Our focus is existing operations — miners looking to recover more, lift grade and drive down cost per tonne without rebuilding the plant. HPSA targets a handful of well-defined points in a standard flowsheet, each a self-contained modification rather than a new circuit.
HPSA can be deployed at many points, but four stand out in a typical concentrator. They sit on a simple spectrum: the closer to the end of the circuit, the easier and quicker the install; the further upstream, the larger the benefit cascading down the rest of the flowsheet.
Illustrative flowsheet — actual circuit configuration varies by operation. HPSA is modular and skid-mounted, so each insertion point is a self-contained addition to an existing circuit.
The last chance to capture value before it leaves as tailings. Much of what's lost in the scavenger tail is poorly-liberated middling — valuable mineral still locked to gangue. HPSA re-liberates it and returns it to flotation, minimising losses to tailings at source rather than leaving the value in the waste stream.
Conditioning the feed to the rougher so more of the target mineral is liberated before flotation even begins. Cleaner liberation here means a higher proportion reports to concentrate from the first stage, lifting overall recovery and grade.
Inserted into the secondary regrind loop, HPSA liberates material more effectively at a coarser size, so it moves forward instead of recirculating. The reduced recirculating load frees mill capacity for additional fresh feed — more product through the same equipment, improving recovery, throughput and cost per tonne of product.
The same recirculating-load logic, applied furthest upstream. Because it sits early in the circuit, the benefit cascades down the entire downstream flowsheet — the largest potential prize. It also carries the most implementation complexity, with mass-balance effects to design for up and downstream of the insertion point.
A meaningful share of recoverable mineral reports to tailings simply because it was never fully liberated — the valuable grains stay locked to gangue and float past the cells. That loss happens every shift, on fresh ore.
Applying HPSA at the scavenger feed re-liberates that locked fraction and gives it one more pass at recovery — so the value is captured now, in today's production, instead of being buried in the dam as a future reprocessing project. It's the most direct way to lift recovery on an operating circuit.
Wherever it sits in the circuit, HPSA's value rests on one thing: selective liberation that actually improves grade and recovery. Each result below comes from a DISA test programme on real ore. Headline figures are DISA-published; fuller campaign data is available under technical engagement.
Benchmarked against a rod mill in a regrind circuit, HPSA improved both copper grade and recovery in the finer size fractions — concentrating the valuable mineral into less mass and reducing the volume sent downstream.
Applied to a gold tailings stream, HPSA's selective liberation concentrated the gold into less mass — substantially lifting recovery while reducing the particle size needing downstream processing.
Evaluated as a replacement for a ball mill in a secondary grinding circuit, HPSA raised graphite flotation concentrate grade at a coarser grind size while maintaining recovery — pointing to fewer downstream regrind stages.
In phosphate rock, HPSA selectively liberates acid-consuming and silicate gangue minerals from the apatite host — lifting P₂O₅ grade and stripping magnesium-bearing impurities that penalise downstream acid plants.
The same selective liberation that minimises losses at source can also recover value from tailings already deposited. Reprocessing legacy material is a bigger, more complex project with a longer route to reality — but where the value justifies it, HPSA supports it, and the same mechanism can clean and recycle process media or reduce the volume of contaminated material requiring disposal.
Re-liberating and recovering the locked mineral fraction in existing tailings storage — turning a closed-out loss into a recoverable resource where grades and volumes justify the project.
Bigger project · longer horizonCleaning and recycling spent process media such as filter sand, and concentrating contaminants into a smaller fraction so the bulk of the material is left cleaner — including specialised remediation of legacy waste.
Specialised programmesRemediation applications include specialised legacy materials handled as dedicated programmes. Specific recovery and mass-reduction figures are available under technical engagement.
Tell us your flowsheet and where you're losing value, and we'll point to the position — and the win — that makes sense to test first.
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