnetic, electrostatic separation, optical sorting, and biochemical methods.

He now serves as Laboratory Manager at Bunting-Redditch's Customer Experience Centre, where he leads hands-on tests and demonstrations for students, researchers, and industry partners using a wide array of equipment: Rare Earth Roll, Magnetic Disc, Wet High Intensity Magnetic Separators (WHIMS), Eddy Current, Electrostatic, and Stainless-Steel Separators. He was with Bunting-Redditch's Technical Sales Manager Phil Tree and Application Engineer / Sales Engineer Michael Allen, who gave a talk at the conference on magnetic separation. Neil's long time colleague at Birmingham was Terry Veasey, who also consulted for Bunting-Redditch when it was known as Master Magnets.

Phil, Michael and Neil

Sepro Mineral Systems Corp., founded in 1987 and based in Langley, British Columbia, Canada, specialises in designing and manufacturing mineral-processing equipment and offering full process engineering services. The Sepro booth was manned by local man Doug Caffell, a regular at the Cornish Mining Sundowners, who reported strong interest in Sepro's Frontier bowl for Falcon gravity concentrators. Doug is seen talking to Val Coetzee, Director of Process and Technology, and Paul Morgan, Senior Process Consultant - Comminution, of DRA Projects Europe, renowned for dense media separation, particularly on platinum-group metal ores, as well as flotation, milling, and classification design.

Paul, Val and Doug

It was good to catch up with Paul, who graduated in mineral processing technology from Camborne School of Mines in 1985, and to talk to him and another of my CSM students, Paul Benjamin, who also graduated in mineral processing technology at CSM in 1985. Paul is now VP Research at Ocean Partners UK Limited.

With Paul Morgan and Paul Benjamin

Jens-Michael Bergmann

There were, of course, a number of presentations at the conference on developments in mining in Cornwall, particularly tin and lithium, but I have kept up to date with those developments on the sundowner postings. I regularly report on developments at South Crofty tin mine in Camborne and in March I spoke with Cornish Metals metallurgical consultant Mike Hallewell who outlined the proposed mill circuit, using pre-concentration to reduce downstream processing and pastefill costs. The latest TOMRA XRT technology for the coarser fractions and Gekko jigs for the finer fractions will be used and TOMRA was another of the small number of mineral processing companies represented at the conference. It was good to see Jens-Michael Bergmann, TOMRA's Area Sales Manager for Europe, MENA, and India, who gave a presentation showing how TOMRA Mining is pushing the boundaries of sensor-based sorting with cutting-edge AI to drive efficiency, sustainability, and smarter decision-making in mining operations.

Although not a mineral processor, Alan Butcher is a highly respected geologist/mineralogist with a strong interest in process mineralogy. We go back a long way since we were both lecturers at CSM in the 1990s before he moved to Australia in 1998 to aid with the development of QEMSCAN automated mineralogy with CSIRO. In 2003 he became part of Intellection Pty Ltd, incorporated specifically to bring QEMSCAN to market. During his 5 years with Intellection Alan and I organised three annual conferences on automated mineralogy in Brisbane, which evolved into MEI's current process mineralogy series. Alan is now Chief Scientist and Technical Director with Hafren Scientific Ltd, UK and is an advisor to MEI's Process Mineralogy '26 and Critical Minerals '26. In the photo below Alan (right) is with fellow mineralogists, Al Cropp of Geotek, James Strongman of Petrolab and Mike Snape and Jack Thornton of Rockwash Geodata.

The Critical Minerals Association (CMA) is an industry advocate to MEI's next major conference, Flotation '25. The CMA is an influential voice in securing responsible mineral supply chains. Its major strengths include policy advocacy, cross-sector working groups, robust networking events, and close ties with Parliament and government, all aimed at supporting the transition to a green economy.

Jeff  Townsend is a co-founder of the CMA and a leading voice in the global critical minerals sector. He is also the son of my long time friend Ian Townsend, a well known mineral processor who for many years was with Larox and Outotec before his retirement.

With Ian Townsend at UK Mining 2023

It was good to see Jeff and Becca Kirk, who collaborates with CMA ’s technical and event teams, serving as a specialist on biogeochemistry.

