The flotation process in seawater is highly complex and multifaceted, wherein the chemistry is very different to that of pure water. The high saline environment compresses the electrical double layers resulting in (i) enhancement of the floatability for surfaces that are already hydrophobic; (ii) mitigation of the slime coatings; (iii) increase of the entrainment; (iv) reduction of the bubbles size; and (v) better froths stability. In parallel, the secondary ions present in seawater cause a colloidal precipitation and a strong buffering effect, which difficult the operation at high alkaline condition. The objective of this review is to present a summary of the current knowledge on the subject of seawater flotation processes, highlighting the copper sulphide ores flotation. This review includes a description of the underlying flotation mechanisms affected by the presence of saline water and seawater, as well as a more practical description of industrial flotation operations.

In the present work an intense bibliographic search is developed, with updated information on the microscopic fundamentals that govern the behavior of flotation operations of chalcopyrite, the main copper mineral in nature. In particular, the effect caused by the presence of pyrite, a non-valuable mineral, but challenging for the operation due to its ability to capture a portion of collector and float, decreasing the quality of the concentrate, is addressed. This manuscript discusses the main chemical and physical mechanisms involved in the phenomena of reagent adsorption on the mineral surface, the impact of pH and type of alkalizing agent, and the effect of pyrite depressants, some already used in the industry and others under investigation. Modern collector reagents are also described, for which, although not yet implemented on an industrial scale, promising results have been obtained in the laboratory, including better copper recovery and selectivity, and even some green reagents present biodegradable properties that generate a better environmental perspective for mineral processing.

Given the active growth of emerging technology industries, it has become essential to have large quantities of critical metals to meet the current demand. In the Chilean mining industry, there is a depletion of high-grade mineral ores, and there is hence a need to increase production levels in the copper industry and diversify its market by extracting other elements. One of the strategies is to foster the production of lithium batteries, but the manufacture requires reserves of cobalt (Co) and manganese (Mn). Currently, Co reserves are not being exploited in Chile, and Mn production is almost negligible. This is due to the apparent shortage of high-grade ores on the land surface of the country. Given this scenario, the seabed manganese nodules are presented as a good alternative due to their high average grades of Co and Mn, which in turn would allow the growth of strategic value-added industries including lithium battery production. Chile’s current environmental regulations prevent the exploitation of marine resources. However, given technological advances worldwide, both in collection mechanisms and extractive processes, in addition to the needs generated from the future strategic plans, leads us to think about a project to exploit manganese nodules locally.

Polymers have interesting physicochemical characteristics such as charge density, functionalities, and molecular weight. Such attributes are of great importance for use in industrial purposes. Understanding how these characteristics are affected is still complex, but with the help of molecular dynamics (MD) and quantum calculations (QM), it is possible to understand the behavior of polymers at the molecular level with great consistency. This study was applied to polymers derived from polyacrylamide (PAM) due to its great use in various industries. The polymers studied include hydrolyzed polyacrylamide (HPAM), poly (2-acrylamido-2-methylpropanesulfonate) (PAMPS), polyacrylic acid (PAA), polyethylene oxide polymer (PEO), and guar gum polysaccharide (GUAR). Each one has different attributes, which help in understanding the effects on the polymer and the medium in which it is applied along a broad spectrum. The results include the conformation, diffusion, ion condensation, the structure of the water around the polymer, and interatomic polymer interactions. Such characteristics are important to selecting a polymer depending on the environment in which it is found and its purpose. The effect caused by salinity is particular to each polymer, where polymers with an explicit charge or polyelectrolytes are more susceptible to changes due to salinity, increasing their coiling and reducing their mobility in solution. This naturally reduces its ability to form polymeric bridges due to having a polymer with a smaller gyration radius. In contrast, neutral polymers are less affected in their structure, making them favorable in media with high ionic charges.

The presence of fine and ultra-fine gangue minerals in flotation plants can contribute to sub-optimal valuable ore recovery and incomplete water recycling from thickeners, with the performance of the latter equipment relying on adequate flocculation. In order to study the dependence of the flocculation process on the suspension-flocculant mixing conditions, a series of experiments—chosen using chemometric analysis—were carried out by varying mixing conditions, solid concentration, water salinity and flocculant dosage. To this purpose, two different tailings (both featuring coarse and fine content) were considered and a response surface methodology based on a Doehlert experimental design was used. The results suggest that the operational conditions to optimise the flocculated tailings settling rate and the suspended solids that report to a thickener overflow are not necessarily the same. This is a reasonable outcome, given that the settling rate depends on the coarse aggregates generated in the slurry, while the overflow solids content is governed both by either fine particle content (and its characteristics) or small aggregates. It is inferred that to maximise dewatering performance two stages should be involved—a separate treatment of the thickener overflow to remove fine content and thickening at optimal flocculant dosage to enhance this process.