The reuse of mineral processing wastewater remains a challenge in certain scenarios, as residual reagents could substantially

impair separation effi ciency. In this fundamental research, magnetic fl occulation separation technology was applied 

to remove residual surfactants from synthesized mineral processing wastewater. Micron-sized iron powder and polyaluminum

chloride (PAC) are adopted as magnetic medium and fl occulants. A total organic carbon (TOC) removal effi ciency of 

94.31% can be achieved through optimization of the experimental process, and surface tension of solution elevated from 

26.75 mN/m to 65.34 mN/m. Zeta potential analysis and X-ray photoelectron spectroscopy (XPS) characterization shows 

that micron-sized iron powder signifi cantly enhanced the fl occulation process. Observation of microscopy and scanning 

electron microscopy (SEM) reveals that the fl oc size and density were greatly increased during the sedimentation process, 

thus improving solid-liquid separation effi ciency. Real mineral processing wastewater treated with magnetic fl occulation 

separation method was reused in fl otation, and the results shows signifi cant improvement for the metal concentration. The 

recycled micron iron powder shows similar behavior during the magnetic fl occulation separation process. This research 

provides a practical solution for mitigating the accumulation of residual reagents when recycling the mineral processing 

wastewater.