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Collaborative Consortium for Coarse Particle Processing Research

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About the Collaborative Consortium for Coarse Particle Processing Research

The Collaborative Consortium for Coarse Particle Processing Research (CPR) was initiated by the Sustainable Minerals Institute’s Julius Kruttschnitt Mineral Research Centre (JKMRC) to tackle the multidisciplinary aspects of coarse particle processing such as flotation, comminution, classification, and equipment design and process chemistry. 

As the demand for copper and other base metal production continues to increase, so too does the pressure on mining operations to become more water and energy efficient. The processing of coarse particles is considered one of the key research areas for developing improved energy efficiency of mineral processing operations.

From 2020-2025, the CPR Program Phase 1 delivered important progress in areas such as flotation performance, modelling, circuit design, and process chemistry. Phase 2 is currently underway with new industry partners and will run from 2025-2030. 

    Aims

    More copper will be needed by 2050 than all copper mined in human history, so improved mining and processing technologies are needed to help mining operations to achieve this goal while becoming more sustainable and reducing their environmental, water and energy impact, even as ore grades decline and deposits become harder to access and process.

    One area that shows strong promise to deliver on this is coarse particle flotation (CPF). Better processing of coarse particles can bring a range of benefits, including higher plant throughput, lower energy use, improved water recovery, reduced Acid Mine Drainage, increased metal recovery, and even access previously unviable ore deposits.

    To support and coordinate these efforts, the SMI–JKMRC established the Collaborative Consortium for Coarse Particle Processing Research (CPR Program). The consortium's goal was to bring together expertise, reduce duplicated work, and create shared value for all participants. By contributing once, members gained access to a wide range of research outcomes across multiple areas. 

    Objectives

    The CPR focuses on five main objectives: 

    • Maximising the recovery of coarse particles. 
    • Developing ways to predict coarse particle performance. 
    • Optimising overall circuit design. 
    • Understanding the technical and economic benefits of HydroFloat®. 
    • Supporting scale-up of the technology for real operations.

    Phase 2: 2025-2030

    Program Chair

    Professor Rick Valenta
    View Rick Valenta's research profile

    Program Director

    Associate Professor Liza Forbes
    View Liza Forbes' research profile

    Program Deputy Directors

    Dr Bellson Awatey
    View Bellson Awatey's research profile

    Dr Unzile Yenial Arslan
    View Unzile Yenial Arslan's research profile

    Scientific Advisor

    Associate Professor Kym Runge
    View Kym Runge's research profile

    Administration team

    Claire Dover

    Andrea Gray
    View Andrea Gray's profile

    Sherrie Palmer
    View Sherrie Palmer's profile

    Senior Workshop Technical Officer

    Mick Kilmartin
    View Mick Kilmartin’s profile

    Researchers

    Dr Candice Brill
    View Candice Brill's research profile

    Dr Susana Lima Goncalves Brito e Abreu
    View Susana Lima Goncalves Brito e Abreu’s research profile

    Professor Nick Cook
    View Nick Cook 's research profile

    Dr Farhana Diba
    View Farhana Diba's research profile

    Dr Lucia Dzinza
    View Lucia Dzinza’s research profile

    Dr Gordon Forbes
    View Gordon Forbes's research profile

    Dr Marko Hilden
    View Marko Hilden’s research profile

    Dr Mayra Jefferson
    View Mayra Jefferson's research profile

    Dr Qi Shao
    View Qi Shao’s research profile

    Anna Skliar
    View Anna Skliar's research profile

    Lizette Verster
    View Lizette Verster's research profile

    Dr Dion Weatherley
    View Dion Weatherley's research profile

    Professor Mohsen Yahyaei
    View Mohsen Yahyaei's research profile

    Phase 2: 2025-2030

    Full partnership participation to be announced soon.

