A review of the effect of rheology on grinding, classification, flotation, and leaching processes

Slurry rheology, which encompasses the overall impact of inter-particle interactions such as aggregation, dispersion, and sedimentation particularly pronounced under fine-particle conditions, has long been acknowledged as a critical factor in determining processing efficiency. Fine particles can increase slurry viscosity and yield stress, making it more difficult to pump, transport, and process. These complex flow behaviors in slurries can influence various unit operations, including grinding, classification, flotation, and leaching. For example, in flotation, poor rheological control can hinder bubble-particle attachment, reducing recovery rates, while in dewatering, high viscosity can impede filtration and thickening processes. To address these challenges, advancements in rheology modifiers, dispersants, and process optimization strategies are being explored to improve the handling and processing of such complex ores, ensuring sustainable and economically viable mining operations. This review provides a comprehensive framework for understanding and leveraging rheological principles to enhance mineral processing performance in modern mining operations.