U.S. patent application number 17/168347 was filed with the patent office on 2021-05-27 for sulfonated modifiers for froth flotation.
The applicant listed for this patent is Ecolab USA Inc.. Invention is credited to Daniel N.T. Hay, Jianjun Liu, Kevin O'Brien, Paul Wiatr.
Application Number | 20210155791 17/168347 |
Document ID | / |
Family ID | 1000005387129 |
Filed Date | 2021-05-27 |
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United States Patent
Application |
20210155791 |
Kind Code |
A1 |
Liu; Jianjun ; et
al. |
May 27, 2021 |
SULFONATED MODIFIERS FOR FROTH FLOTATION
Abstract
Improved sparge compositions for reverse froth flotation
separation and uses thereof, and methods of reverse froth flotation
are described. The sparge compositions comprise sulfonated
polymeric modifiers which can act as dispersants and depressants,
and the compositions are suitably used in the reverse froth
flotation of particulate material containing ultrafine particles.
For example, the compositions and methods can be used in the
separation of phosphate beneficiary from ores comprising
phosphates, dolomite, calcite, clay, silica, silicates, carbonates,
and mixtures thereof.
Inventors: |
Liu; Jianjun; (Aurora,
IL) ; O'Brien; Kevin; (Saint Charles, IL) ;
Wiatr; Paul; (Roselle, IL) ; Hay; Daniel N.T.;
(Naperville, IL) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ecolab USA Inc. |
St. Paul |
MN |
US |
|
|
Family ID: |
1000005387129 |
Appl. No.: |
17/168347 |
Filed: |
February 5, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15686732 |
Aug 25, 2017 |
10927248 |
|
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17168347 |
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62380143 |
Aug 26, 2016 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C08L 2201/54 20130101;
C08L 33/02 20130101; C08L 35/00 20130101; C01B 25/10 20130101; B03D
1/016 20130101; B03D 2203/02 20130101; B03D 1/012 20130101; B03D
1/021 20130101; B03D 2201/007 20130101; C08L 33/12 20130101; B03D
2201/02 20130101; B03D 2203/06 20130101; C08L 33/26 20130101; B03D
1/008 20130101; C01G 49/08 20130101 |
International
Class: |
C08L 35/00 20060101
C08L035/00; B03D 1/02 20060101 B03D001/02; B03D 1/012 20060101
B03D001/012; B03D 1/016 20060101 B03D001/016; C01B 25/10 20060101
C01B025/10; C08L 33/02 20060101 C08L033/02; C08L 33/12 20060101
C08L033/12; C08L 33/26 20060101 C08L033/26; C01G 49/08 20060101
C01G049/08 |
Claims
1. A sparge composition comprising: (i) a medium; (ii) a phosphate
ore comprising a phosphate beneficiary and a gangue; (iii) a
collector; and (iv) a sulfonated polymer comprising (a) a monomer
residue having the structure ##STR00018## and a counterion selected
from NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium, (b) a monomer residue having the
structure ##STR00019## (c) a monomer residue having the structure
##STR00020## wherein n is 1, 2, or 3, and a counterion selected
from NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium, (d) a monomer residue having the
structure ##STR00021## wherein n is 1, 2, or 3, (e) a monomer
residue having the structure ##STR00022## (f) a monomer residue
having the structure ##STR00023## and a counterion selected from
NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium, (g) a monomer residue having the
structure ##STR00024## wherein R.sub.4 is alkyl, (h) a monomer
residue having the structure ##STR00025## wherein R.sub.4 is alkyl,
and a counterion selected from NH.sub.4.sup.+, Na.sup.+, K.sup.+,
primary organic ammonium, secondary organic ammonium, tertiary
organic ammonium, and quaternary organic ammonium, (i) a monomer
residue having the structure ##STR00026## (j) a monomer residue
having the structure ##STR00027## and a counterion selected from
NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium, or (k) any combination thereof,
wherein the phosphate beneficiary comprises a phosphate.
2. The sparge composition of claim 1, wherein the gangue comprises
a silicate, silica, a carbonate, or any combination thereof.
3. The sparge composition of claim 1, wherein the sparge
composition further comprises a sulfonated lignin, a sulfonated
starch, a sulfonated cellulose, a sulfonated guar gum, a sulfonated
xanthan gum, or any combination thereof.
4. The sparge composition of claim 1, wherein the sulfonated
polymer has a weight average molecular weight of from about 300
g/mole to about 100,000 g/mole.
5. The sparge composition of claim 1, wherein the sulfonated
polymer further comprises a residue of acrylic acid, methacrylic
acid, acrylamide, vinyl alcohol, maleic acid, a maleic acid ester,
or any combination thereof.
6. The sparge composition of claim 1, wherein the phosphate
beneficiary comprises an apatite.
7. The sparge composition of claim 1, the sparge composition
further comprising phosphoric acid.