    Phase 1: 2020-2025

    The program was financially supported by;

    • Aeris Resources, 
    • Anglo American, 
    • Eriez Flotation Division, 
    • Glencore, 
    • Hudbay, 
    • Newcrest Mining, 
    • Newmont, 
    • Rio Tinto, 
    • UQ's strategic Complex Ore Bodies program (which later transformed into the "Resourcing Decarbonisation" program)

    Phase 2: 2025-2030

    Full project details to be announced soon.

    Phase 1: 2020-2025

    An Experimental Study of the Hydrodynamics Inside a Fluidised Bed Flotation Cell 

    The aim of this project was to develop a detailed understanding of the hydrodynamic behaviour of fluidised bed flotation cells under varying particle size distributions, densities, and operating conditions, and to link this behaviour to flotation performance. Specifically, the project sought to:

    • Quantify hydrodynamic behaviour (bed expansion and porosity) under two- and three-phase conditions, using both synthetic materials (silica and hematite) and real copper ore (El Soldado).
    • Measure flotation outcomes across a controlled range of particle sizes, water rates, and air rates, in order to identify how hydrodynamics influence metallurgical performance.
    • Develop and validate CFD models of the laboratory-scale cells, using them to mechanistically explain observed fluidisation and flotation behaviour and provide predictive capacity for scale-up.

    For more information, please contact project leader Dr Bellson Awatey (b.awatey@uq.edu.au).

        An Assessment of the use of the Loesche VRM for HydroFloat® Feed Preparation

        This project had the following objectives:

        • To conduct "proof of concept" testing of VRM treatment strategies in preparing the feed for the HydroFloat®.
        • To compare the characteristics of the feed prepared by VRM and the conventional laboratory-scale grinding circuit and the related HydroFloat® performances.

        For more information, please contact project leader Associate Professor Kym Runge (k.runge@uq.edu.au).

        Development of a Robust Bubble Size Measurement Method

        The project aimed to develop a software solution for improved (speed and accuracy) bubble size measurement in images collected with the PVM probe

        The specific objectives were:

        • Identify the best CNN architecture for bubble detection.
        • Train CNN on labelled image dataset.
        • Evaluate the effectiveness of the trained CNN.
        • Develop easy-to-use software solution.

        For more information, please contact project leader Dr Gordon Forbes (g.forbes@uq.edu.au).

        Development of a Semi-Empirical Model of the HydroFloat® Cell

        The objective of this project was to develop a semi-empirical model of the HydroFloat® flotation cell. 

        • Designing,constructing and commissioning a fully instrumented pilot plant rig capable of performing HydroFloat® experiments. 
        • Development of a procedure for measuring bubble size in theHydroFloat® pilot cell. 
        • Deployment of the pilot rig to Newcrest’s (now Newmont’s) Cadia operation to measure performance in theHydroFloat® pilot cell, when processing deslimed scavenger tail, under a range of different conditions. 
        • Regression analysis of the pilot plant data to determine key performance drivers. 
        • Full scale surveys of the two different installations of HydroFloat® cells at Cadia and analysis of the data produced to assess whether the drivers observed at pilot scale, remained applicable at larger scale. 
        • Use of the learnings developed in the pilot and full-scale testing to assess different process modelling options. 
           

        For more information, please contact project leader Associate Professor Kym Runge (k.runge@uq.edu.au).

        Improving Coarse Particle Recovery in Conventional Flotation Cells 

        The aims of this project were to improve coarse particle recovery in a conventional flotation cell.

        This project is a PhD study which consists of the following scope of work:

        • Literature review to identify cell design and operational modifications for testing that would have the potential to minimise coarse particle detachment and maximise coarse particle froth recovery in a conventional cell.
        • Design, construction and commissioning of a 1m3 conventional cell, in partnership with Tailings Technology, to test the identified cell design and operational modifications.
        • Test work in a 60-litre laboratory flotation cell to determine measurement protocols for assessing suspension and perform a preliminary suspension study,
        • Test work using the pilot 1m3 cell to measure suspension capability, froth disturbance and gas distribution when the cell was operated using different impeller sizes, baffling arrangements, impeller clearance, air rate and % solids.
        • Construction of a froth mesh and test work to determine the extent to which it can reduce froth disturbance.
        • Use of regression analysis and optimisation to determine the design and operation conditions that have the greatest potential to increase coarse particle flotation recoveries
        • Development of a 2 phase CFD model of the 1m3 conventional flotation cell and simulation to hydrodynamically explain the reasons for the results obtained in the pilot plant test work.

