Microfluidic Pre-Concentration of Metals from Fine Flotation Tailings

The large volumes of fine flotation tailings constitute a persistent challenge for the conventional treatment of minerals due to their wide particle size distribution and their low metal contents. In this work, the potential of passive inertial microfluidics for the selective redistribution of mineral particles from actual copper flotation tailings is studied. A suspension of tailings was treated in a rectangular microfluidic channel in a laminar regime, without an external magnetic field or sheath flux. The solid fractions obtained were characterized in terms of particle size distribution, phase composition and element content. The microfluidic treatment induced a systematic distribution of the particles between the output fractions. The central fraction was enriched with coarser particles, the median particle size increasing from about 15 µm in the feed to about 20 µm, and had high concentrations of Cu, Fe, Ag and Zn, with enrichment factors reaching 2.0 to 2.7 depending on the element. On the other hand, the lateral fraction was mainly composed of finer particles (D50 ≈ 13 µm) and depleted in metalliferous phases. The elemental mass balance confirmed that the observed enrichment results from selective redistribution rather than from a loss of material. These results indicate that the separation of the particles cannot be explained solely by size effects and are consistent with a preferential migration of the denser and metal-rich particles towards stable inertial focusing trajectories.