Revolutionizing coarse particle flotation Part III – The impact of ultrafine particles on coarse particle separation

The development of HydroFloat™ technology marks a significant milestone in the mineral processing industry, especially for coarse particle flotation by shifting the limits often referred to as the “Elephant Curve”. This innovative technology has transformed mineral separation, enabling more efficient recovery of valuable minerals from coarser ore particles. However, the presence of ultrafine particles can significantly influence separation performance, affecting both hydrodynamics and particle interactions within the flotation system. This study investigates the impact of ultrafine particles on coarse particle flotation efficiency, focusing on their effects on bubble-particle attachment, and fluidization dynamics in fluidized bed flotation systems. Through a series of controlled laboratory-scale tests, it is analyzed how varying ultrafine particle concentrations influence coarse particle recovery, entrainment, and reagent interactions. The results provide insight into strategies for mitigating ultrafine interference, including selective reagent schemes, dispersion control, and process modifications. By addressing these challenges, this research contributes to the optimization of coarse particle flotation separation performance, paving the way for improved resource recovery in modern flotation circuits.