From the Mine to your Phone: Advances in Copper Flotation for a Sustainable Future

Mary Casey

HST 401

Professor Horgan

28 January 2026

I pledge my Honor that I have abided by the Stevens Honor System.

From the Mine to Your Phone: Advances in Copper Flotation for a Sustainable Future

If you take a look around the room, you might spot your phone charger, laptop, headphones, or light switches. You might look outside and see traffic lights, or go to your kitchen and heat up some Dino Nuggets in the microwave. All of these objects depend on copper, even the objects you cannot always see, like the wiring in your walls or air conditioning unit. The public rarely thinks about where this copper comes from, but as the world pushes toward renewable energy, such as electric vehicles and smarter technology, copper has become one of the most essential materials. The future of copper does not depend on mining more of it, however, instead it depends on how it is separated from rock, using a process called flotation.

Copper demand is constantly increasing. According to the industry and sustainability research, copper is vital for electricity, clean-energy infrastructure, EVs, and nearly every modern technology the world relies on. Simultaneously, the quality of the copper ore is declining, as most copper ore today contains only about 0.5%-1% actual copper. In other words, for every ton of rock mined, only a handful of copper is recovered, so an efficient process is critical. 

Copper flotation is the process of turning low-grade rock into usable copper concentrate. After the ore is crushed, it is mixed with water and reagents, where air is injected into the slurry, creating bubbles. One of the reagents is copper-selective and covers the copper particles with a hydrophobic layer, where such particles attach the air bubbles. The bubbles float to the surface and are collected, increasing copper concentration from less than 1% to around 30%. Without the flotation process, mining alone would yield very little usable copper. 

I worked at ASARCO Ray Mine Complex this past summer, and what excited me about flotation was how much it has evolved in response to environmental and economic pressures. Metallurgists and engineers are currently developing new reagent chemistry that improves copper selectivity while reducing chemical waste. Instead of older, more expensive, and more aggressive chemicals, newer collectors and frothers are being developed to work more efficiently with less environmental impact. As a result, copper recovery would increase with less input, which is a positive factor for both mining companies and the ecosystem. 

Another major advancement is the improvement of fine particle recovery. The degrading copper ore grade causes copper particles to become smaller and harder to capture; however, new flotation cell designs (such as columns) and improved bubble control allow for plants to recover copper that would normally end up lost in tailings. Efficient recovery of the fine particles not only increases output but also reduces the amount of waste material that is left behind. 

Technology has also transformed how flotation systems are controlled. Plants today are increasingly using smart sensors, automation, and AI-based control systems to monitor and optimize flotation in real time. Instead of relying on human controls, the systems adjust air flow, reagent dosage, and pulp conditions consistently, which maximizes efficiency while minimizing energy and water use. Flotation is becoming more precise, consistent and sustainable due to the shift toward intelligent control. 

Advancements in flotation contribute heavily to environmental benefits. Improved flotation technology reduces water consumption, lowers energy demand, and decreases the overall mining footprint. Water scarcity and climate change are current concerns, so such improvements matter just as much as copper production itself. 

Beyond copper flotation, recycling plays a vital role in copper’s sustainability story. Copper is 100% recyclable, and recycling it uses up to 85% less energy than producing copper from raw ore. Many devices that are thrown away such as phones, laptops, and chargers, contain valuable copper that can be recovered and reused. Supporting electronics recycling programs such as Apple or Dell are small actions but leave a larger impact. 

A review published in the International Journal of Mining Science and Technology highlights how advances in flotation chemistry and processing help improve the difficult copper mineral recovery while also reducing the environmental costs (Feng et al.). Such innovations display that mining does not need to be stuck in the past, it can develop alongside sustainability goals. 

Many people do not usually think about copper flotation, but it quietly supports nearly everything the world depends on. As the world evolves and transitions toward cleaner energy and smarter technology, the science behind copper flotation helps ensure that copper production is maintained responsibly. In my opinion, this makes flotation not just an industrial process, but a core piece of a more sustainable future.

Works Cited

Feng, Qiming, et al. “Flotation of Copper Oxide Minerals: A Review.” International Journal of Mining Science and Technology, vol. 32, no. 3, 2022, pp. 399–412, https://doi.org/10.1016/j.ijmst.2021.12.006. Accessed 28 January 2026.

International Copper Association. Copper Recycling: A Circular Solution to Sustainable Development. International Copper Association, 2022, https://copperalliance.org/resource/copper-recycling/. Accessed 28 January 2026.

Miller, Gregory, and Joel Jaeger. “How Recycled Copper Plays a Pivotal Role in the Energy Transition.” World Resources Institute, 19 Aug. 2022, https://www.wri.org/insights/pivotal-role-recycled-copper-energy-transition. Accessed January 2026.