Becca showed me the first copy of the UK Critical Minerals Investment Prospectus, showcasing investment opportunities in projects and services across the UK. Becca is also in her final year of a PhD at CSM on lithium biogeochemistry.

Becca and Jeff, with CSM Director Pat Foster

It was good to see strong female representation, something which would have been unheard of in my early days at CSM in the 1970s. The Women in Mining (WIM) UK organisation is shaping a more inclusive and high‑performing mining industry by empowering women through recognition, networking, education, and advocacy. The Managing Director of WIM UK is Cornwall-based Lucy Crane, who in recent years has been a high profile member of the Cornish Lithium team, as ESG and Sustainability Manager. She recently took up the role of Sustainability Consultant at Satarla, which supports organisations in making informed, risk-based decisions that turn Sustainability and ESG goals into practical action. Lucy (centre) and some of her WIM colleagues are shown in the photo below.

Lucy was one of the panelists on the Peter Hackett Education Panel discussion, which ended the first day of the conference. Chaired by CSM Director Pat Foster, the other panelists were Angela Bentley of Earth Science Teachers' Association, Suzie Doe, of Minerals Matter and Mark Cutifani of Vale Base Metals, and former CEO of Anglo American. The most important questions concerned how we attract and retain talent in our industry and how we change outdated perceptions along the way. "I don't think you can understate the problem," said Mark Cutifani, "the mining industry is facing a "grey tsunami" as experienced professionals retire without enough new talent being recruited to replace them. It touches most senior leadership, middle management, frontline supervisory in the field, and safety - everything in the industry. We have a lot of work to do to turn it around". 

Suzie Doe said meaningful and early engagement with young people is essential, something which I've often echoed on the MEI Blog (notably the post of 25th August 2024). Industry and mining institutions could take inspiration from the 1970s Minerals Industry Manpower and Careers Unit (MIMCU), a brilliant initiative led by Geoff Cox and supported by the then CSM Principal Peter Hackett (see also post from September 9, 2024).

Pat Foster, Angela Bentley, Mark Cutifani and Suzie Doe
Photo: Minerals Matter

It was an interesting first day and Jay One Events must be congratulated on organising such a large conference so efficiently. This is probably due to the fact that, as with MEI, they have a small dedicated team, led by Managing Director Jane Isaacs, who brings extensive experience in event management. Their mission of building business connections through targeted events was clearly realised here.  Well done team! 

The next UK Mining Conference in Cornwall is scheduled for 10-11 June 2026 in Falmouth. 

The Evolution of Flotation Cell Technology and the Lasting Legacy of Australia's University of Newcastle

When I began my career in mineral processing 56 years ago, flotation circuits were fairly basic, and little had changed in decades. Anyone who had worked in a mill in the 1930s would have felt quite at home in the 1970s. Grinding was carried out in small ball mills operating in parallel, and flotation took place in small mechanical machines arranged in banks, each bank containing as many as 20 cells.

That all changed rapidly in the early 1980s with the dawn of the computer revolution. Automated control strategies and improved design methods led to much larger equipment. I remember some of the flotation banks at Nchanga, Zambia, where small Denver cells were replaced by "massive" 11 m³ Wemco units. But few could have imagined that Wemco machines would eventually evolve into the enormous 600 m³ SuperCells we see today. Even more impressive is the development in China of BGRIMM’s 800 m³ Super-large Flotation Machine - the world’s largest flotation cell - which will be showcased at Flotation '25.

Before these giant cells emerged, column flotation cells became common in the mid-1970s. These pneumatic cells were once predicted to replace mechanical machines for both roughing and cleaning duties. At the time column flotation dominated mineral processing conferences, and led to the publication of the seminal Column Flotation by Glen Dobby and MEI’s flotation consultant, Jim Finch.

However, columns ultimately did not live up to early expectations. Limitations in flotation kinetics, operational complexity, and a narrower range of applications meant they failed to become the universal solution many had hoped for. Mechanical flotation machines remained dominant, particularly for roughing, while columns found niche applications in scavenging and cleaning duties.

These limitations sparked the search for a flotation device that could combine the benefits of columns (selectivity and froth washing) with the robustness and kinetics of mechanical cells. This led to the mid-1980s development of the Jameson Cell. Featuring a high-shear mixing zone and froth washing capabilities, the Jameson Cell proved especially effective for fine particle recovery. Now marketed by Flotation '25 sponsor Glencore Technology, over 500 units have been installed across 30 countries in coal, base metals, and other sectors and a paper from Glencore Technology will feature the installation of a Jameson Cell at the Bozshakol copper-gold-molybdenum mine in Kazakhstan.

