Phosphate Ore Organic Removal via pH-Controlled Slurry
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Solution Overview
Problem
Phosphate ores often contain organic compounds that hinder beneficiation processes, such as calcination and flotation, due to high operating costs and ineffective separation of target minerals from gangue and organic materials.
Innovation Solution
A method involving preparing ore to a specific size, mixing it with a pH-modifying reagent in a slurry, and maintaining a controlled pH range to release gangue and organic materials, allowing for their separation and subsequent refinement through attrition scrubbing and froth flotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If calcination process is used to combust organics at high temperatures, then organic removal is achieved, but operating costs and gaseous emissions increase
Solution Approach 1:
The patent changes the chemical parameters of the slurry by controlling pH levels (maintaining between pH 2-4 using sulfuric acid or pH 10-12 using sodium hydroxide) to alter the chemical environment in which organics exist, making them more susceptible to removal through flotation rather than requiring high-temperature combustion
Solution Approach 2:
The patent replaces the thermal/mechanical combustion process with a chemical-flotation process. Instead of using high temperatures to combust organics, the method uses pH-modified slurry chemistry combined with mechanical agitation and air flotation to separate organics from the ore, thereby avoiding the high energy consumption of calcination
2Productivity
If flotation is used for mineral separation, then target mineral extraction is improved, but effectiveness decreases when organic material adheres to ore particles
Solution Approach 1:
The patent applies preliminary action by modifying the pH of the slurry before the flotation process begins. By adjusting and maintaining the pH at specific ranges (2-4 or 10-12) through chemical reagents, the slurry environment is prepared in advance to prevent organic adhesion and enhance the effectiveness of subsequent flotation operations
Solution Approach 2:
The patent changes the chemical parameters of the slurry by controlling pH levels (maintaining between pH 2-4 using sulfuric acid or pH 10-12 using sodium hydroxide) to alter the chemical environment in which organics exist, making them more susceptible to removal through flotation rather than requiring high-temperature combustion
3Manufacturing precision
If excessive grinding is applied to liberate target minerals, then mineral liberation is improved, but energy consumption and operating costs increase
Solution Approach 1:
The patent introduces an intermediary chemical environment (pH-modified slurry) that facilitates mineral separation without requiring excessive mechanical grinding. The pH-adjusted slurry acts as a mediator that enables chemical and physical separation processes to achieve mineral liberation more efficiently, reducing the need for high-energy grinding operations
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 enhances the grade and recovery of phosphate ores by reducing the need for excessive grinding, improving mineral separation, and increasing production while extending mine life, with the ability to handle varying ore compositions and conditions.
Implementation Method 1
mixing the ore with a reagent having an initial pH value in a slurry comprising the ore and the reagent; and while mixing the slurry, maintaining a pH level in the slurry to a pH range
Implementation Method 2
The slurry may be mixed using an attrition scrubber or other vessel equipped with a mechanical agitator
Implementation Method 3
while mixing the slurry, a supernatant containing gangue minerals and organic material is removed and a refined, higher grade sediment is produced
Implementation Method 4
subsequent refinement through attrition scrubbing and froth flotation
Data Source
AI summary
This disclosure describes methods, processes and devices that remove or release organics from ores, such as phosphate ores or secondary sources such as mine tailings or waste. The method comprises: preparing an ore to a pre-set size; mixing the ore with a reagent having an initial pH value in a slurry comprising the ore and the reagent; and while mixing the slurry, maintaining a pH level in the slurry to a pH range. While mixing the slurry, the slurry may produce a supernatant containing organic material removed from the ore and sediment containing refined ore. The method may also screen the slurry to create a first stream of materials that does not pass through the screen and a second stream of materials and refined ore that pass through the screen.