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Minerals
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Kinetic Characterization and Its Applications in Mineral Processing
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Kinetic Characterization and Its Applications in Mineral Processing

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

Deadline for manuscript submissions: 30 June 2026 | Viewed by 7362

Special Issue Editors

Dr. Luis Vinnett

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Guest Editor
Department of Chemical and Environmental Engineering, Universidad Técnica Federico Santa María, Av. España 1680, Valparaíso, Chile
Interests: flotation; modelling and simulation; optimization; hydrodynamics and gas dispersion; process control
Special Issues, Collections and Topics in MDPI journals
Dr. Ahmad Hassanzadeh

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Guest Editor
Maelgwyn Mineral Services Ltd., Ty Maelgwyn, 1A Gower Street, Cathays, Cardiff CF24 4PA, UK
Interests: particle-bubble interactions; flotation machines; surface and colloidal chemistries; kinetics and thermodynamics; ultrafine grinding; gold and silver leaching
Special Issues, Collections and Topics in MDPI journals
Dr. Diego Mesa

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Guest Editor
Department of Earth Science & Engineering, Imperial College London, London SW7 2AZ, UK
Interests: flotation design; multiphase fluid dynamics; froth stability; sustainable geometallurgy

Special Issue Information

Dear Colleagues,

Kinetic characterizations have been used extensively in mineral processing to determine the rates at which a product is obtained. These rates are related to several sub-processes in both comminution and concentration. A kinetic characterization typically consists of measuring a metallurgical index as a function of time, determining parameters associated with the decay ratios and steady performances. From these results, ore or machine features are determined, which are critical to the scale-up of metallurgical results from laboratory tests to industrial systems. Kinetic responses also allow for the comparison of different operating conditions and machines in mineral processing. Although kinetic studies are widely used in academic research and routinely conducted in industrial applications, it has widely been accepted that there is a lack of experimental and modelling standards, which has justified further investigations in this regard. Under the advancements in analytical, mineralogical and computational tools, kinetic characterizations have been expanded to incorporate different particle properties, new models and estimation algorithms, or both together. The aim of this Special Issue is to invite contributions from a group of experts to present the latest results and recent advancements in the following areas:

  • Kinetic characterizations at laboratory, pilot or industrial scales to evaluate and compare metallurgical performances.
  • Kinetic modelling and its applications in mineral processing.
  • Recent advancements in kinetic characterizations incorporating different particle properties, such as size, composition, liberation, association, among others.
  • The use of new tools, model strategies and algorithms to characterize kinetic responses in mineral processing.
  • Scale-up of laboratory results to continuous/industrial systems, and the implications for machine and circuit sizing.

Dr. Luis Vinnett
Dr. Ahmad Hassanzadeh
Dr. Diego Mesa
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

  • flotation kinetics
  • breakage rate
  • flotation rate
  • selection function
  • scale-up
  • time-recovery data
  • flotation modelling
  • comminution modelling
  • simulation

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Published Papers (6 papers)