8. The sparge composition of claim 1, the sparge composition
further comprising a pH adjusting agent, wherein the pH of the
sparge composition further comprising the pH adjusting agent is
from about 4 to about 7.
9. A method of reverse froth flotation comprising: forming a sparge
composition comprising (i) a medium, (ii) a phosphate ore
comprising a phosphate beneficiary and a gangue, (iii) a sulfonated
fatty acid, and (iv) one or more sulfonated polymers; sparging the
sparge composition to yield a sparged composition, the sparged
composition comprising a froth and a sparged slurry, wherein the
sparged slurry comprises a concentrate of the phosphate beneficiary
and the froth comprises tailings of the gangue; and separating at
least a portion of the concentrate from the sparged slurry.
10. The method of claim 9, wherein at least one of the one or more
sulfonated polymers comprises a residue of sulfonated vinyl
alcohol, sulfonated acrylamide, sulfomethylated acrylamide,
2-acrylamido-2-methylpropane sulfonate, styrene sulfonate, or any
combination thereof.
11. The method of claim 10, wherein the at least one of the one or
more sulfonated polymers further comprises a residue of acrylic
acid, methacrylic acid, acrylamide, vinyl alcohol, maleic acid, a
maleic acid ester, or any combination thereof.
12. The method of claim 9, wherein the one or more sulfonated
polymers comprises a sulfonated lignin, a sulfonated starch, a
sulfonated cellulose, or any combination thereof.
13. The method of claim 9, wherein the phosphate beneficiary
comprises an apatite.
14. The method of claim 9, wherein the sparge composition further
comprises phosphoric acid.
15. The method of claim 9, wherein the sparge composition further
comprises a pH adjusting agent and the pH of the sparge composition
is about 4 to about 7.
16. A method of froth flotation comprising: forming a sparge
composition comprising (i) a medium, (ii) a phosphate ore
comprising a phosphate beneficiary and a gangue, (iii) a collector,
and (iv) a sulfonated polymer comprising (a) a monomer residue
having the structure ##STR00028## and a counterion selected from
NH.sub.4.sup.-, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium, (b) a monomer residue having the
structure ##STR00029## (c) a monomer residue having the structure
##STR00030## wherein n is 1, 2, or 3, and a counterion selected
from NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium, (d) a monomer residue having the
structure ##STR00031## wherein n is 1, 2, or 3, (e) a monomer
residue having the structure ##STR00032## (f) a monomer residue
having the structure ##STR00033## and a counterion selected from
NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium, (g) a monomer residue having the
structure ##STR00034## wherein R.sub.4 is alkyl, (h) a monomer
residue having the structure ##STR00035## wherein R.sub.4 is alkyl,
and a counterion selected from NH.sub.4.sup.+, Na.sup.+, K.sup.+,
primary organic ammonium, secondary organic ammonium, tertiary
organic ammonium, and quaternary organic ammonium, (i) a monomer
residue having the structure ##STR00036## (j) a monomer residue
having the structure ##STR00037## and a counterion selected from
NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium, or (k) any combination thereof, and
sparging the sparge composition.
17. The method of claim 16, wherein the sulfonated polymer further
comprises a residue of acrylic acid, methacrylic acid, acrylamide,
vinyl alcohol, maleic acid, a maleic acid ester, or any combination
thereof.
18. The method of claim 16, wherein the phosphate beneficiary
comprises an apatite.
19. The method of claim 16, wherein the sparge composition further
comprises phosphoric acid.
20. The method of claim 16, wherein the sparge composition further
comprises a pH adjusting agent and the pH of the sparge composition
is about 4 to about 7.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S.
patent application Ser. No. 15/686,732 entitled "SULFONATED
MODIFIERS FOR FROTH FLOTATION", which is incorporated by reference
herein in the entirety and for all purposes. This application
claims priority to Provisional Patent Application 62/380,143, filed
Aug. 26, 2016, which is incorporated by reference herein, in the
entirety, and for all purposes.
[0002] The present invention relates to improved methods,
modifiers, and compositions for froth flotation, in particular for
separation of beneficiaries from mineral ores that require fine
comminution.
BACKGROUND
[0003] The invention relates to novel materials, compositions, and
methods for improving the effectiveness of froth flotation
beneficiation processes. In a beneficiation process, two or more
materials which coexist in a mixture of particulate material are
separated from each other using mechanical processes with/without
chemicals. Often one of the materials, the beneficiary, is more
valuable or desired than the other material, the gangue.
[0004] One form of beneficiation is froth flotation separation. In
froth flotation separation, to make a slurry a particulate material
comprising an ore, such as ground or comminuted ore is slurried
with water (or another solvent or solvent mix) along with chemicals
such as collectors, modifiers, depressants and/or activators that
assist in the separation of beneficiary from gangue. The role of
the collector is to make targeted particles more hydrophobic,
thereby assisting in their flotation from the slurry. The slurry is
then doped with a frothing agent (frother) if necessary and sparged
to form bubbles, which rise up out of the slurry carrying
hydrophobic particles therewith and form a froth layer above the
sparged slurry. The froth layer may then be deposited on a launder.
