Ultrafine hematite particles (<10 μm), commonly generated in beneficiation circuits, exhibit poor flocculation and slow settling, posing challenges for solid–liquid separation. This study investigates the influence of the anionic polyacrylamide (APAM) molecular weight on ultrafine hematite flocculation under controlled laboratory conditions, combining macroscopic experiments with molecular dynamics simulations (MDSs). Sedimentation tests show that the APAM molecular weight strongly affects settling kinetics, supernatant clarity, and floc structure, with the settling rate, flocculation-stage reaction time, supernatant turbidity, and underflow concentration exhibiting a non-monotonic trend and optimal performance at seven million. Under this condition, particles aggregate most efficiently, achieving a turbidity of 182 NTU, an underflow concentration of 51.5%, and the largest compact flocs, averaging 379.8 μm with a fractal dimension of 1.71. Higher molecular weights (≥9 million) induce chain coiling, reduce floc compactness, increase water retention, and impair settling. MDS indicates that polymer–surface interactions improve with an increasing polymerisation degree only up to an intermediate chain length; a polymerisation degree of 30 exhibits the most favourable extended–flexible conformation, maximal surface enrichment, strongest coordination between carboxyl groups and surface Fe atoms, lowest adsorption energy, and fastest adsorption kinetics. The functional-group distribution and hydrogen-bond analyses show that –NH2 and –COO– groups dominate interfacial interactions, with a polymerisation degree of 30 yielding the highest density of interfacial hydrogen bonds. By correlating macroscopic experiments with molecular-scale observations, this work provides mechanistic insight into how the APAM chain length governs ultrafine hematite flocculation, highlighting the role of polymer conformation and multipoint adsorption in controlling the settling performance.
Zhou et al. (Sun,) studied this question.