The processing of low grade mineral ores using large scale flotation cells is obviously more advantageous than smaller-scale processing. Large-scale flotation cells have become increasingly important for effective volume scale-up. In this study, the latest and largest flotation cell in China, with an effective volume of 680 m³, is considered. Hydrodynamics and flotation kinetics analyses are conducted using computational fluid dynamics (CFD) simulation. It is demonstrated that the flotation cell with a typical impeller produces suitable hydrodynamics for mineral particles based on analysis of the flow pattern, gas dispersion and solid suspension. The performance of the large-scale flotation cell is studied using hydrodynamic performance parameters. The variation of the performance parameters, such as the power number (N_p), the Froude number (F_r), the air flow number (N_a), and so on, with the flotation cell volumes, followed trends similar to that of previous cells of a different size, which were proven to be effective for engineering applications. To decrease the detachment of mineral particles, a new type of impeller, for which the impeller plate is a hyperbolic curve, viz. an arc impeller, was developed. Compared with the typical impeller, the arc impeller expands and lifts the low circulating flow, thereby shortening the transportation distance of the mineral particles. The data indicates that kinetic eddy dissipation plays a key role in determining the collision kernel and collision probability profile. The newly designed arc impeller leads to a higher collision probability than the typical impeller, resulting in better flotation performance. This research should aid in the optimization of the structure of the 680 m³ flotation cell.

Precise evaluation of flotation performance facilitates process optimization and separation efficiency enhancement, while bubble load quantification emerges as a critical diagnostic tool increasingly recognized within mineral processing research. This study introduces an enhanced bubble load measurement system that integrates equilibrium principles with vacuum suction technology. The system ensures stable and continuous sampling, significantly improving the precision and efficiency of bubble load measurements in flotation processes. Through synchronized testing in roughing and scavenging operations, dynamic variations in bubble load and their relationships with particle size and ore grade were analyzed. Results reveal contrasting trends: bubble load increased during roughing but decreased during scavenging. The distributions of particle size and mineral content carried by bubbles further highlight correlations between bubble stability and flotation efficiency. These findings provide practical guidelines for optimizing equipment design and operational parameters, demonstrating significant potential for advancing intelligent monitoring in mineral processing systems.

The fundamental processes in flotation involve the collision, adhesion, and detachment between bubbles and mineral particles. The hydration film, which is commonly found on the surface of both particles and bubbles, hinders the effective interaction between the gas, liquid, and solid phases. To address this challenge, this paper introduces a Reverse Sequence Collision Flotation (RSCF) model, which changes the conventional sequence of gas–liquid–solid interactions. Theoretical analysis reveals that, compared to the traditional flotation process, the proposed model enhances the collision and adhesion between bubbles and mineral particles. Building upon this, preliminary studies were carried out to develop both a single-bubble static reverse sequence collision testing system and a multi-bubble dynamic reverse sequence collision testing system. These systems were used to conduct both qualitative and quantitative analyses of the collision and adhesion effects, thereby confirming the feasibility and separability of the RSCF model. Furthermore, the study demonstrated that mechanical disturbance can be used to adjust the bubble loading, thus creating a new enrichment strategy based on the RSCF model. In conclusion, the RSCF model presents a novel approach to improving flotation efficiency. Future research should focus on optimizing this model and exploring its application potential across different mineral systems.