A Case Study on the Mineralogical Origins of Zinc Misreporting to an Industrial Pyrite Concentrate and Its Mitigation by Regrinding-Assisted Flotation

The selective separation of sphalerite from Fe-bearing sulphides remains a persistent challenge in the flotation of complex sulphide ores and can lead to Zn misreporting to Fe-bearing concentrates. This study aimed to identify the origins of Zn misreporting to a pyrite concentrate and to evaluate whether regrinding-assisted flotation could mitigate Zn misreporting. XRF, XRD, zinc phase analysis, flotation experiments, and process mineralogical characterisation were used to determine Zn deportment and evaluate the effect of regrinding on mitigating Zn misreporting to the pyrite concentrate. The results showed that the Zn was mainly associated with sphalerite rather than water-soluble Zn species. Reagent adjustment and additional cleaning stages reduced Zn misreporting moderately, but were insufficient to fully separate Zn-bearing phases from the pyrite concentrate. Process mineralogical characterisation further revealed that Zn was predominantly hosted in sphalerite, which commonly occurred as attached, locked, or disseminated particles associated with pyrite. Under the same Na2SiO3 dosage, regrinding-assisted flotation reduced the Zn grade in the final pyrite concentrate from 0.29% to 0.14%, indicating reduced Zn misreporting. These findings indicate that close sphalerite–pyrite association and incomplete sphalerite liberation were the principal mineralogical factors governing Zn misreporting, while regrinding-assisted flotation provides a practical approach for reducing Zn misreporting to pyrite concentrates. This study provides a process mineralogy-guided approach for diagnosing Zn misreporting and improving impurity control in pyrite-rich concentrate production.