        For more information, please contact project leader Associate Professor Kym Runge (k.runge@uq.edu.au).

        Key Chemistry Drivers for HydroFloat® Flotation Performance 

        The project aimed to achieve the following:

        • Understand the interaction mechanisms between chemistry and hydrodynamics in the fluidised bed flotation system, examining how these factors influence the system's operation and efficiency.
        • Understand the coalescence mechanisms, specifically within the novel hydrodynamic environment created by the fluidised bed flotation system.
        • Develop a basis for optimising bubble size using frothers in the coarse particles' flotation process. 

        For more information, please contact project leader Associate Professor Liza Forbes (l.forbes@uq.edu.au).

        Novel Reagent Addition Method 

        The project aimed to improve coarse particle recovery by dosing collector reagents as an aerosol.

        The specific objectives were:

        • Develop an effective and safe method of dosing aerosol collectors to laboratory-scale flotation systems
        • Determine whether aerosol collector dosing increases coarse particle recovery in conventional- and fluidised bed flotation systems
        • Determine the mechanisms by which aerosol collector dosing improves coarse particle recovery

        For more information, please contact project leader Associate Professor Liza Forbes (l.forbes@uq.edu.au).

        Side Quest: Antapaccay Zero Conditioning 

        The overall objective of this project was to test the impact of collector aerosol dosage compared to more traditional method of collector pre-conditioning.

        The specific objectives of the work were to:

        • To investigate the impact of different collector dosing methods on copper recoveries in fluidised bed flotation.
        • To investigate collector deportment in coarse particle flotation using different collector dosing methods.

        For more information, please contact project leader Associate Professor Liza Forbes (l.forbes@uq.edu.au).

        Side Quest: Building Additional JKHFmini Units 

        The objective of this project is to build and provide additional JKHFmini prototype units for the CPR Program sponsors. While it is acknowledged that the JKHFmini is not yet developed to the point of commercialisation, these additional units are intended to be used for "beta testing" at the sponsor's laboratories.

        For more information, please contact project leader Lizette Verster (l.verster@uq.edu.au).

        Side Quest: Trailblazer

        The work aims to test the ability of the JKHFmini to predict full-scale fluidised bed flotation performance and develop a scale-up procedure and will consist of:

        • Refining the prototype design based on industry testing.
        • Comparing the JKHFmini to pilot- and full-scale performance to identify a scale-up approach.
        • Combining physics-based (CFD) modelling and empirical modelling using the JKHFmini ore-specific data to develop a scale-up procedure.
        • Preliminary validation of the scale-up procedure.

        The JKHFmini prototype is an essential component for model development as it provides information about ore characteristics and will be used to calibrate empirical models.

        For more information, please contact project leader Lizette Verster (l.verster@uq.edu.au).

        Small-Scale Test Development 

        This project aimed to design and build a novel small-scale test apparatus, requiring approximately 1-2 kg of sample per test, and to develop a test procedure to allow for rapid and efficient screening of ores under different test conditions to assess their amenability for treatment by the HydroFloat®.

        The work was carried out in four stages:

        • Design and Build.
        • Commissioning.
        • Test Development.
        • Site Validation.

        For more information, please contact project leader Lizette Verster (l.verster@uq.edu.au).

