The efficiency of froth flotation, a cornerstone of modern mineral processing, depends strongly on the chemistry of frothing agents that regulate froth formation, stability, and dynamics. This study investigates the effect of frother type and dosage on froth height, stability, bubble morphology, and flotation kinetics through laboratory-scale and industrially relevant experiments. A set of frothers, including conventional methyl isobutyl carbinol (MIBC) and advanced reagents such as T-92, Penoflot-1304, TPM, DF-1012, and three composite formulations, were systematically evaluated. Surface tension measurements, critical coalescence concentration (CCC) analysis, and pendant-drop techniques were applied to characterize physicochemical properties, while chalcopyrite flotation tests provided kinetic data and recovery profiles. Results revealed clear structure–property–performance relationships. MIBC promoted rapid froth generation but limited stability, whereas complex reagents such as DF-1012 and TPM produced highly stable froths with persistent fine bubbles. Kinetic modeling showed that composite frothers, particularly Composition-3, markedly enhanced chalcopyrite recovery, achieving flotation rate constants up to 0.24 min⁻¹ compared with 0.10 min⁻¹ for MIBC. In addition, economic and environmental assessments indicated that novel frothers can lower reagent consumption while improving selectivity and sustainability. Overall, this study establishes a direct link between frother chemistry and froth layer dynamics, providing practical guidelines for reagent selection in sulfide ore flotation. The findings not only improve metallurgical performance but also highlight pathways toward more sustainable and environmentally responsible mineral processing.
Kenjayev et al. (2025) studied this question.