The Jameson Cell was invented by Professor Graeme Jameson of the University of Newcastle, Australia. He remains the only mineral processor to be elected a Fellow of the Royal Society. Had he been based in the UK, he may well have received a knighthood - many argue he deserves that level of global recognition. Although Australia no longer awards knighthoods, Prof. Jameson holds its equivalent honour as an Officer of the Order of Australia, and is also a recipient of the IMPC’s Lifetime Achievement Award.

Prof. Jameson at the 30th Anniversary of the Jameson Cell at Flotation '19

At Flotation '17, and with Barbara and me in Santiago, 2014

Prof. Jameson continued to innovate well beyond the original Jameson Cell, focusing on the challenges of ultrafine particle recovery and improving the sustainability of flotation processes. His two major follow-up inventions are the Concorde Cell and the NovaCell.

The Concorde Cell, designed for particles smaller than 10 microns, provides a high-shear environment with a large bubble surface area flux, allowing for faster flotation kinetics. It also features enhanced froth recovery and selectivity, while forced air input offers improved process control and stability. Flotation '25 sponsor Metso launched the first industrial Concorde Cell units in Africa last year, and they will be sharing updates on its application at the conference.

Prof. Jameson's most recent invention is the NovaCell, licensed to Flotation '25 sponsor Jord. Designed to handle a wide particle size range, from the ultrafine to coarser fractions, NovaCell uses separate environments for each; fine particles are captured in a high-energy aerator, while coarse particles are recovered in a gentler, fluidised bed. Papers at Flotation '25 will showcase the technology’s industrial progress.

Another major innovation from the University of Newcastle is the Reflux Flotation Cell (RFC), invented by Professor Kevin Galvin, a Laureate Professor and Director of the ARC Centre of Excellence for Enabling Eco‑Efficient Beneficiation of Minerals. Prof. Galvin’s accolades include the Ian Wark Medal, the ATSE Clunies Ross Award, and the SME’s Antoine Gaudin Award.

Kevin Galvin (right) with the FLS team in Cape Town in 2024

Licensed to sponsor FLS (FLSmidth), the RFC has received the 2023 Mining Magazine Technology Innovation Award after moving successfully through pilot and full-scale trials and has since achieved its first commercial sale. Following successful pilot testing at BHP’s Carrapateena copper operation in South Australia, FLS announced last month that it is set to supply its first full-scale cell island to the mine to enhance copper concentrate grade and recovery. The RFC is known for its enhanced cleaning performance, while the lower system of inclined channels increases its capacity. More recently FLS launched its CoarseAir, for use in coarse particle flotation, based on Prof. Galvin's Reflux Classifier.

It is quite remarkable that five major advances in flotation technology have originated from the University of Newcastle. This single department has profoundly shaped the future of mineral processing, and we are privileged to welcome their team and their licensing partners to Flotation '25.

#Flotation25

June Cornish Mining Sundowners and news of innovation and industry recognition

There were two mining sundowners this month at Falmouth's Chain Locker. The first was organised by Camborne School of Mines and was held two day's before the UK Mining Conference in Falmouth (report next Thursday). There was a fairly low turnout, but it was good to see a few past students from CSM who were in Falmouth for the conference.

David Winsor, final year geology student, with CSM Director Pat Foster,
former CSM Association Secretary Linda Shimmield
and CSM Student President Daniyah Gallagher

The regular monthly Cornish Mining Sundowner coincided with the hottest day of the year so far and unfortunately it saw the lowest attendance to date. Just three of us were present: myself, Dean Eastbury (former Publications Manager for Minerals Engineering) and Patrick McComb (former Vice-Principal of Falmouth School of Art).

At last week's UK Mining Conference, Cornish Lithium Executive Chairman Jeremy Wrathall announced the purchase of cutting-edge technology developed by Australian group Lepidico. The move gives the company the ability to mine, process and refine battery-grade lithium hydroxide within its site at Trelavour Downs in east Cornwall. This end-to-end "pit to battery-grade product" capability helps to de-risk extraction, refining and processing. Cornish Lithium’s acquisition follows extensive pilot testing of the technology under license since 2021 (see also posting of 10th December 2020). 

