Optimization of Zinc Flotation Parameters for the Chaabet El Hamra Ore: A Kinetic and Mineralogical Approach

Abstract

The Chaabet El Hamra deposit in northeastern Algeria represents a promising but mineralogically complex zinc resource. This study investigates the optimization of flotation parameters to enhance zinc recovery and concentrate quality. Detailed mineralogical and granulometric analyses revealed that sphalerite was the primary zinc-bearing mineral, finely disseminated within a gangue matrix dominated by quartz and dolomite. Experimental grinding tests indicated that milling for 42–45 min achieved optimal liberation at 74 µm, a critical threshold for effective flotation. Flotation trials were performed under varying conditions of copper sulfate activation, amyl xanthate dosage, and froth scraping times. The highest zinc recovery (86.31%) and concentrate grade (49.05%) were obtained at a collector dosage of 150 g/t, an activator dosage of 200 g/t, and a 7-min scraping duration. Kinetic modeling using both first-order and Kelsall’s two-component models confirmed the flotation system’s efficiency and highlighted the coexistence of fast- and slow-floating mineral fractions. Response surface methodology (RSM) further elucidated the nonlinear interaction between reagents, defining an optimal operating window. The study provides a comprehensive framework for industrial flotation optimization and demonstrates the value of integrating kinetic modeling with mineralogical characterization. These findings contribute to improving the economic and environmental performance of zinc beneficiation in polymetallic ore contexts. The optimum flotation conditions (pH 9, 500 g/t collector dosage, and 10 min conditioning time) provide a robust basis for upscaling the process to industrial scale.