Froth Flotation Collector Composition for Phosphate Recovery
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Solution Overview
Problem
Current froth flotation processes for phosphate ores face challenges with froth stability and selectivity due to the use of nonylphenol ethoxylates, which have environmental concerns and result in decreased recovery and grade, and issues with froth product pumping.
Innovation Solution
A process involving a primary collector and a collector aid, optionally with a secondary collector, pre-mixed to form a collector composition that is added to the ore, improving froth flotation results by enhancing froth density and stability, and allowing for better recovery of phosphate minerals without the need for separate conditioning steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nonylphenol ethoxylates are used as co-collector, then collector performance is improved, but environmental harm increases and selectivity decreases
Solution Approach 1:
The patent changes the chemical composition parameters by replacing nonylphenol ethoxylates with alternative co-collectors such as alkyl polyglucosides, alkyl polyethers, or fatty acid esters. These alternatives maintain the necessary surface activity and collector performance while eliminating the environmental toxicity associated with nonylphenol ethoxylates, thus resolving the contradiction between performance and environmental harm.
Solution Approach 2:
The patent employs biodegradable co-collector alternatives that break down quickly in the environment, effectively replacing persistent harmful substances. These short-living, environmentally benign compounds provide the necessary flotation performance temporarily during the process but do not accumulate or cause long-term environmental damage, addressing both performance and environmental concerns.
2Reliability
If froth stability is increased, then flotation performance is improved, but entrainment increases and selectivity decreases
Solution Approach 1:
The patent employs dynamic froth stability control by using specific co-collector formulations that adjust froth characteristics during the flotation process. The collector composition is designed to provide optimal froth stability during the flotation operation but allows the froth to collapse appropriately after air supply stops, preventing excessive entrainment while maintaining good flotation performance and selectivity.
Solution Approach 2:
The patent optimizes the chemical composition parameters of the collector system, specifically the ratio and type of primary collector to co-collector, to achieve balanced froth characteristics. By adjusting these composition parameters, the system achieves sufficient froth stability for good flotation performance while preventing excessive stability that would cause entrainment and reduce selectivity.
3Reliability
If separate conditioning steps are used for primary collector and co-collector, then collector performance is optimized, but process complexity increases
Solution Approach 1:
The patent combines the primary collector and co-collector into a single pre-mixed collector composition formulation. This merged composition maintains the optimized performance benefits of separate conditioning while simplifying the operational process to a single addition step, thereby reducing process complexity without sacrificing collector effectiveness.
Solution Approach 2:
The patent creates a universal collector composition that performs multiple functions simultaneously - providing both the primary collection action and the co-collector enhancement effects in a single formulation. This multi-functional composition eliminates the need for separate conditioning steps while maintaining optimized collector performance, resolving the contradiction between performance optimization and process simplicity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The use of the collector composition significantly improves the recovery and grade of phosphate minerals, with up to 4% improvement in recovery and better frothing characteristics, compared to processes without the collector aid, while maintaining a favorable environmental profile.
Implementation Method 1
conditioning a phosphate-containing ore with both these compounds
Implementation Method 2
separate the valuable phosphate minerals from the gangue by using a froth flotation process where the phosphate minerals are enriched in the float
Implementation Method 3
enhancing froth density and stability
Data Source
AI summary
The invention relates to a process for froth flotation of an ore to recover phosphate-containing materials from the ore, that includes adding a primary collector and a collector aid to the ore, next performing a conditioning step of the ore, wherein theprimarycollector is selected from the group consisting of an amphoteric surface- active compound, an anionic surface-active compound and combinations thereof; and thecollector aidhasthe formula R 3 -CO-O-A n -R 4 where R 3 is a linear or branched, alkyl or hydroxyalkyl group having from 3 to 8 carbon atoms, R 4 is a linear or branched, alkyl or hydroxyalkyl group having from 3 to 10 carbon atoms and at least one of R 3 and R 4 contains a hydroxyl group; A is either ethoxy, propoxy or butoxy and n is 0-10.