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Research

23 pages, 4268 KB  
Article
Enhanced Rougher Recovery of Ultrafine Molybdenum Tailings Using a Novel Pilot-Scale Turbulent Micro-Vortex Mineralizer
by Yande Chao, Zhiyang Li, Juntao Chen, Hao Xue, Jianguo Yang, Bin Lin, Bolong Zhang, Haijun Zhang and Hainan Wang
Minerals 2026, 16(2), 201; https://doi.org/10.3390/min16020201 - 14 Feb 2026
Viewed by 501
Abstract
Constrained by the low grade and poor floatability of the run-of-mine ore, the beneficiation of porphyry-type copper–molybdenum sulfide ores generates large quantities of molybdenum tailings, leading to significant environmental risks and resource losses and necessitating urgent recovery and reutilization. In this study, a [...] Read more.
Constrained by the low grade and poor floatability of the run-of-mine ore, the beneficiation of porphyry-type copper–molybdenum sulfide ores generates large quantities of molybdenum tailings, leading to significant environmental risks and resource losses and necessitating urgent recovery and reutilization. In this study, a representative sample of molybdenum tailings with a Mo grade of 0.354% was investigated to analyze its process mineralogy. The results show that molybdenite predominantly exists as fine, flaky particles intimately intergrown with quartz, pyrite, and aluminosilicate minerals, exhibiting an extremely low degree of liberation and an overall ultrafine particle size. Laboratory flotation tests show that the flotation kinetics conform to a first-order model; however, a considerable amount of molybdenum remains in the tailings, indicating that the mineralization process needs to be intensified. Through structural optimization and confined-space design, a vortex-based mineralization reactor was developed. Computational fluid dynamics simulations demonstrate that the mineralizer can generate flow fields with high turbulence intensity and dissipation rates and can induce high-energy, small-scale micro-vortices. On this basis, a semi-industrial rougher flotation system was established by coupling the developed mineralizer with a flotation column. Under optimized operating conditions, namely a feed pressure of 0.06 MPa and an impeller frequency of 20 Hz, single-stage treatment of the tailings produced molybdenum concentrates with a grade of 1.90% and a recovery of 81.29%, while the Mo grade of the tailings was reduced to 0.08%. The results are markedly superior to those obtained using a conventional laboratory flotation cell, demonstrating a substantial enhancement in mineralization efficiency and molybdenum recovery. The proposed approach, therefore, provides a practical reference for the flotation recovery of molybdenum tailings as well as other micro-fine, low-grade metal tailings. Full article
(This article belongs to the Special Issue Kinetic Characterization and Its Applications in Mineral Processing)
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14 pages, 1669 KB  
Article
Modelling and Simulation of Intensified Flotation Cells for Fine Particles Flotation
by Paulina Vallejos, Juan Yianatos, Matías Benítez, Ian Sherrell, Alejandro Yáñez and Dominique Betancourt
Minerals 2025, 15(12), 1270; https://doi.org/10.3390/min15121270 - 30 Nov 2025
Viewed by 933
Abstract
New intensified flotation technologies have emerged to enhance fine and ultrafine particle recovery. However, their modelling remains challenging, as it requires defining the effective collection volume, residence time, and internal recirculation, factors not included in conventional models, while also facing operational complexity and [...] Read more.
New intensified flotation technologies have emerged to enhance fine and ultrafine particle recovery. However, their modelling remains challenging, as it requires defining the effective collection volume, residence time, and internal recirculation, factors not included in conventional models, while also facing operational complexity and the limited availability of key hydrodynamic and kinetic data. This study presents the development of a flotation model for the Concorde Cell technology, which separates the flotation process into three stages: collection zone, separation tank, and froth transport. The collection zone was represented as a plug-flow reactor with a rectangular rate of constant distribution; the separation zone as a perfect mixer with a detachment efficiency factor; and the froth recovery as a function of froth stability, residence time, and transport distance. Water recovery and gangue entrainment were also modelled to estimate concentrate grades. The model was tested and calibrated using experimental results from tests conducted in a Concorde Cell Lab Unit. A case example is presented for a semi-batch exhausting test performed with minerals from a copper concentrator plant. Good agreement between simulated and experimental results demonstrated the robustness and flexibility of the model. Additionally, the results showed collection rate constants significantly higher than those typically reported for conventional flotation cells (more than 100 times higher for Cu), due to the smaller collection volume and shorter residence time in the Concorde Cell. The calibrated model was then applied to simulate an industrial operation, where sensitivity analyses showed consistent responses to variations in operating conditions. Overall, the proposed model provides a practical tool for predicting the metallurgical performance of intensified flotation cells, supporting the integration of this new technology into modern concentrator flowsheets for the development of hybrid circuits. Full article
(This article belongs to the Special Issue Kinetic Characterization and Its Applications in Mineral Processing)
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28 pages, 4317 KB  
Article
Evaluation of Pyrite Recovery via Bench-Scale Froth Flotation from a Sulfide Ore Deposit in Southwestern Spain
by Amina Eljoudiani, Moacir Medeiros Veras, Carlos Hoffmann Sampaio, Josep Oliva Moncunill and Jose Luis Cortina Pallas
Minerals 2025, 15(12), 1234; https://doi.org/10.3390/min15121234 - 23 Nov 2025
Cited by 1 | Viewed by 958 | Correction
Abstract
In recent decades, there has been an upsurge in focus on the extraction of pyrite from sulfide ore deposits due to its vital role in the process of metal extraction and environmental management. This study explores the flotation behavior of pyrite in sulfide [...] Read more.
In recent decades, there has been an upsurge in focus on the extraction of pyrite from sulfide ore deposits due to its vital role in the process of metal extraction and environmental management. This study explores the flotation behavior of pyrite in sulfide ores using mechanical-cell flotation. This study compared the performance of two commonly used flotation collectors, potassium butyl xanthate (KXT) and diethyl dithiophosphate (DTP), in the beneficiation of a sulfide ore from southwestern Spain. Statistical analysis performed using MiniTab 4.0 revealed that collector type, reagent dosage, and pulp pH were the principal factors affecting pyrite recovery. Under the tested conditions, KXT exhibited superior metallurgical performance and selectivity compared with DTP. The flotation kinetics demonstrate that the chemical was more efficacious throughout both the rougher and cleaner phases of the process. The findings robustly corroborate the notion that employing xanthate-based chemicals to enhance pyrite concentration facilitates metal extraction from the Sulfide Ore Deposit in southwestern Spain. The study sets out a basis for process growth, and it is proposed that further research be conducted under industrial water conditions to validate the findings. Full article
