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Minerals
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Design, Modeling, Optimization and Control of Flotation Process, 2nd Edition
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Design, Modeling, Optimization and Control of Flotation Process, 2nd Edition

A special issue of Minerals (ISSN 2075-163X). This special issue belongs to the section "Mineral Processing and Extractive Metallurgy".

Deadline for manuscript submissions: closed (20 December 2025) | Viewed by 5762

Special Issue Editors

Dr. Fardis Nakhaei

E-Mail Website
Guest Editor
Department of Mining & Explosives Engineering, Missouri University of Science and Technology, McNutt Hall, Rolla, MO 65409, USA
Interests: flotation; ultra-fine particle processing; surface chemistry; coal preparation; modelling; artificial intelligent; image analysis, nano-bubbles
Special Issues, Collections and Topics in MDPI journals
Prof. Dr. Wengang Liu

E-Mail Website
Guest Editor
School of Resources and Civil Engineering, Northeastern University, Shenyang 110819, China
Interests: flotation reagents; separation and purification of complex minerals; hydrometallurgical processing of minerals; comprehensive utilization of tailings
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The ultimate goal of a flotation process is to achieve the economically optimum combination of the desired mineral grade and recovery in the final concentrate from a feed of varying composition. The industrial operation of froth flotation faces many challenges, such as sudden decreases in the recovery and grade of recovered materials. The quality of the final concentrate determines the success of the downstream processes, and achieving the optimum metallurgical performance requires proper characterization, optimization, and control of the process. The efficiency of a flotation circuit operation relies on several factors pertinent to mineral nature and structure (variability of ore feed, particle size, complex mineralogy, and morphology), as well as on the type of instrumentation and operational parameters (design parameters, reagents, quality of process water, air flow rate, and solid content) used, which require both advanced theoretical and practical studies. Hence, new techniques in the fields of design, modelling, optimization, and control of flotation processes have attracted a great deal of attention.

This Special Issue is dedicated to sharing the latest findings on methodologies, applications, and case studies in the field of flotation to improve process efficiency, reduce energy consumption, and increase the sustainability of these processes. This Special Issue welcomes a wide range of research and practical topics, including those related to design, simulation and instrumentation, and process control. We welcome reviews, original articles, and multidisciplinary studies, including but not limited to the following topics:

  • Conceptual or simulation of flotation processes;
  • Optimization of flotation processes (single or multi-objectives, uncertainty, and sensitivity analyses);
  • Novel perspectives in designing flotation circuits, machinery, and the minimization of energy consumption;
  • Modification and improvement of flotation circuits;
  • Numerical modelling of flotation processes (molecular modelling, computational fluid dynamics, intelligent computation, image analysis);
  • Kinetic models and their scale-up in industrial cells;
  • Process control (data management, automation, sensors, and measurements);
  • Mechanical, column, and pneumatic flotation cells (Jameson, ImhoflotTM and RefluxTM flotation cells);
  • Impact of operation parameters on designing flotation cells (gas hold-up, superficial gas velocity, bubble size distribution and orifice type, etc.);
  • Measurement and modelling of slurry residence time in flotation cell/circuits.

The first edition explored innovative approaches to modelling, optimizing, and controlling flotation processes. These techniques aim to enhance efficiency by maximizing the recovery of valuable minerals while minimizing energy and reagent consumption in relevant studied flotation processes. The second edition of the Special Issue will continue to serve as a platform for future multidisciplinary research in modelling, designing, and optimizing the flotation process.