        Teeter-Bed Flotation Waste Rejection Circuit Options

        This project aimed to develop a methodology for characterising ore breakage response, mineral deportment, and liberation to support the simulation of grinding circuits incorporating HydroFloat® technology 

        The scope of work of this project consisted of: 

        • Use of density separation to produce particle classes of similar mineral liberation for different sized particles ranging from -2.36mm to +300 micron.
        • Measure single particle breakage behaviour of these proxy liberation classes in Short Impact Load Cells (SILC) and Rigidly Mounted Roll Mill (RMRM) devices.
        • Characterise progeny in terms of size, liberation and surface exposure using Xray tomography 
        • Demonstrate the application of these data in an integrated circuit simulation.

        For more information, please contact project leader Professor Mohsen Yahyaei (m.yahyaei@uq.edu.au).

        The CPR Program was designed primarily to deliver impactful research for the minerals processing industry. However, the research team has also invested significant efforts to make the funding of the program more widely available through more traditional academic output, such as peer-reviewed publications and conference presentations. The wider dissemination of knowledge through these channels is expected to further facilitate future research on coarse particle processing in other centres around the world.

        Peer-reviewed journal papers

        1. Brill, C., I. Verster, G. V. Franks and L. Forbes, (2022) "Aerosol Collector Addition in Coarse Particle Flotation – A Review." Mineral Processing and Extractive Metallurgy Review: 1-10 https://doi.org/10.1080/08827508.2022.2095377 
        2. Forbes, L, Brill, C., and Verster, I. (2023). Aerosol collector addition in flotation – evaluation of delivery options. Physicochemical Problems of Mineral Processing. https://doi.org/10.37190/ppmp/174475
        3. Brill, C., Verster, I., & Forbes, L. (2025). Aerosol Collector Addition in Flotation – Pathways to Improvement Through Understanding of the Mechanisms. Mineral Processing and Extractive Metallurgy Review, 1–12. https://doi.org/10.1080/08827508.2025.2540316
        4. Verster, I., Awatey, B., Forbes, L., Morrison, A., Mankosa, M., and Runge, K. (2024). Small-scale fluidised bed flotation device for ore amenability testing. Minerals Engineering 216 108848 108848. https://doi.org/10.1016/j.mineng.2024.108848
        5. Demir, K., Morrison, A.J., Evans, C., Kohmuench, J., Runge, K., (2024) "The bubble size produced in a pilot HydroFloat® cell and its effect on Flotation", Minerals Engineering, Vol 218, pp 109021 https://doi.org/10.1016/j.mineng.2024.109021
        6. Forbes, L., C. Brill, I. Verster and G. V. Franks (2025). "Novel reagent addition method for improved copper recovery." Cleaner Engineering and Technology 26: 100958 https://doi.org/10.1016/j.clet.2025.100958
        7. Skliar, A., I. Verster, U. Yenial-Arslan, G. Forbes and L. Forbes "Impact of the Fluidised Bed Flotation Hydrodynamics on Bubble Interfacial Film Rupture and Coalescence." Mineral Processing and Extractive Metallurgy Review: 1-12. https://doi.org/10.1080/08827508.2025.2542830
        8. Bellson Awatey, Isabella Verster, Kym Runge, "Understanding Copper Flotation in the JKHFmini: a Small-scale Fluidised Bed Cell," Minerals Engineering, 2026 Volume 235, Part 2, https://doi.org/10.1016/j.mineng.2025.109864

