Phosphate Ore Flotation Collector Blend for Selective Mineral Recovery
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Solution Overview
Problem
Current methods for froth flotation of ores containing phosphate and non-phosphate minerals face challenges in achieving high recovery of phosphate minerals while minimizing the content of non-phosphate minerals, particularly in differentiating between calcium-containing minerals like apatite, calcite, and dolomite, which adsorb collectors with similar affinity, leading to economic inefficiencies and phosphate losses in tailings.
Innovation Solution
A method involving a surfactant system comprising a fatty acid and a blend of ethoxylated and non-ethoxylated aliphatic alcohols, specifically a reaction product of a C12-C16 aliphatic alcohol with 10 to 20 equivalents of ethylene oxide and a second C12-C16 aliphatic alcohol, is used in the froth flotation process to enhance the recovery and selectivity of phosphate minerals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional collectors are used for flotation of phosphate minerals, then phosphate recovery can be achieved, but selectivity is poor due to similar adsorption affinity between apatite, calcite, and dolomite
Solution Approach 1:
The patent changes the chemical parameters of the collector system by using a blend of ethoxylated (10-20 equivalents) and non-ethoxylated C12-C16 aliphatic alcohols in specific ratios (80:20 to 20:80). This parameter modification creates differential adsorption behavior that enhances selectivity between phosphate minerals and calcium-containing gangue minerals while maintaining recovery
Solution Approach 2:
The invention employs a composite surfactant system combining fatty acids with a blend of ethoxylated and non-ethoxylated alcohols. This composite collector system exploits the synergistic effects of different molecular structures to achieve both high recovery and improved selectivity, differentiating between apatite, calcite, and dolomite through combined adsorption mechanisms
2Quantity of substance
If ore quality decreases with more complex mineralogy, then phosphate supply can be maintained, but beneficiation requirements become more sophisticated
Solution Approach 1:
The patent modifies the chemical parameters of the flotation system by controlling the ethoxylation degree (10-20 equivalents) and the ratio of ethoxylated to non-ethoxylated alcohols (80:20 to 20:80). These parameter changes enable effective separation of phosphate minerals from complex mineral matrices, reducing the need for additional sophisticated beneficiation steps
3Ease of manufacture
If chemical dosage is reduced to improve economics, then operational costs decrease, but flotation performance may be compromised
Solution Approach 1:
The invention uses a composite collector blend of ethoxylated and non-ethoxylated alcohols with fatty acids that exhibits enhanced collector efficiency. The synergistic interaction between the different components allows for reduced chemical dosage while maintaining or improving flotation performance, thereby reducing operational costs without compromising recovery
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
This approach results in a concentrate enriched in phosphate mineral content with improved recovery and selectivity, reducing phosphate losses in tailings and offering economic benefits by potentially reducing chemical dosage and shortening the process time.
Implementation Method 1
a surfactant system comprising a fatty acid and a blend of a reaction product of a first C12-C16 aliphatic isoalcohol and ethylene oxide and a second C12-C16 aliphatic isoalcohol
Data Source
AI summary
The invention relates to a method for manufacturing a concentrate enriched in a phosphate mineral content from an ore, which contains a phosphate mineral and a non-phosphate mineral, by a flotation, which method comprises the step of adding a surfactant system comprising (A) a fatty acid, (B) a blend of ethoxylated and non-ethoxylated alcohols, which is obtainable by blending (i) a reaction product of a first C12-C16 aliphatic alcohol having an average degree of branching of 1.9 to 3.5 and 10 to 20 equivalents of ethylene oxide, and (ii) a second C12-C16 aliphatic alcohol having an average degree of branching of 1.9 to 3.5, wherein the amount of (i) is 80 to 95 wt. % and the amount of (ii) is 5 to 20 wt. % and wt. % is based on the overall weight of the mixture of ethoxylated and non-ethoxylated alcohols, to a prepared aqueous pulp of the ore and optionally one or more flotation auxiliaries to obtain an aqueous mixture. Furthermore, a use of the surfactant system as flotation collector is disclosed.