Froth flotation is the most widely used mineral processing technique in the raw materials industry. It separates valuable minerals from waste by exploiting differences in surface properties using chemical reagents. Despite its industrial importance, conventional flotation systems show reduced efficiency when processing fine (<20 µm) and coarse particles (>150 µm), resulting in significant mineral losses and lower resource efficiency. As ore grades continue to decline and demand for critical raw materials increases, improving flotation performance has become a major challenge in modern mineral processing.

FrothPiping introduces a novel froth fractionation device for the multi-stage, selective separation of ultrafine and coarse particles. Unlike conventional flotation, where froth primarily acts as a passive by-product, FrothPiping transforms the froth into an active separation medium. In this process, particle-loaded froth flows horizontally through a modular pipeline equipped with addition inlets (for wash water or reagents) and outlet drainage channels for selective discharge of particle fractions. Additional modules, such as ultrasonication, temperature control, or electromagnetic fields, can be integrated to further enhance selectivity. This approach significantly improves separation efficiency for fine and coarse particles in complex, multi-component systems.

The device can be integrated into existing flotation plants as an add-on or retrofit and will be commercialized through licensing to flotation equipment manufacturers. Mining companies benefit from higher selectivity and improved product yields, increasing profitability. By reducing process complexity, FrothPiping lowers operational costs through reduced energy, water, and reagent consumption. It also shows strong application potential in recycling, chemical engineering, and wastewater treatment, enabling selective recovery of valuable particle fractions from complex industrial streams.