Dr. Fardis Nakhaei
Prof. Dr. Wengang Liu
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 250 words) can be sent to the Editorial Office for assessment.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Minerals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • froth flotation processes
  • optimization tools
  • modelling and simulation
  • froth control
  • cell design
  • flotation kinetics
  • modification and improvement of flotation circuits
  • gas dispersion
  • RTD measurement and modelling
  • particle–bubble modelling
  • first principal modelling
  • experimental design
  • mechanical and column cells
  • pneumatic flotation cells
  • experimental design

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Related Special Issue

Published Papers (4 papers)

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Research

14 pages, 9407 KB  
Article
Synergistic Recovery of Copper, Antimony, and Silver Refractory Sulfide Minerals Using an ADD/Z-200 Mixed Collector System
by Baobao Yan, Yongmao Liu, Xianbing Jia, Otgonjargal Enkhtur, Azzaya Tumendelger and Zhiwei Bian
Minerals 2025, 15(11), 1219; https://doi.org/10.3390/min15111219 - 19 Nov 2025
Viewed by 1026
Abstract
Copper polymetallic sulfide ore from the Asgat copper polymetallic deposit in Mongolia has been found to contain a high grade of antimony and silver in addition to copper. In this research, flotation experiments using sodium butyl xanthate (SBX), ammonium dibutyl dithiophosphate (ADD), isopropyl [...] Read more.
Copper polymetallic sulfide ore from the Asgat copper polymetallic deposit in Mongolia has been found to contain a high grade of antimony and silver in addition to copper. In this research, flotation experiments using sodium butyl xanthate (SBX), ammonium dibutyl dithiophosphate (ADD), isopropyl ethyl thionocarbamate (Z-200), and their mixtures were conducted on a sample from the deposit under natural pH conditions. The results of the flotation tests indicate that optimal conditions were achieved with a feeding of 92% −0.074 mm (92% finer than 0.074 mm), sodium silicate dosage of 800 g/t, sodium humate dosage of 300 g/t, sodium sulfite dosage of 300 g/t, and collectors of 60 g/t of ADD and 60 g/t of Z-200. The closed-circuit flotation tests showed that the recovery of copper, antimony, and silver from the ADD/Z-200 combination was 8.13%, 5.41%, and 9.26% higher than that form the single Z-200 while reducing the reagent cost by 12.75%. Full article
(This article belongs to the Special Issue Design, Modeling, Optimization and Control of Flotation Process, 2nd Edition)
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22 pages, 4081 KB  
Article
Coarse Froth Flotation to Optimise Scheelite Recovery
by Emmanuel Dogara Musa, Julie Hunt, Mohammadbagher Fathi, Owen P. Missen, Greg Doherty and Marcus Mollison
Minerals 2025, 15(11), 1183; https://doi.org/10.3390/min15111183 - 10 Nov 2025
Viewed by 1193
Abstract
The flotation of coarse-sized particles is an important step in the pathway to sustainable recovery as it can reduce reagents usage, energy consumption, and environmental impact, as well as minimise overgrinding. This study assessed the floatability of coarse-sized scheelite, a mineral containing the [...] Read more.
The flotation of coarse-sized particles is an important step in the pathway to sustainable recovery as it can reduce reagents usage, energy consumption, and environmental impact, as well as minimise overgrinding. This study assessed the floatability of coarse-sized scheelite, a mineral containing the critical element tungsten (W), using plant-derived samples from the Kara mine magnetite–scheelite skarn deposit in Tasmania, Australia. The recovery of three sizes of coarse-size scheelite (+150, +300, and +425 µm) was tested under optimised conditions determined through laboratory experiments (i.e., 900 rpm, pH 9, collector sodium oleate 5 g/t, and depressant mixture of 4 g/t of sodium silicate and 4 g/t of quebracho). Results show that WO3 recoveries of 91.76% and 84.14% and grades of 61.03% and 58.73%, respectively, were achieved for samples containing the +425 µm and +300 µm size scheelite. These samples had lower mass recoveries (70.95% and 84.15%), reflecting the selective flotation of coarse scheelite. Lower WO3 recovery (79.44%) and grade (45.76%) but higher mass recovery (88.81%) were obtained for the samples with +150 um scheelite. This paper provides details of the test work and provides a framework for adapting coarse scheelite particle flotation strategies to other scheelite skarn deposits and high-density mineral systems to help enable improved recovery and enhanced economic efficiency in mineral processing plants. Full article
