Functional PS-DVB-CTAB-PAX Nanocollectors to Promote Selective Fine-Particle Chalcopyrite Flotation

The low recovery of fine chalcopyrite particles and the limited Cu/Fe selectivity with conventional thiol collectors prompted the evaluation of a Polystyrene–Divinylbenzene–Cetyltrimethylammonium Bromide–Potassium Amyl Xanthate (PS-DVB-CTAB-PAX) polymeric nanocollector. The copolymer was synthesized by emulsion polymerization and characterized using Total Organic Carbon (TOC) analysis, Scanning Electron Microscopy (SEM), Transmission Electron Microscopy (TEM), Particle Size Analysis, and contact angle measurement. Its performance was tested in a Hallimond cell (150 mL) using a synthetic industrial water solution (0.010 mol/L NaCl + 0.005 mol/L CaCl2) at a natural pH range of 6.0 to 8.0. PAX concentrations ranged from 0 to 16.19 mg L−1, and nanocollector doses equivalent to 0 to 45 mg g−1 of solid were tested. The nanocollector increased chalcopyrite recovery to 98 ± 1% for the −53 + 38 µm size fraction and maintained values greater than 95% in the coarse fractions, outperforming PAX across the entire dosage range. The PAX + nanocollector combination achieved the same recovery by reducing the total xanthate dosage by one-third, demonstrating a synergistic effect. TOC assays showed preferential adsorption of 96.6% on chalcopyrite versus 86.4% on pyrite, a difference that explains the observed Cu/Fe selectivity (pyrite floatability < 70%). The contact angle of chalcopyrite increased from 56.4° (water) to 86.5° in the presence of the nanocollector, demonstrating the generation of localized superhydrophobicity that reduces interfacial free energy and favors bubble–particle adhesion, whereas pyrite showed lower values of 51.1°, 58.3°, and 75.1°, confirming its more hydrophilic nature. These findings indicate that PS-DVB-CTAB-PAX enables optimized copper sulfide recovery, reduced thiol collector consumption, and improved metallurgical selectivity, making it a promising alternative for flotation circuits with high ionic strength water and for scaling up to pilot tests.