(This article belongs to the Special Issue Kinetic Characterization and Its Applications in Mineral Processing)
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9 pages, 693 KB  
Article
Flotation Kinetics of Copper-Bearing Shale in the Presence of NaCl and α-Terpineol
by Wojciech Nowak and Tomasz A. Ratajczak
Minerals 2025, 15(7), 689; https://doi.org/10.3390/min15070689 - 27 Jun 2025
Cited by 1 | Viewed by 734
Abstract
This study investigates the influence of salt (NaCl) and, separately, frother (α-terpineol) on flotation of copper-bearing shale. It was shown, as expected, that increasing concentration of either NaCl or α-terpineol improves both ultimate shale recovery and the kinetics of flotation, except for very [...] Read more.
This study investigates the influence of salt (NaCl) and, separately, frother (α-terpineol) on flotation of copper-bearing shale. It was shown, as expected, that increasing concentration of either NaCl or α-terpineol improves both ultimate shale recovery and the kinetics of flotation, except for very high frother concentrations, which lead to a drop in flotation. It appears that the relationship between the first-order flotation rate constant and ultimate recovery for both applied reagents follows the same pattern regardless of the different mechanisms of NaCl and frother action. Full article
(This article belongs to the Special Issue Kinetic Characterization and Its Applications in Mineral Processing)
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18 pages, 3737 KB  
Article
On the Sensitivity of Kinetic Modeling to the Selection of Flotation Intervals in Batch Tests
by Luis Vinnett, Alex Esteban, Francisca Orellana, Marcelo Rivera and Matías Benítez
Minerals 2025, 15(6), 583; https://doi.org/10.3390/min15060583 - 29 May 2025
Cited by 2 | Viewed by 1222
Abstract
Batch tests were conducted to recover copper minerals by flotation. Seven intervals (cumulative flotation times) were chosen to characterize flotation kinetics in terms of maximum recoveries, R∞, and flotation rate distributions, f(k). The responses were subsampled, removing one [...] Read more.
Batch tests were conducted to recover copper minerals by flotation. Seven intervals (cumulative flotation times) were chosen to characterize flotation kinetics in terms of maximum recoveries, R∞, and flotation rate distributions, f(k). The responses were subsampled, removing one datapoint at a time to obtain seven datasets with six time-recovery datapoints. The main objective of this subsampling procedure was to assess the sensitivity of the R∞–f(k) estimates to moderate changes and arbitrary selection of flotation intervals in batch tests. These datasets were fitted to the Single Flotation Rate (SFR), Rectangular, and Gamma models. The R∞–f(k) pairs proved to be sensitive to changes in the flotation intervals, particularly under poor model fitting and noisy kinetic responses. The former was observed with the SFR model in all cases and with the Rectangular model in one test, whereas the latter was observed with the Gamma model for the noisiest kinetic response, showing a trend to overfitting. A simplified scale-up procedure was performed, showing significant uncertainties in the predicted recoveries when the R∞–f(k) pairs were strongly influenced by different flotation intervals. The scale-up results presented a variability that was directly justified by the R∞–f(k) uncertainties, caused by the arbitrary selection of flotation intervals in the batch tests. The analysis highlights the need for more robust experimental designs in kinetic characterizations, particularly for the prediction of metallurgical results at a large scale. Full article
(This article belongs to the Special Issue Kinetic Characterization and Its Applications in Mineral Processing)
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10 pages, 1227 KB  
Article
Using Intensified Flotation Cells to Improve Cleaning Circuit Performance
by Paulina Vallejos, Juan Yianatos, Marcelo Rodríguez and Jorge Cortínez
Minerals 2025, 15(5), 453; https://doi.org/10.3390/min15050453 - 27 Apr 2025
Viewed by 1920
Abstract
The cleaning circuit of the collective Cu-Mo flotation plant at Collahuasi (north of Chile) consisted of two parallel flotation rows, each one of three first cleaner cells in series with six cleaner–scavenger cells. The second cleaner consisted of 10 parallel columns (6 rectangular [...] Read more.
The cleaning circuit of the collective Cu-Mo flotation plant at Collahuasi (north of Chile) consisted of two parallel flotation rows, each one of three first cleaner cells in series with six cleaner–scavenger cells. The second cleaner consisted of 10 parallel columns (6 rectangular and 4 circular), whose tailings were directly recycled to the first cleaner. Recently, a project was developed to upgrade the cleaning circuit by decreasing the large Mo circulating load and improving the cleaning circuit performance. For this purpose, a testing strategy was set up at a pilot scale to evaluate the use of intensified flotation (Jameson cells), mainly for collecting the fine Mo particles accumulated in the circulating load, which contributes to the Mo losses from the scavenger stage into the final tailings. The preliminary results regarding kinetics at the pilot scale showed good potential to improve the metallurgical performance of Mo and Cu, and a sensitivity study was carried out to evaluate the application of this technology in the industrial cleaning circuit. Then, two parallel Jameson cells were selected to re-treat the whole column tailings stream. This operation allowed for the generation of a direct final Cu-Mo concentrate (that joins the columns concentrate) while recycling their tailings to the first cleaner. After commissioning, three sampling campaigns were performed on the whole flotation plant, particularly on the overall cleaning circuit, to evaluate the impact of the new flotation cells. Results showed that the Jameson cells effectively decreased the minerals circulating loads in the cleaning stage, mainly for Mo (in 49%). The Jameson cells directly contribute 48% of Mo and 25% Cu of the minerals in the final concentrate and allow for increasing the Mo final grade (0.45% Mo vs. 0.29% from columns). These results were in good agreement with predictions from the pilot testing. Full article
(This article belongs to the Special Issue Kinetic Characterization and Its Applications in Mineral Processing)
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