Separating dolomite from phosphate rock by reactive flotation: Fundamentals and application

Florida is currently one of the largest phosphate producers in the world. Unfortunately, the phosphate industry in Florida is suffering from depletion of the phosphate-rich ore. Dolomite, however, is a major impurity in the ores. The presence of MgO, in dolomite, can cause several problems during production of phosphoric acid and final fertilizers. Efforts to solve the dolomite problem have been reported by several researchers throughout the world. Yet, only heavy media separation process has been applied commercially. However, the process was discontinued because of its low separation efficiency in terms of grade and recovery.; In this study, we tested an innovative idea based on simple fact that dolomite, as a carbonate mineral, generates CO2 when exposed to a slightly acidic solution, capturing CO2 bubbles at dolomite particle surface can selectively float the dolomite and separate it from phosphate. Formation of such bubbles requires a surface-active agent(s) at solution/dolomite interface. Preliminary tests indicated that polyvinyl alcohol (PVA) could serve this function. This process is called the Reactive Flotation, RF.; To develop this process and to scale it up for industrial use, we conducted fundamental and applied research studies. Among these studies were optimizing of RF process by investigating the factors affecting the process (including bench and pilot scale tests) using statistical experimental designs. It was found that the acid concentration, PVA concentration, and particle size are the main factors. The optimum conditions were determined and applied to usage in a gravity separation device, (i.e., a sluice). Using such a device, a concentrate contains 0.65% MgO with >94 MgO % removal can be achieved. In addition, fundamental studies revealed that the hydrogen bonding is the adsorption mechanism confirmed by adsorption isotherm of PVA on dolomite and phosphate, adhesion of PVA to dolomite surface (using contact angle and surface tension), Fourier Transform InfraRed (FTIR), and Zeta potential. Moreover, PVA film thickness and polymer film elasticity (using dynamic surface tension) revealed that the optimum conditions could keep the PVA film at its highest elasticity. On the other hand, modeling was developed and used to predict CO2 formation rate and subsequent particle density change.