          Conference proceedings

          • Demir, Konuray, Whiten, W. J., Morrison, Angus, Runge, Kym, Evans, Cathy, and Kohmuench, J. (2019). “Developing a semi-empirical model of the HydroFloat™ Cell: part 1: a hindered settling classification model.” Flotation’19, Cape Town, South Africa, 11-14 November 2019.
          • Morrison, A.J, van Heerden, M., Sweet, J., (2019), “The hydrodynamics of a fluidised bed flotation device using positron emission particle tracking”, Flotation’19. Cape Town, South Africa, 11-14 November 2019.
          • Morrison, A.J. S.Kia, K. Demir, and K. Runge , (2021) "The role of the fluidised bed in the HydroFloat® as a coarse particle recovery device", XXXI IMPC, Melbourne, Australia
          • Verster, I., Awatey, B., Forbes, L., Morrison, A., Mankosa, M., and Runge, K. (2023). Small-scale Fluidised bed flotation device for ore amenability testing. Flotation '23, Cape Town, South Africa, 6-9 November 2023.
          • Demir, K., A.J. Morrison, C. Evans and J. Kohmuench, K. Runge The Bubble Size Produced in a Pilot HydroFloat® Cell and Its Effects on Flotation, Flotation '23, 2023, Cape Town, South Africa, 6-9 November 2023.
          • K. Demir, A. Morrison, K. Runge, C. Evans and J. Kohmuench, (2021) "The drivers of HydroFloat® performance in a metalliferous application", XXXI IMPC, Melbourne, Australia
          • Miceli, H., Yahyaei, M., Hilden, M., Runge, K., Tavares, L.M. (2022) "The breakage characteristics of different liberation classes during primary breakage". In: 17th European Symposium on Comminution & Classification, Toulouse, France. p. 114.
          • Brill, C., Verster, I., Franks G. V., and Forbes, L. (2023). " Aerosol collector addition in coarse particle flotation" Advanced Chemistry World Congress, Barcelona, Spain, 27 - 28 March 2023, Keynote Address
          • Awatey, B, Verster, I., Forbes, L., and Runge, K., (2024). Testing the scalability of a small-scale fluidised bed device for coarse particle flotation. XXXI IMPC-International Mineral Processing Congress, Washington, DC, United States, 29 September - 3 October 2024. Washington, DC, United States: IMPC-International Mineral Processing Congress
          • Skliar, A., Verster, I., Yenial Arslan, U., Forbes, G., and Forbes, L. (2024). Coalescence in Fluidised Bed Flotation: Understanding the Interplay Between Chemistry and Hydrodynamics. XXXI International Minerals Processing Congress, Washington, DC United States, 29 September - 3 October 2024. Washington, DC United States: SME.
          • Brill, C., Verster, I., Franks, G. V., and Forbes, L. (2024). Effect of Aerosol Collector Dosing on Flotation of a Complex Ore. XXXI International Minerals Processing Congress, Washington, DC United States, 29 September - 3 October 2024. Washington, DC United States: SME.
          • Frausto, J.J., Awatey, B., Runge, K., Valdés, F, Martens, J., (2024) Integrating the Vertical Roller Mill technology with coarse flotation to significantly reduce comminution energy requirements - a preliminary assessment., XXI Syensqo Conference, Mexico City

            Collaborative Consortium for Coarse Particle Processing Research in the news

            1. Collaborative Approach to Mining Research Bears Fruit, Australian Mining Review, March 2025, https://australianminingreview.com.au/issue/2025/03/collaborative-approach-to-mining-research-bears-fruit https://australianminingreview.com.au/issue/2025/03/collaborative-approach-to-mining-research-bears-fruit/
            2. Sustainable Minerals Institute recognised at the UQ Awards, MINING, September 2022, https://miningmagazine.com.au/sustainable-minerals-institute-recognised-at-uq-awards
            3. Reducing the Daily Grind, The Chemical Engineer, 54-58, April 2021, https://www.thechemicalengineer.com/features/reducing-the-daily-grind
            4. Top miners, University of Queensland join forces to research coarse particle processing, The Northern Miner, October 2020, https://www.northernminer.com/subscribe-login/?id=1003823677
            5. Anglo American, Glencore, Newcrest and Newmont join coarse particle recovery consortium, International Mining, October 2020, https://im-mining.com/2020/10/15/anglo-american-glencore-newcrest-newmont-join-coarse-particle-recovery-consortium/

              Contact us

              Get in touch to learn more about the CPR Consortium.

              Current Program Director

              Associate Professor Liza Forbes

              Principal Research Fellow,
              Julius Kruttschnitt Mineral Research Centre

              JKMRC homepage