Phosphate Ore Collector Composition for Carbonate Flotation Separation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods struggle to efficiently separate phosphate ores from high carbonate impurities due to their similar physical and chemical properties, leading to difficulties in downstream acid treatment and low phosphate concentrate grades.
Innovation Solution
A collector composition comprising fatty acids, sulfonate or sulfate compounds, phosphorous-bearing inorganic acids or salts, alkoxylated alcohols, and modifier compounds is used to enhance the flotation process, allowing for improved separation of phosphate ores from carbonate impurities, particularly in the presence of fine particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional collectors are used for flotation, then the separation of phosphate from carbonate impurities is attempted, but the similar physical and chemical properties of phosphate and carbonate make effective separation difficult
Solution Approach 1:
The patent employs a composite collector system comprising multiple components: fatty acids (primary collector), sulfonate or sulfate compounds (secondary collector), phosphorous-bearing inorganic acids or salts, alkoxylated alcohols, and modifier compounds. This composite approach leverages the complementary properties of each component to achieve effective separation of phosphate from carbonate impurities, overcoming the limitation of single-collector systems that cannot adequately address the similar properties of these minerals.
Solution Approach 2:
The patent utilizes pH modification as a critical parameter to enhance separation efficiency. By adjusting the pH of the flotation circuit using phosphorous-bearing inorganic acids or salts, the collector system achieves optimal performance in differentiating between phosphate and carbonate surfaces, enabling effective separation despite their similar physical and chemical properties.
2Manufacturing precision
If high-grade phosphate concentrate is produced, then downstream acid treatment is improved, but carbonate impurities disturb the acid treatment process
Solution Approach 1:
The collector system selectively extracts and removes carbonate impurities from the phosphate ore during flotation, concentrating the phosphate in the concentrate stream. By effectively separating carbonate from phosphate at the flotation stage, the downstream acid treatment process is protected from carbonate interference, enabling efficient phosphoric acid production.
Solution Approach 2:
The collector composition acts as an intermediary substance that facilitates the separation process. The multiple collector components work together to create differential surface hydrophobicity, allowing carbonate impurities to be selectively removed while leaving phosphate intact, thus protecting the downstream acid treatment from carbonate disturbances.
3Productivity
If traditional flotation methods are used, then processing is performed, but high fines content in ores reduces processing efficiency
Solution Approach 1:
The patent employs pH modification as a key parameter to handle fines effectively. The phosphorous-bearing inorganic acids or salts adjust the pH to optimize collector performance on fine particles, enabling efficient flotation of phosphate even in ores with high fines content, thereby maintaining processing efficiency despite the presence of fine particles.
Solution Approach 2:
The composite collector system includes specifically designed components that effective on fine particles. The combination of fatty acids, sulfonate/sulfate compounds, phosphorous-bearing inorganic acids, alkoxylated alcohols, and modifier compounds creates a synergistic effect that enhances flotation efficiency in the presence of high fines, allowing effective processing without requiring desliming.
4Manufacturing precision
If more flotation volume is used to process high carbonate ores, then separation is improved, but water usage and operational complexity increase
Solution Approach 1:
The multi-component collector system achieves superior separation performance in a single flotation circuit, eliminating the need for multiple flotation stages or excessive water usage. The synergistic action of fatty acids, sulfonate/sulfate compounds, phosphorous-bearing inorganic acids, alkoxylated alcohols, and modifier compounds enables effective carbonate removal with reduced water consumption compared to traditional single-collector systems.
Solution Approach 2:
By optimizing pH through phosphorous-bearing inorganic acids or salts, the collector system achieves maximum separation efficiency under controlled conditions, reducing the need for excessive water addition. The pH optimization enables effective separation in a compact flotation circuit, minimizing water usage while maintaining high separation performance.
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 new collector composition achieves higher P2O5 concentrate grades and recoveries, reduces foaming, and minimizes flotation volume and water usage, effectively processing ores with high fines content without desliming.
Implementation Method 1
The most widely adopted technique in beneficiating phosphate ores is froth flotation, whose efficiency largely depends on the ability of the flotation collectors to differentiate the surface hydrophobicity of the valuable minerals and the unwanted impurities in the ore.
Implementation Method 2
the ability of the flotation collectors to differentiate the surface hydrophobicity of the valuable minerals and the unwanted impurities in the ore
Data Source
AI summary
The invention is related to a collector composition for the beneficiation of phosphate ores, particularly those with high content of carbonate impurities. The collector may be a combination of chemicals, comprising: (1) any kind of fatty acids, e.g., conventional fatty acid, saponified fatty acid, or modified fatty acid; (2) chemicals with sulfonate or sulfate groups, such as dodecylbenzene sulfonic acid (DDBSA) or its salt, sodium dodecyl sulfate (SDS), sodium lauryl sulfate (SIS), sodium coco sulfate (SCS), etc.; (3) phosphorous-bearing inorganic acids or salts, such as sodium tripolyphosphate (STPP), sodium hexametaphosphate (SFMP), trisodium phosphate (TSP), Tetrasodiumpyrophosphate (TSPP), etc.; (4) alkoxylated alcohols, preferably ethoxylated C8-C24 linear or branched fatty alcohols with a degree of ethoxylation higher than five; and (5) modifier compositions selected from one or more of the modifier agents such as insoluble oils, silicones, fatty alcohols, esters, glycols, etc.