Hydrodynamic Mechanisms of a Fractal Blade Enhancing the Pulp Conditioning and Flotation Separation of Fine-Grained Malachite and Quartz

High-intensity conditioning (HIC) is a common pretreatment process for enhancing the flotation of fine-grained minerals. This study introduces fractal theory into the structural design of pulp conditioning impellers. A fractal blade with multi-scale fractal edge features was proposed, and its separation performance was evaluated in a fine-grained malachite (−20 μm) and quartz flotation system. Computational fluid dynamics simulation revealed that the fractal blade altered the energy dissipation pattern. Compared with conventional rectangular blades, it induced stronger fluid compression and collision effects in localized regions. These hydrodynamic changes improved the suspension homogeneity and dispersion efficiency of fine-grained malachite. Furthermore, the fractal blade reduced the scale of turbulent vortices while increasing local turbulent kinetic energy and shear rates. This optimized turbulent flow field effectively reduced mass-transfer resistance and promoted interfacial interactions between flotation reagents and mineral particles. Adsorption experiments and optical microscopy indicated that after conditioning at 1500 rpm for 3 min, the fractal blade increased sodium oleate adsorption on malachite compared to the conventional blade. This enhanced adsorption promoted the aggregation of fine-grained malachite, increasing its aggregate size by 15.52%, while no significant aggregation was observed for quartz particles. Consequently, the single mineral flotation recovery of fine-grained malachite increased by 4.13%. For artificial mixed minerals, the copper concentrate grade and recovery were improved by 2.28% and 1.04%, respectively. This study provides a theoretical basis for equipment optimization and structural innovation design in HIC processes.