A review of fine particle flotation: mechanistic insights and advances

Abstract

Fine particle flotation has emerged as a critical area in mineral processing due to increasing demand for resource recovery and the growing presence of ultrafine particles in ore deposits and tailings. These particles, typically smaller than 38 µm, pose significant challenges including low mass, high surface energy, high reagent consumption, and reduced bubble-particle collision efficiency. This review provides a comprehensive analysis of the mechanisms affecting the flotation of fine particles and explores various technical strategies developed to overcome these limitations. These include particle size enlargement through flocculation and agglomeration, bubble size reduction via micro- and nanobubbles, and advanced cell designs aimed at improving particle-bubble interaction. Emerging technologies such as dissolved air flotation, electroflotation, and pneumatic and column cells are also discussed. Furthermore, the article critically evaluates the applicability, limitations, and industrial scalability of these methods. Emphasis is placed on integrating environmentally friendly reagents and optimizing process efficiency to enhance sustainability in mineral processing. The review concludes by outlining future research needs, including the multivariate study of interacting flotation parameters and the development of industrial-scale solutions for fine particle recovery.