Rotor/stator unit nextSTEP™

Overview
Featuring the patented nextSTEP™ rotor/stator mounted at the bottom of the cell, these forced-air flotation cells deliver a more stable froth surface and deeper froth layer to enhance mineral recovery and separation efficiency. The design reduces power requirements versus conventional forced-air cells and can be retrofitted to existing installations.

Key features

• Patented nextSTEP™ rotor/stator positioned at the bottom of the cell for a stabilized froth surface and deeper froth layer.
• Optimised rotor/stator geometry and matched profiles for high energy transfer efficiency to the slurry (best-in-class energy efficiency).
• Even wear patterns and reversible rotor operation to extend mechanism life and reduce maintenance interventions.
• Retrofit capability — nextSTEP™ can be installed on existing forced-air flotation cells using adaptor flange and baseplate, and optimised drive sheaves.
• Optional add-ons and instrumentation: froth cameras, smart flotation package (algorithmic recovery adjustment using froth cameras and online analysers), radial froth crowders to optimise froth pull rate across rows.
• Suitable for both rectangular and round cell geometries.

Key benefits

• Improved mineral recovery and higher-grade concentrate via a stabler, deeper froth and improved separation of valuable minerals from gangue.
• Lower energy consumption compared with comparable forced-air designs — typically 15–40% less power required, reducing operational energy costs and component wear.
• Extended wear life and lower maintenance costs — nextSTEP mechanisms often demonstrate operating lives up to 2× typical wear life.
• Proven retrofit path to convert existing forced-air cells with low mechanical risk and minimal layout change.
• Enhanced process control options (froth cameras, smart flotation) enable automated recovery adjustments and improved metallurgical performance.

Applications

• Suitable for rougher, scavenger and cleaner flotation duties across a wide range of metals and minerals.
• Applicable where controlled air distribution, deep froth stability and energy efficiency are operational priorities.

Services and support (product-related)

• Laboratory testing and pilot evaluation at Minerals Testing and Research Centres to determine optimal sizing, configuration and operating practices for specific feed materials.
• Global service centre network offering full‑lifecycle technical assistance, inspections, maintenance supervision and tailored operator training to sustain flotation performance.

Technical specifications

• Commercial designation: nextSTEP™
• Mechanism location: rotor/stator positioned at the bottom of the cell (stabler froth surface, deeper froth layer)
• Energy reduction vs other forced-air designs: typically 15%–40% lower power consumption
• Wear life: even wear patterns and reversible rotor extend operating life (often up to 2× typical wear life)
• Retrofit: existing mechanism assembly reused; adaptor flange and baseplate fitted; drive sheaves replaced to optimise speed; successful retrofits reported for cells from ~1.7 m³ up to ~250 m³
• Available cell volumes: rectangular cells with active volumes ~1.7 m³ to 2.8 m³; round cells with active volumes ~5 m³ to 600 m³
• Typical applications: rougher, scavenger and cleaner flotation for various metals and minerals
• Optional instrumentation: froth cameras, smart flotation package (algorithms + online analysers), radial froth crowders