Silicate minerals, primarily quartz and clays, are frequently encountered as impurities in sedimentary phosphate ores. If not effectively removed, these gangue minerals can undermine the entire phosphate value chain. In this study, the challenge of selectively recovering silicates from a sedimentary carbonaceous siliceous phosphate ore was successfully addressed, enabling the recovery of an enriched phosphate concentrate as the main product, along with a high-purity quartz concentrate as a valuable by-product. This approach aligns with circular economy principles, promoting integrated waste management. The effective flotation of quartz was investigated using various amine-based collectors, including fatty alkyl amines, ether amines, diamines, quaternary ammonium salts, alkanolamines, and Gemini amines. Preliminary tests yielded unsatisfactory results, characterized by a lack of selectivity and substantial apatite losses. Consequently, this study identified the detrimental impact of dissolved ionic species on the adsorption of collector molecules onto quartz surfaces, which hindered effective flotation. To mitigate this issue, an acid-washing and water substitution process was implemented, resulting in significant improvements in flotation efficiency. The integration of response surface methodology (RSM) and automated mineralogical characterization enabled a comprehensive analysis and optimization of the flotation process. A systematic evaluation of operating parameters enabled the effective removal of most silicate impurities from the phosphate ore. This approach resulted in the recovery of high-purity silicate concentrates (greater than 80% SiO2), suitable for various industrial applications. Furthermore, the optimized flotation process reduced the silicate content in the final phosphate concentrate from 18.83% to below 2%.
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