Cornish Lithium now owns sole rights to the intellectual property and associated patents of its lithium extraction process and intends to licence this technology globally under its own brand. The new technology, incorporated into the company’s recently commissioned, state-of-the-art demonstration plant at the Trelavour Hard Rock Project, operates at atmospheric pressure and at moderate temperature, significantly reducing carbon emissions and helping to set a new sustainability standard in the sector. The acquisition helps secure the UK’s future lithium supply, all on one single domestic site in Cornwall. ‍‌‌‌‍‍‌‍‌‌‌‍‌​‍‌‌​​‌​‌​​‍‌‌​​‌​‌​​‍‌‌​​‍​​‍​​‍​‌‌‍​​‌‌‌‍‌‌​​​​‌‍​‌​‍‌​‍​‌‍​‍​​​‍‌‌​​‍​​‍​‍‌‌​‌‌‌​‌​​‍‍‌‌​‌‍‌‌‌‍​‌‌​​‌‍​‍‌‍​‌‌​‌‍‌‌‌‌‌‌‌​‍‌‍​​‌‌‍‍​‌‌​‌‌​‌​​‌​​‍‌‌​​‌​​‌​‍‌‌​​‍‌​‌‍​‍‌‌​​‍‌​‌‍‌‍​‌‍‌​‍‌‍‍‌‍‍‌‌​‌‍‍​​‍‌‌‍​‌‍‍‌‌‌​‌‍‍​‌‍‍‌‌‌‌‌‍‌​‍‍‌​‌‍​‌‌‍‍‌‍‍‌‌‌​‌‍‌​‍‍‌​‌‌​‌‌‌‌‍‌​‌‍‍‌‌‍​‍‌‍‌‍‍‌‌‍‌​​‌​‌‌‌‍​‌​‌‌‍​‍​​‍​‌‌‍‌‍‌‍​‍​‍‌‌‍​‍‌‍‌‍​​​​‍‌​‍‌​‌​​​‍​‌​​‍​‍‌​‍‌​‌‌‌‍‌‌​‌​‍‌​‍​​​‍‌‍‌​​‌‌​‍‌‌‍‌‌​‍‌​‌​​‌‍‌‍‌​‌‍‌‌​‌‌​‍‌‍‌‌​‌‍‌‌​​‌‍‌‌​‌‌​​‌‍‌​‌‌​​‍‌‍‌​​‌‍​‌‌‌​‌‍‍​​‌‌​​‌‍​‌‌‍‌‌‍‌‌‌​​‍‌‌‌‌‍‍‌‌‍​‌‍‌​‌‍‌‌‌​‍​‍‌‌​‌‌‌​​‍‌‌‌‍‍‌‍‌‌‌‍‌​‍‌‌​​‌​‌​​‍‌‌​​‌​‌​​‍‌‌​​‍​​‍​‍​​‌‍​​‍​‌‍‌‍‌‌‌‍​​​​​‌‌‍‌‌​‍‌‌‍​‌‍‌‌​‍‌‌​​‍​​‍​‍‌‌​‌‌‌​‌​​‍‍‌‌​‌‍‌‌‌‍​‌‌​​‍‌‌​‌‌‌​​‍‌‌‌‍‍‌‍‌‌‌‍‌​‍‌‌​​‌​‌​​‍‌‌​​‌​‌​​‍‌‌​​‍​​‍​​‍‌‍​‌‍‌​​​‌​‌‌​‌​​‍​​‍‌‍‌‌‌‍​‌​‌‌​‌​​‍‌‌​​‍​​‍​‍‌‌​‌‌‌​‌​​‍‍‌‍​‌‍‍​‌‍‍‌‌‍​‌‍‌​‌​‍‌‍‌‌‌‍‍​‍Currently over 60-70% of the world’s lithium refining (conversion of raw lithium into battery-grade lithium compounds like lithium hydroxide and lithium carbonate) takes place in China.‌‌‌​​‍‌‌‌‍‍‌‍‌‌‌‍‌​‍‌‌​​‌​‌​​‍‌‌​​‌​‌​​‍‌‌​​‍​​‍​​‍​‌‌‍​​‌‌‌‍‌‌​​​​‌‍​‌​‍‌​‍​‌‍​‍​​​‍‌‌​​‍​​‍​‍‌‌​‌‌‌​‌​​‍‍‌‌​‌‍‌‌‌‍​‌‌​​‍‌‍‌​​‌‍‌‌‌​‍‌​‌​​‌‍‌‌‌‍​‌‌​‌‍‍‌‌‌‍‌‍‌‌​‌‌​​‌‌‌‌‍​‍‌‍​‌‍‍‌‌​‌‍‍​‌‍‌‌‌‍‌​​‍​‍‌‌ 