(This article belongs to the Special Issue Design, Modeling, Optimization and Control of Flotation Process, 2nd Edition)
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18 pages, 1829 KB  
Article
Cell-Specific Relationships Between Froth Parameters and Flotation Performance: Insights from the Flash and Rougher Cells
by Egemen Guney and Ozlem Bicak
Minerals 2025, 15(11), 1137; https://doi.org/10.3390/min15111137 - 30 Oct 2025
Cited by 1 | Viewed by 1740
Abstract
Recent advances in machine vision systems make froth image analysis a promising tool for real-time monitoring, evaluating, and controlling flotation performance. This study investigates the characteristics of the froth in two mechanical industrial flotation cells: a Flash Cell and Cell 6, which is [...] Read more.
Recent advances in machine vision systems make froth image analysis a promising tool for real-time monitoring, evaluating, and controlling flotation performance. This study investigates the characteristics of the froth in two mechanical industrial flotation cells: a Flash Cell and Cell 6, which is the final cell in the rougher stage of a gold-bearing sulfide ore processing plant. Froth parameters, including bubble velocity (BV) and bubble size (BS), were measured online using the Stone Three Froth Camera System under varying operating conditions such as air flow rate and froth height. The results showed that BV was the most predictive froth parameter in both cells. BS exhibited predictive value only in the Flash Cell, where gold grade increased linearly with BS. In Cell 6, however, no significant relationship was found between BS and performance. These findings demonstrate that froth monitoring strategies must be cell-specific. BS is a useful control parameter in Flash flotation, but not in Cell 6, where entrainment dominates. Overall, the study shows that, effective optimization requires simultaneous consideration of froth parameters and feed characteristics, rather than reliance on a single indicator. Full article
(This article belongs to the Special Issue Design, Modeling, Optimization and Control of Flotation Process, 2nd Edition)
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19 pages, 1124 KB  
Article
A Targeted Approach to Critical Mineral Recovery from Low-Grade Magnesite Ore Using Magnetic and Flotation Techniques
by Mohammadbagher Fathi, Mostafa Chegini and Fardis Nakhaei
Minerals 2025, 15(7), 698; https://doi.org/10.3390/min15070698 - 30 Jun 2025
Cited by 1 | Viewed by 1321
Abstract
As a critical mineral, magnesite plays a vital role in industries such as steelmaking, construction, and advanced technologies due to its high thermal stability and chemical resistance. However, the beneficiation of low-grade magnesite ores (~38.36% MgO) remains challenging due to the presence of [...] Read more.
As a critical mineral, magnesite plays a vital role in industries such as steelmaking, construction, and advanced technologies due to its high thermal stability and chemical resistance. However, the beneficiation of low-grade magnesite ores (~38.36% MgO) remains challenging due to the presence of iron, silica, and calcium-bearing impurities. This study proposes an integrated beneficiation strategy combining medium-intensity magnetic separation and flotation techniques to upgrade a low-grade magnesite ore. After grinding to 75 µm (d80), the sample was subjected to two-stage magnetic separation at 5000 Gauss to remove Fe-bearing minerals, reducing Fe2O3 below 0.5%. The non-magnetic fraction was then treated through a two-stage reverse flotation process using dodecylamine (350 g/t) and diesel oil (60 g/t) at pH 7 to reject silicate gangue. This was followed by a four-stage direct flotation using sodium oleate (250 g/t), sodium silicate (350 g/t), and SHMP (100 g/t) at pH 10 to selectively recover magnesite while suppressing Ca-bearing minerals. The optimized flowsheet achieved a final concentrate with MgO > 46.5%, SiO2 ≈ 1.05%, Fe2O3 ≈ 0.44%, and CaO ≈ 0.73%, meeting the specifications for refractory-grade magnesite. These results highlight the effectiveness of a combined magnetic–flotation route in upgrading complex, low-grade magnesite deposits for commercial use. Full article
(This article belongs to the Special Issue Design, Modeling, Optimization and Control of Flotation Process, 2nd Edition)
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