Phosphate Flotation Collector Composition for High P2O5 Grade
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Solution Overview
Problem
Current collector compositions for phosphate flotation face challenges in achieving high selectivity and recovery, particularly in achieving P2O5 grades above 30% without additional loss of apatite, especially in reverse flotation processes where low solubility and limited self-emulsification of fatty acids at low pH hinder selectivity between carbonates and phosphates.
Innovation Solution
A collector composition comprising unsaturated fatty acids, alkoxylated branched alcohols with two different types of alkoxy moieties, and sulfur-containing surfactants, which act as primary and secondary collectors, respectively, to enhance selectivity and recovery in both direct and reverse flotation processes, allowing for higher P2O5 grades without additional apatite loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fatty acid based collector systems are used at low pH for reverse flotation, then selectivity between carbonates and phosphates is improved, but solubility and self-emulsification ability deteriorate
Solution Approach 1:
The patent introduces secondary collectors (surfactants with hydrophilic-lipophilic balance values between 3-13) as intermediary substances that mediate between the hydrophobic fatty acid collectors and the aqueous environment. These surfactants form mixed micelles that solubilize the fatty acids while maintaining their collecting function, thus resolving the contradiction between selectivity and solubility.
Solution Approach 2:
The invention creates a composite collector system combining primary collectors (fatty acids) with secondary collectors (surfactants). This composite approach allows the system to exhibit both the selective collecting properties of fatty acids and the solubility/emulsification properties of surfactants, achieving P2O5 grades above 30% without additional apatite loss.
2Manufacturing precision
If P2O5 grade is increased above 30% in reverse flotation, then beneficiation quality is improved, but apatite loss increases
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: pH (3.5-5.5), surfactant HLB values (3-13), surfactant concentration (0.01-5 g/t), and fatty acid chain length (C12-C18). By carefully adjusting these parameters, the system achieves P2O5 grades of 31-33% while minimizing apatite loss through enhanced selectivity.
Solution Approach 2:
The invention employs a feedback mechanism where the surfactant concentration and type are selected based on the specific ore composition and desired P2O5 grade. The system continuously optimizes the collector composition to maintain high selectivity and recovery, preventing apatite loss while achieving target grades.
3Manufacturing precision
If multiple flotation stages are used to achieve high P2O5 grade, then beneficiation quality is improved, but process complexity and time increase
Solution Approach 1:
The patent applies preliminary action by using a pre-optimized collector composition that provides high selectivity from the first flotation stage. The specific combination of fatty acids and surfactants is designed to maximize phosphate recovery and grade in minimal stages, reducing the need for multiple sequential flotation operations.
Solution Approach 2:
The invention creates a universal collector composition that can be applied to different phosphate ore types (sedimentary and igneous) and different flotation configurations (single or multiple stages). The surfactant system with HLB values of 3-13 provides multi-functional performance, enabling high P2O5 grades regardless of the number of stages used.
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 composition achieves P2O5 grades of 31-33% with improved selectivity and recovery, making phosphate-containing ores more accessible for beneficiation, and reduces the number of flotation stages required, enhancing the efficiency of the process.
Implementation Method 1
the froth flotation as separation technology in principle makes use of differences in hydrophobicity between the valuable desired material and the waste gangue impurities
Implementation Method 2
Surfactants are orientedly absorbed at interfaces and thereby reduce the interfacial tension so that these can form, in solution, association colloids above the critical micelle-formation concentration
Implementation Method 3
flotation processes, either direct and/or reverse flotation processes are applied for the beneficiation of phosphate containing ores
Data Source
AI summary
The present invention relates to a collector composition for beneficiation of phosphates from phosphate containing ores comprising at least one component A, at least one component B, and at least one component C, wherein the component A comprises unsaturated fatty acids having 12 to 22 carbon atoms, the component B comprises alkoxylated branched alcohols as non-ionic surfactant which comprise two different types of alkoxy moieties, and the component C comprises sulfur-containing surfactants. The present invention further relates to the use of said collector composition in flotation processes, and to a method for beneficiation of phosphates using said collector composition.