There was more good news from Cornwall at last week's UK Mining Conference, where two of the five award winners at the Gala Awards Dinner had Cornish connections:

Chloé Bayliss received the Rising Star within the Mining Sector award. Chloé recently left Cornish Lithium to take up a new role as a stakeholder consultant with ERM, the world’s largest specialist sustainability consultancy.

ESG, and stakeholder engagement in particular, has always been central to Chloé’s work in supporting the development of critical minerals in Cornwall. After receiving an MSc in Sustainable Development from the University of Exeter, she went on to work with Cornish Metals, Heartlands Museum, and Cornish Lithium. At Cornish Lithium, she drew on her academic background to lead grassroots community engagement efforts. Her work connected technical operations with local communities through educational outreach and initiatives that honoured Cornwall’s environmental, historical, and social heritage. A truly deserving winner, Chloé clearly has a very bright future ahead.

Also recognised at the awards dinner was Owen Mihalop, who received the Exploration Discovery of the Year award.

Owen, a familiar face at sundowners during his time as COO of Cornish Metals, stepped down in April after nearly 11 years with the company. He played a key role in transforming the South Crofty project from a historic mine into a viable, modern mining operation with strong economic and strategic potential.

The next Cornish Mining Sundowner will be at Falmouth's Chain Locker on Thursday July 17th from 5.30pm. I hope to see a few more there next month!

Two flotation cell innovators are the latest sponsors of Flotation '25

We are pleased to welcome two flotation cell innovators, Jord International and the Beijing General Research Institute for Mining & Metallurgy (BGRIMM) Technology Group, as the latest sponsors of Flotation '25. Both organisations, leaders in advanced flotation cell design, are supporting an MEI Conference for the first time.

BGRIMM: Driving Innovation in Large-Scale Flotation

BGRIMM, a leading Chinese state-owned enterprise, is renowned for its expertise in mining, metallurgy, and advanced materials. A global pioneer in flotation technology, the company is instrumental in developing large-scale, energy-efficient flotation equipment and novel reprocessing solutions.

With over 30,000 flotation cells installed worldwide, and a commanding 85% share of the Chinese market, BGRIMM’s technologies are utilised in major mining operations across South Africa, Peru, Canada, and the Democratic Republic of Congo.

The company’s Machinery & Automation Technology division offers a wide portfolio of flotation machines, including mechanical agitation, forced-air, and self-aspirated cells. Among its flagship developments is the KYF-680 flotation cell, one of the largest in the world, with a capacity of 680 m³. It has been successfully deployed at the Dexing Copper Mine in China to enhance tailings reprocessing.

At Flotation '25, BGRIMM will present its work on the 800 m³ Super-large Flotation Machine, the world’s largest flotation cell, installed at the Pulang Copper Mine, one of China’s most advanced underground mining operations.

Jord and NovaCell^TM: Redefining Coarse and Fine Particle Flotation

The NovaCell^TM developed by Professor Graeme Jameson, is licensed to Jord, a privately owned, international company that designs and delivers custom process equipment and systems globally.

NovaCell^TM technology is engineered to improve coarse and fine particle flotation, offering benefits such as reduced energy use, higher recovery rates, and a smaller environmental footprint. Jord supports its application through pilot-scale testing, process design, and full-scale plant installation.

NovaCell^TM has already demonstrated success in operational environments. At the Pinto Valley Mine in Arizona, USA, trials showed substantially improved copper recovery, particularly in coarse particle fractions, compared to conventional mechanical cells. Pilot and lab tests have also been conducted across mines in Chile, Peru, Canada, India and Australia.

