Upgrading of calcareous phosphate ores by flotation: Effect of ore characteristics

Abstract

Sedimentary phosphates contain-besides the phosphate minerals-, various associated gangue minerals such as: clays, silica, calcareous minerals (mainly calcite and dolomite), carbonaceous matter, iron oxides and/or pyrite. The common practiced flow-sheets for concentrating these types of phosphate ores consist of a combination of various mineral processing units such as: crushing and screening, attrition, washing, magnetic separation, and/or flotation. However, none of these combinations was successfully efficient to upgrade the calcareous ores because of the close similarity of the physical properties (density, particle size, particle shape, etc.) as well as the surface physico-chemical properties of the carbonate and phosphate minerals. For the last five decades extensive efforts have been spent to adopt flotation for separating carbonates from phosphate ores. These efforts include thermodynamic analysis, modification of the technique, controlling the pulp environment, and finding new reagents that can specifically differentiate between carbonates and phosphates. This paper reviews some of the published work on the separation of carbonates from phosphate ores by flotation and presents the flotation results of phosphate ore samples different in their physical properties and mineralogical composition. The results obtained reflect the effect of ore nature on the flotation performance and the reagents consumption.