Optimization of the Froth Flotation Process for the Enrichment of Cu and Co Concentrate from Low-Grade Copper Sulfide Ore

The increasing demand for critical raw materials such as copper and cobalt highlights the need for efficient beneficiation of low-grade ores. This study investigates a copper–cobalt sulfide ore (0.99% Cu, 0.028% Co) using froth flotation to produce high-grade concentrates. Various types of surfactants are applied in different ways, each serving an essential function such as acting as collectors, frothers, froth stabilizers, depressants, activators, pH modifiers, and more. A series of flotation tests employing different collectors (SIPX, PBX, AERO, DF 507B) and process conditions was conducted to optimize recovery and selectivity. Methyl isobutyl carbinol (MIBC) was consistently used as the foaming agent, and 700 g/L was used as the slurry density at 25 °C. Dosages of 30 and 100 g/t1 were used in all tests. Notably, adjusting the pH to ~4 using HCl significantly improved cobalt concentrate separation. The optimized flotation conditions yielded concentrates with over 15% Cu and metal recoveries exceeding 80%. Mineralogical characterization confirmed the selective enrichment of target metals in the concentrate. The results demonstrate the potential of this beneficiation approach to contribute to the European Union’s supply of critical raw materials.