FAQ when upgrading self-aspirated pneumatic flotation cells with the Concorde Blast Tube™

What metallurgical improvements can I expect?

Traditional flotation cells often struggle to efficiently recover fine and ultrafine particles. Introducing supersonic velocities and high local energy dissipation unlocks recovery from ore fractions that would otherwise pass through untouched.

The Concorde Blast Tube™ upgrade significantly boosts bubble-particle interaction, improving flotation selectivity and resulting in:

• Up to 11% higher metallurgical yield in challenging fine particle size fractions (10–45 microns)
• In some cases, over 1% increase in copper recovery, with enrichment gains of up to 2%
• Improved concentrate quality, especially in copper, gold, nickel, and coal operations

That’s value straight to your bottom line — and your concentrator's performance.

What is the capacity of a single Concorde Blast Tube?

The Concorde Blast Tube sets a new standard for the flotation of fine and ultrafine particles. It operates efficiently with slurry solids concentrations between 10–25% and handles particle sizes ranging from 10 to 45 microns.

The system supports slurry densities of up to 1.35 t/m³. Each Blast Tube is optimized for a volumetric flow rate of up to 85 m³/h, and nozzle configurations can be adjusted to meet specific flow demands for applications requiring higher throughput.

Is the upgrade complicated?

This is not a major plant overhaul. The upgrade is a direct, plug-and-play replacement for your existing self-aspirated pneumatic (SAP) flotation cell downcomers, compatible with both circular and rectangular cells.

No moving parts mean lower maintenance, and installation can be completed in less than a week.

 Why it matters:

• Minimal downtime — blower installation can start while the plant is still running
• Simplified maintenance with durable, easily replaceable components
• Tailored integration that adapts to your current layout and slurry conditions

What is the scope of supply?

• Concorde Blast Tube
• Slurry/air distributor
• Flotation air control
• Flotation blower arrangement
• Control panel
• Engineering, optimization & maintenance services

How do I assess whether this upgrade is viable for my process?

Implementing the Concorde Technology into existing flotation cells begins with a tailored approach to address each plant’s specific needs. The process starts with a detailed assessment phase, followed by a closely connected engineering phase — both designed to ensure seamless integration and optimal results.

Metso’s experts collaborate directly on-site, conducting effective testing to validate economic viability and long-term sustainability. This customized support ensures that every upgrade delivers measurable improvements in performance and efficiency.

Where has it worked?

This isn’t just theory — it’s already delivering results in operations across the globe:

• Australia (Coal): Up to 11% higher yield in fine particle fractions and 4.8% mass pull improvement compared to unmodernized SAP cells.
• Zambia (Copper): Over 1% increase in recovery and 2% higher concentrate grade, even with challenging ore conditions.

With a typical ROI within six months, it’s a change that pays for itself — and then some.

Will the upgrade help me achieve my sustainability targets?

This upgrade isn’t just about improving recovery — it’s also about doing more with less. The Concorde Blast Tube accelerates flotation kinetics, meaning less residence time, reduced reagent consumption and a smaller plant footprint. 

The result is a cleaner, more efficient operation that aligns with your sustainability goals while improving bottom-line performance.

What support is available for the upgrade?

Beyond the hardware, there is a full suite of performance services support available to keep your operations running at their best:

• Expert installation & commissioning, including training for your teams.
• Tailored process optimization, using advanced control algorithms to reduce reagent use while improving stability.
• Preventive inspections and shutdown services that reduce maintenance costs and maximize uptime.
• Smart wear part strategies, using materials like polyurethane and ceramics for extended service life and performance.

Because when you modernize, it's more than just new technology — Metso is your #1 partner from pit to port.

Is the Concorde Blast Tube easy to maintain?

This upgrade is engineered for simplicity and reliability, making maintenance straightforward and efficient. With no moving parts, the design significantly reduces the risk of mechanical failure and minimizes wear. Its modular structure allows for quick access and easy replacement of components, while the durable materials—such as polyurethane, ceramic, and stainless steel — extend the service intervals.

What is the average service life of the wear components?

The wear components of the Concorde Blast Tube are designed for long service life, due to careful material selection tailored to each application. Nozzles are available in durable polyurethane or ceramic, while the Blast Tubes are constructed from a combination of polyurethane and stainless steel to withstand demanding conditions.

The optimal wear materials are determined during the sizing and selection phase based on detailed metallurgical and mechanical evaluations conducted during on-site testing. When components eventually reach the end of their service life, replacement parts are readily available through Metso’s comprehensive performance service packages.

Bottom line

The Concorde Blast Tube delivers proven improvements in grade, recovery, and process control without the cost and complexity of a full system replacement. For operations facing finer ore, tighter margins, and pressure to decarbonize, it’s an upgrade that pays for itself, in both performance and peace of mind.

Ready to discover what's still hiding in your tailings?