Rethinking Mineral Processing for a Cleaner Future
As global demand for critical metals like copper continues to surge—driven by electrification, renewable energy infrastructure, and battery technologies—mining operations are under growing pressure to optimize resource use while reducing their environmental footprint.
One of the key challenges lies in improving the efficiency of flotation, the process that separates valuable mineral particles from the surrounding waste rock. Traditional flotation techniques struggle to recover larger mineral particles efficiently, often requiring excessive grinding, energy consumption, and water use.
This is where aerosol-based reagent delivery enters the scene—and where Tekceleo’s Micronice® ultrasonic nebulization technology plays a pivotal role.
Objectives and Method
In a 2025 peer-reviewed study published in Cleaner Engineering and Technology by researchers at the University of Queensland, scientists investigated a novel approach: introducing flotation collectors not in bulk solution, but as a fine aerosol mist carried by air bubbles.
The team compared two methods:
- Conventional preconditioning, where reagents are mixed into the slurry ahead of flotation,
- Aerosol addition, where reagents are introduced during the flotation process by nebulizing them into the air line using the Tekceleo Micronice® T45-M05 device.
They conducted tests across two systems:
- A mechanical flotation cell, typically used in processing plants.
- A fluidized bed flotation column, designed to handle coarser mineral particles with greater energy efficiency.
Micronice Technology’s Role in the Process
At the heart of this innovation was Tekceleo’s Micronice® T45-M05, an ultrasonic mesh nebulizer that produces a stable, monodisperse aerosol without altering the chemical composition of the reagent.
Instead of using high-pressure jets or heat, the Micronice device relies on low-energy piezoelectric vibration to atomize liquid into micrometer-scale droplets. In the University of Queensland study, this enabled the precise delivery of xanthate collectors directly into the flotation system’s air stream.
This method ensures a higher probability of collector contact with mineral surfaces, especially in larger particles where air bubble collision rates are naturally higher—turning flotation into a more targeted and efficient separation process.
For more information on the technology behind Micronice®, visit our Micronice product page.
Results and Key Findings
The results were clear and compelling:
- In fluidized bed flotation, aerosolized collector addition resulted in ~50% copper recovery for coarse particles (+425–850 µm), compared to only ~21% using traditional methods.
- This performance gain came without sacrificing selectivity—meaning valuable minerals were recovered without significantly increasing unwanted materials like pyrite.
- The Micronice® method also showed promise in simplifying industrial operations by eliminating the need for complex preconditioning tanks.
- Implementation required only a minor equipment modification: placing the nebulizer on the air line feeding the flotation column.
In summary, aerosol delivery improves both copper recovery rates and process sustainability, particularly in the treatment of coarse particles where traditional methods fail.
Conclusion and Future Perspectives
This research validates the role of Micronice® ultrasonic nebulization as a disruptive enhancement to industrial mineral processing.
By delivering reagents more precisely and efficiently:
- Mining companies can increase resource yield without additional energy or grinding,
- Operations can lower reagent consumption and water waste,
- Environmental risks associated with fine tailings and energy-intensive processing are reduced.
As the mining sector moves toward greener, more circular models, solutions like Micronice® offer a low-barrier, high-impact upgrade to existing infrastructure.
Tekceleo is proud to support scientific innovation with robust, field-ready aerosol generation systems. We believe this is just the beginning of what ultrasonic nebulization can bring to cleaner, smarter resource extraction.
📄 Access the full study here: DOI: 10.1016/j.clet.2025.100958
Related links:
Learn more about fluidized bed flotation and critical minerals in the energy transition.
