A Contribution to Carbonates-Phosphate Separation by Flotation Technique

INTRODUCTION A current need of the phosphate industry is the development of process technology for treatment of high carbonate content ore. About 75 to 80 percent of the world phosphate reserves (1) are associated with carbonate gangue, which is not amenable to treatment by the existing techniques. Numerous laboratory and pilot plant studies have been devoted to carbonate-phosphate separation. Different techniques were involved (washing, sieving, attrition, flotation, calcination, and leaching). For technical and economical considerations, flotation appears to be an efficient process for this problem. Separation of carbonates (calcite and dolomite) from igneous phosphate is applied in industrial plants in Brazil, Finland, and South Africa. But, for sedimentary phosphate, no industrial realization exists at this time, with the possible exception of some plants in China. The main problems with sedimentary phosphates are: • high substitution by CO3-2 and F- for P04 -3 in the apatite lattice. • larger surface area of the phosphate particles because their surface is porous and irregular. • tendency of sedimentary minerals to produce more slimes in conditioning than the crystalline minerals, hence, larger dosages of collectors are required for sedimentary minerals. Investigations reported in the literature indicate that most processes developed for sedimentary carbonate-phosphate separation involved inverse flotation of carbonates using fatty acids as collectors (2), (3) associated with phosphoric acid (4), monosodium phosphate (5), F- (6), or SiF6 -2 (7) as phosphate depressants. Later investigations, conducted by A. Henchiri and G. Baudet (8), (9), (10), (11), (12), (13) in the BRGM technology department, of phosphoric esters revealed that these reagents are selective collectors for carbonate-phosphate separation. The above investigators developed a process which used phosphoric esters to collect carbonate minerals and sulfuric acid or sodium fluorosilicate as depressants for phosphate. Extensive comparative tests for different processes on the same phosphate sample show that the process developed at BRGM is one of the most promising methods proposed for sedimentary phosphate-carbonate separation. It should be pointed out, however, that phosphoric esters make abundant froths. The handling of these excessive froths will be a problem in an industrial-scale plant. This paper outlines test work performed in order to optimize and to improve the efficiency of the flotation process on a sedimentary phosphate ore selected from the Sra Ouertane orebody. The Sra Ouertane flotation process, illustrated on Figure 1, first removes carbonate minerals by inverse flotation and then recovers phosphate as a froth product, leaving quartz as a cell product.