Enhanced Rougher Recovery of Ultrafine Molybdenum Tailings Using a Novel Pilot-Scale Turbulent Micro-Vortex Mineralizer

Constrained by the low grade and poor floatability of the run-of-mine ore, the beneficiation of porphyry-type copper–molybdenum sulfide ores generates large quantities of molybdenum tailings, leading to significant environmental risks and resource losses and necessitating urgent recovery and reutilization. In this study, a representative sample of molybdenum tailings with a Mo grade of 0.354% was investigated to analyze its process mineralogy. The results show that molybdenite predominantly exists as fine, flaky particles intimately intergrown with quartz, pyrite, and aluminosilicate minerals, exhibiting an extremely low degree of liberation and an overall ultrafine particle size. Laboratory flotation tests show that the flotation kinetics conform to a first-order model; however, a considerable amount of molybdenum remains in the tailings, indicating that the mineralization process needs to be intensified. Through structural optimization and confined-space design, a vortex-based mineralization reactor was developed. Computational fluid dynamics simulations demonstrate that the mineralizer can generate flow fields with high turbulence intensity and dissipation rates and can induce high-energy, small-scale micro-vortices. On this basis, a semi-industrial rougher flotation system was established by coupling the developed mineralizer with a flotation column. Under optimized operating conditions, namely a feed pressure of 0.06 MPa and an impeller frequency of 20 Hz, single-stage treatment of the tailings produced molybdenum concentrates with a grade of 1.90% and a recovery of 81.29%, while the Mo grade of the tailings was reduced to 0.08%. The results are markedly superior to those obtained using a conventional laboratory flotation cell, demonstrating a substantial enhancement in mineralization efficiency and molybdenum recovery. The proposed approach, therefore, provides a practical reference for the flotation recovery of molybdenum tailings as well as other micro-fine, low-grade metal tailings.