Concorde Cell™ continues to unlock value from complex ores

Raising the bar in fine particle recovery 

Since its introduction, the Concorde Cell has set a new benchmark in high-intensity pneumatic flotation. Designed to address the growing challenge of declining ore grades and increasingly complex mineralogy, the technology enables efficient recovery of particles smaller than 20 microns, historically one of the biggest sources of losses in flotation circuits.  

By combining high shear and supersonic slurry acceleration with fine bubble generation, the Concorde Cell significantly improves particle–bubble attachment and flotation kinetics. This results in higher recovery rates, improved concentrate grades, and better overall plant performance. The latest example is the Concorde Cell installed in a cleaner duty in the nickel circuit of Boliden’s Kevitsa mine (Finland) in Q1 2025. When processing the Ni rougher concentrate, up to 80% Ni recovery is achieved at an enrichment ratio above 1.6. When flotation selectivity is prioritized, a Ni enrichment ratio exceeding 2.5 is achieved at over 65 % Ni recovery. Despite being fed with a bleed stream only, the impact of the Concorde Cell is measured at plant level with a positive improvement in both grade and recovery of Ni. Further information can be found in Mattsson, 2026, published at the latest general CMP in Ottawa. Importantly, these gains come alongside lower energy and water consumption per ton of metal produced, supporting customers’ sustainability targets while improving profitability.  

Strong uptake in major projects

Recent project wins highlight the growing industry confidence in the technology. In January 2026, Barrick continued trusting Metso’s hybrid flowsheet after Reko Diq - Opens in a new window and selected the Concorde Cell technology for its Lumwana copper expansion project in Zambia - Opens in a new window, integrating it with TankCell® flotation to optimize overall flowsheet performance.  

This hybrid approach combining proven TankCell® technology with Concorde Cells offers a low-risk pathway to boost recovery in challenging ores, while maintaining operational stability and flexibility. Metso will be presenting a detailed trade-off between the conventional approach and the hybrid flowsheet at the COM 2026 in Calgary, BC in late August 2026. Using a real-life copper-gold greenfield project, it was demonstrated that Metso’s reimagined concentrator led to up to 28% reduction in footprint, up to 18% reduction in OPEX with a 12% decrease on the overall EPC scope. 

Industrial-scale applications across commodities such as copper, gold, platinum, and rare-earth oxides have demonstrated consistent metallurgical improvements, particularly in reducing fine particle losses to tailings. In North America, the next Concorde Cells to be commissioned are for reverse iron ore flotation for Mesabi Metallics - Opens in a new window while outside North America, FQM’s Kansanshi cleaner Concorde Cells have been running since Q3 2025 and are the largest Concorde Cell installation to date. 

Modular solutions accelerate deployment 

To further support customers, Metso has introduced modular Concorde Cell Plant Units, a major step forward in simplifying installation and reducing time to value.  

These prefabricated, containerized units: 

• Minimize on-site construction and installation work 
• Reduce plant footprint and integration complexity 
• Enable faster commissioning and return on investment 
• Include built-in automation, sampling, and maintenance capabilities  

This modular approach is particularly valuable for brownfield expansions and remote operations, where speed, safety, and ease of integration are critical. 

Upgrade pathways unlock immediate gains 

Beyond new installations, Metso is also enabling existing operations to benefit from Concorde technology through the Concorde Blast Tube™ upgrade. This plug-and-play retrofit solution allows operators to upgrade current self-aspirated pneumatic flotation cells with minimal downtime and no major plant modifications.  

Key benefits include: 

• Increased recovery of fine and ultra-fine particles 
• Improved selectivity and concentrate quality 
• Enhanced process control and stability 
• Fast payback, often within months  

These upgrades provide a practical pathway for customers to improve metallurgical performance without large capital investments. Several upgrades conducted in Australia and in Africa showed that the major driver for the increases in recovery and grade after the retrofit is the fine particles, with an increase of up to 10% in recovery in particles below 75, 38 and 20 µm. The performance of one of these upgrades in a copper-gold plant was presented at the CIM Connect in Vancouver in May 2026. 

Continuous innovation and testing capabilities 

Metso continues to invest heavily in R&D to further advance flotation performance. The opening of a new state-of-the-art separation laboratory in Pori, Finland in October 2025 has expanded testing capabilities, including dedicated Concorde Cell test units.  

This facility allows customers to: 

• Quantify fine particle losses and recovery potential 
• Conduct trials and flowsheet optimization, combined with dedicated fine grinding like the HIG Mill 
• Accelerate decision-making with data-driven insights 

Advanced pilot units, equipped with integrated automation and recirculation systems, also enable precise simulation of plant conditions and side-by-side performance comparisons.

Delivering measurable customer value 

Across applications, the Concorde Cell is delivering measurable benefits: 

• Higher recovery of valuable fines and ultrafines 
• Reduced operating costs through fewer flotation stages and optimized energy use 
• Improved sustainability with lower water and power consumption 
• Compact plant design, enabling easier integration and reduced footprint  

As ore bodies continue to decline in grade and complexity increases, technologies like the Concorde Cell are becoming essential for maintaining profitability and maximizing resource efficiency. 

Looking ahead 

With increasing global adoption, new modular offerings, and proven upgrade paths, the Concorde Cell is firmly positioned as a key enabler of next-generation flotation circuits. Backed by ongoing innovation and strong customer results, Metso continues to help operators “recover the unachievable” and unlock greater value from every ton processed.