nextSTEP™ rotor/stator

FLSmidth’s nextSTEP™ rotor/stator provides a step change in both metallurgical performance and energy efficiency compared to any other forced-air design on the market

nextSTEP rotor/stator
  • nextSTEP rotor stator
  • Features

FLSmidth introduces the patent pending nextSTEP™ advanced flotation mechanism; the newest design for forced air flotation technology which reduces OPEX with the lowest power consumption on the market. This new rotor-stator technology is the result of extensive fundamental studies, laboratory test work and full-scale plant testing.

The nextSTEP rotor/stator demonstrates significant improvement in both metallurgical performance and energy efficiency over traditional forced-air designs. The exceptional performance of the nextSTEP mechanism comes from the rotor and stator being perfectly matched which delivers the best energy dissipation flow, thus maximizing the probability of flotation.

The lower energy consumption and the superior metallurgical performance of the nextSTEP mechanism is beneficial for any operation. The nextSTEP mechanism has a strong positive impact on long term operating costs for green field projects. In the case of brown field projects and existing concentrators, the mechanism is interchangeable with existing FLSmidth forced-air flotation mechanisms and can be retrofitted in any forced air flotation cell.


  • Up to 5% better recovery rates
  • More than 20% lower power consumption compared to any other mechanism
  • Superior metallurgical performance as compared to any other design on the market
  • Improves the performance of new and existing machines
  • Dramatic improvements in mineral-bubble attachment rates
  • Better wear distribution increases product life cycle


nextSTEP™ rotor

The nextSTEP rotor is designed to produce ideal flow streams. It also produces strong enough turbulence to enhance bubble-particle attachment. This signifcantly improves recovery rates and concentration grades while lowering energy requirements.

nextSTEP stator

The patent-pending slotted stator dramatically improves attachment rates which translates into statistically significant recovery increases. This new design provides wider jet flow out of the rotor, as well as cross pattern between stator vanes for better chances of particle flotation. By pairing the curved blades of the nextSTEP™ rotor and stator, superior flotation recovery is acheived while significantly decreasing the power consumption of the mechanism. 

Lowest power consumption on the market

The nextSTEP mechanism demonstrates a significant decrease in power consumption in comparison to other flotation technologies and has proven to be the lowest energy flotation mechanism on the market.

Increased wear life

Even wear patterns increase the life cycle of the mechanism as there are no heavy wear spots during operation. This saves money over the life of the rotor/stator and reduces downtime for repairs or replacements. On top of the even wear patterns, the rotor can be run in a reverse direction to further increase the life cycle of the mechanism.

Improved recovery of coarse particles

When compared to other forced-air flotation designs, the nextSTEP mechanism exhibits stronger air dispersion near the rotor-stator region, higher air hold-up and a stronger pumping effect below the rotor. CFD analysis shows that the nextSTEP mechanism generates a preferred slurry flow and positive froth movement pattern near the top of the tank. This improves froth mobility and recovery of coarse particles over other competitive designs.

nextSTEP rotor/stator
nextSTEP video