A paper at Flotation '25 will show how a NovaCell^TM pilot plant performed at Capstone Copper’s Mantos Blancos site in Chile, where it was used to process rougher tailings. The results are now shaping discussions around full-scale application. While industrial scale installations are still emerging, the positive outcomes from these trials suggest that NovaCell^TM is gaining traction within the mining industry.

We are delighted to welcome BGRIMM and Jord International to the growing list of sponsors supporting Flotation '25. Their contributions reflect the evolving landscape of flotation technology and the drive towards more efficient, large-scale mineral processing solutions.

#Flotation25 

MEI's Critical Minerals '26: Addressing the Real Challenges in Processing and Recycling

Critical minerals are natural resources essential to modern economies and national security. They are vital in advanced technologies, clean energy solutions, and defence applications, but are increasingly vulnerable to supply disruptions. Replacing them is often difficult or impossible without compromising performance.

Currently, many conferences are being held on the topic of critical minerals, often focusing on geopolitical dynamics and supply chain vulnerabilities. However, MEI’s Critical Minerals ’26 stands out for its emphasis on processing and the unique challenges of recycling end-of-life products such as smartphones and other waste electrical and electronic equipment (WEEE).

While one could argue that nearly all minerals are becoming "critical," the most frequently cited include:

• Lithium – Crucial for batteries in electric vehicles and energy storage systems.
• Cobalt – Key component in battery technology and superalloys.
• Rare Earth Elements (REEs) – Used in electronics, wind turbines, and military systems.
• Nickel – Vital in stainless steel production and battery manufacturing.
• Graphite – Used in battery anodes and lubricants.
• Platinum Group Metals (PGMs) – Found in catalytic converters and fuel cells.

The processing and recycling of critical minerals present numerous complex technical and economic challenges. Many of these processes are energy- and water-intensive, an issue in regions where such resources are scarce or unsustainable. Critical minerals, such as rare earths, are typically found in low concentrations, and their separation requires energy-intensive, chemically harsh techniques. For example, China dominates the global rare earth processing market but also generates significant toxic and radioactive waste as a byproduct (posting of 11th February 2013).

The Circular Economy is often described as the "holy grail" of sustainable resource use, achievable only through the effective recycling of end-of-life products. Yet, critical minerals are often used in small quantities, dispersed across complex products, making recovery technically difficult and economically unfeasible. Infrastructure gaps further hinder progress; many countries lack adequate facilities for collecting, sorting, and processing these materials from discarded electronics.

Consider the smartphone: each device contains over 30 critical elements, most in trace amounts, yet each essential to its function. With more than 1.5 billion smartphones produced annually, the demand for these materials, and the volume of e-waste, continues to rise. Every year, thousands of tonnes of cobalt, gold, lithium, and rare earth elements are embedded in these devices.

Indium is a notable example. Used in touchscreens (as indium tin oxide), a typical smartphone contains only about 0.02 grams. However, total usage amounts to 100-200 tonnes annually across smartphones and computer/TV monitors. As indium is primarily recovered as a byproduct of zinc mining, scaling up supply in response to demand is difficult. Moreover, known reserves are projected to last only a few more years.

To meet global net-zero targets, the production of critical minerals must increase dramatically. The table below illustrates a sobering reality: at current extraction rates, we lack the physical supply to produce even one generation of renewable energy infrastructure, let alone maintain a sustainable cycle every 20 years, which is the typical lifespan of such technology.

For instance: a full transition away from internal combustion engines would require a massive increase in lithium supply. Achieving net zero would demand a 190-year supply of copper at current production rates.

Critical Minerals ’26, the 2nd in the MEI series (see reports on Critical Minerals '24) will spotlight innovative processing technologies and flowsheets for recovering critical minerals from both primary and secondary sources. Special attention will be given to the recycling of materials from WEEE and lithium-ion batteries, the most complex and pressing challenges in realising a true circular economy.

An early sponsor for Critical Minerals 26 is Promet101, and media partners are International Mining and Minerals Engineering. CEEC: Coalition for Minerals Efficiency is an industry advocate. 

Why not make the most of November next year, and spend a week at Cape Town's Vineyard Hotel with Process Mineralogy '26 immediately preceding Critical Minerals '26?

Sundowner at Critical Minerals '24

#CriticalMinerals26