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State-of-the-Art Gangue Entrainment Reduction Technologies in Mechanical Flotation Machines

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Gangue recovery mechanisms
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Submitted   Jul 25, 2026
Published   Sep 28, 2026
Issue    Vol 6 No 1 (2026)
DOI   10.25082/REE.2026.01.005

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Muammer Kaya corresponding author
Department of Mining Engineering, Osmangazi University, Eskişehir, Turkey
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Abstract

Nowadays, the froth flotation process generally recovers low-grade and complex ores in large quantities. But it suffers from gangue entrainment of fine particles, to obtain high-grade concentrate products. To increase the recovery of valuable minerals, clayey, pyritic, and fibrous ores must be ground to a much smaller size, along with gangue minerals. These finely ground minerals not only affect sub-flotation processes in recovering valuable minerals based on true flotation, but also lead to high entrainment. In flotation, chemically unselective entrainment occurs simultaneously with true flotation. Entrainment occurs without a direct attachment of particles to bubbles. Gangue transport mechanisms and entrainment reduction techniques are serious challenges in mineral separation. This manuscript focuses on undesired gangue recovery mechanisms and their state-of-the-art prevention methods in mechanical flotation cells to increase metallurgical performance, froth stability, and mobility. Several operational, physical, and chemical methods have been developed and used on an industrial scale to decrease the impact of entrainment in the froth phase. The advantages and disadvantages of froth washing, pulp desliming, chemical reagent/binder clay/coarse particle addition, high-intensity conditioning, barrier usage, and ultrasonic pretreatment for gangue rejection in pulp and froth phases of mechanical flotation machines are highlighted in detail. Previous froth washing trials and applications at pilot and industrial scales are comprehensively reviewed to mitigate the entrainment problem in mechanical flotation machines.

Keywords
flotation, entrainment, slime coating, entrapment, froth washing, wash water

Article Details

How to Cite
Kaya, M. (2026). State-of-the-Art Gangue Entrainment Reduction Technologies in Mechanical Flotation Machines. Resources and Environmental Economics, 6(1), 78-115. https://doi.org/10.25082/REE.2026.01.005
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This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.

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