Sodium Polyacrylate as a Rheological Modifier and Selective Depressant in Cu2+-Activated Kaolin–Chalcopyrite Flotation Under Saline Conditions

This study investigates sodium polyacrylate (NaPA) as a rheology modifier and selective depressant in the flotation of Cu2+-activated kaolin–chalcopyrite under industrial water (IW) and seawater (SW) conditions. The work addresses a critical gap in saline systems: how an anionic polymer simultaneously influences clay activation, sulfide floatability, aggregate dispersion, and pulp rheology by varying the medium’s ionic composition. Microflotation, zeta potential, adsorption, yield strength, and Focused Beam Reflectance Measurement (FBRM) assays were used to establish structure–property–response relationships. In IW, Cu2+ strongly promoted NaPA adsorption onto both minerals, shifting them toward more negative potentials and significantly reducing selectivity: kaolin recovery decreased from 86.5% to 40.0% at 50 ppm NaPA. In comparison, chalcopyrite recovery fell below 30% at 100 ppm NaPA. In SW, NaPA maintained its depressant effect on kaolin without affecting chalcopyrite flotation, which remained above 90%. This behavior is consistent with reduced polymer adsorption at high ionic strength, where ionic shielding and coiling limit its interaction with chalcopyrite but allow sufficient adsorption onto kaolin to inhibit the collector’s action. Rheological and FBRM results support this interpretation, showing a decrease in yield strength and aggregate size after NaPA addition, with a more pronounced effect in IW than in SW.