Publikationsrepositorium - Helmholtz-Zentrum Dresden-Rossendorf

The flotation beneficiation of phosphate ore is increasingly facing challenges, especially for finely disseminated sedimentary ores rich in carbonates. This study aims to optimize and assess the impact of key hydrodynamic parameters including pulp density, air flowrate and impeller speed on flotation and metallurgical responses (i.e. grade, recovery, flotation rate constant and selectivity index (SI)). We carried out locked cycle flotation tests using the best conditions from the rougher flotation test to generate an experimental simulation of a continuous circuit. The mineralogical and chemical properties were characterized by mineral liberation analysis (MLA) and inductively coupled plasma optical emission spectroscopy (ICP-OES) techniques, respectively. A modified-McGill bubble size viewer was used for measuring bubble sizes and evaluating the interaction between hydrodynamic factors and bubble diameters. Finally, the design of experiment (DOE) method was applied to determine the relative intensity of the studied factors. It was found that under optimal conditions with the targets of high recovery and maximum SI, the final apatite concentrate achieved a recovery of 86.3 % at a grade of 35.5 %, while the MgO content was 1.2 % and 84.3 % of dolomite was removed from a feed ore containing about 25 % P2O5, 4.6 % MgO, and 41 % CaO. Furthermore, another locked cycle flotation test showed that a 0.82 % MgO content in the final apatite concentrate can be achieved with an apatite recovery of 75.6 % at a P2O5 grade of 36.76 %, and a ratio CaO/P2O5 = 1.33. The obtained concentrate in this investigation under the optimum conditions is the highest in both apatite recovery and grade with low MgO content reported in the literature.