The less hydrophobic material remains behind in the slurry, thereby
accomplishing the froth flotation separation.
[0005] Two common forms of flotation separation processes are
direct flotation and reverse flotation. In direct flotation
processes, the froth comprises the beneficiary or concentrate while
in reverse flotation processes, the froth comprises gangue or
tailings. The object of the flotation in either process is to
separate and recover as much as possible of the beneficiary from
the particulate material in as high a concentration as possible,
which is then made available for further downstream processing
steps. In froth flotation, a sparge composition comprising a slurry
is sparged to form a froth layer and a sparged slurry. In a direct
froth flotation, the froth layer comprises a concentrated
beneficiary (a concentrate), and the sparged slurry comprises
tailings (concentrated gangue). In reverse froth flotation, the
froth layer comprises tailings and the sparged slurry comprises the
concentrated beneficiary. In direct froth flotation, the froth
comprises more beneficiary as a proportion of beneficiary plus
gangue than beneficiary as a proportion of beneficiary plus gangue
in the sparge composition prior to sparging; and the tailings
comprise more gangue as a proportion of beneficiary plus gangue
than gangue as a proportion of beneficiary plus gangue in the
sparge composition prior to sparging. In reverse froth flotation,
the froth comprises more gangue as a proportion of beneficiary plus
gangue than gangue as a proportion of beneficiary plus gangue in
the sparge composition prior to sparging; and the tailings
therefore comprise more gangue as a proportion of beneficiary plus
gangue than gangue as a proportion of beneficiary plus gangue in
the sparge composition prior to sparging.
[0006] Froth flotation separation can be used to separate solids
from solids (such as the constituents of mine ore), and liquids or
semi-solids from solids (such as the separation of bitumen from oil
sands).
[0007] Depressants are commonly used to assist collectors in the
froth flotation separation of mineral ores. Depressants hinder the
flotation of either tailings (in direct froth flotation) or
beneficiary (in reverse flotation).
[0008] Sulfonate moieties have been used as depressants for gangue
such as siliceous materials in the flotation of beneficiary such as
phosphate in direct froth flotation.
[0009] U.S. Pat. No. 4,172,029 discloses a process for
beneficiation of a siliceous phosphate ore by froth flotation with
fatty acid and fuel oil reagents and conditioning the phosphate ore
with an alkyl-substituted aromatic sulfonate before floating the
phosphate ore.
[0010] U.S. Pat. No. 4,514,292 discloses gangue depressants that
consist essentially of the combination of an inorganic sulfite and
salts of certain sulfonated compounds for metallic ore and coal.
The salts disclosed include the salts of benzene disulfonic acids,
naphthalene disulfonic acids, condensates of formaldehyde and
naphthalene sulfonic acids, naphthol sulfonic acids, lignin
sulfonic acids, and sulfonated quebracho.
[0011] U.S. Pat. No. 4,719,009 discloses polyester materials
containing ether groups and metal sulfonate groups useful as
depressants for siliceous gangue in the froth flotation separation
of zinc sulfide concentrates from complex ores.
[0012] U.S. Pat. No. 5,314,073 discloses a process for
beneficiation of siliceous phosphate ore by conditioning an aqueous
slurry of the ore at a pH of 7.5 to 10.5 with a fatty acid and a
fuel oil and a water-dispersible sulfo-polyester, and aerating the
conditioned phosphate slurry to float the phosphate.
[0013] U.S. Pat. No. 5,507,395 discloses a method of depression of
siliceous gangue, wherein the depressant is a graft polymer of
polyvinyl alcohol and an acrylamide. The depressants may include
comonomers such as vinyl sulfonate, 2-acrylamido-2-methyl propane
sulfonic acid, styrene sulfonic acid, and
2-sulfoethylmethacrylate.
[0014] U.S. Pat. No. 5,525,212 discloses a method for the
depression of non-sulfide silicate gangue materials, wherein the
depressant is a mixture of polysaccharide and a graft polymer of
polyvinyl alcohol and an acrylamide. The acrylamide may include a
comonomers such as vinyl sulfonate, 2-acrylamido-2-methyl propane
sulfonic acid, styrene sulfonic acid, and
2-sulfoethylmethacrylate.
[0015] U.S. Pat. No. 5,531,330 discloses a method of depression of
non-sulfide, silicate gangue. The depressant is a polymeric
material comprising the polymerization residue of acrylamide
residue(s), a hydroxyl containing polymer unit, and an anionic
group containing polymer unit. The anionic group containing polymer
unit may comprise the polymerization residue of vinyl sulfonate,
2-acrylamido-2-methyl propane sulfonic acid, styrene sulfonic acid,
and 2-sulfoethylmethacrylate, inter alia.
[0016] U.S. Pat. No. 5,533,626 discloses a method of depression of
non-sulfide silicate gangue, wherein the depressant is a mixture of
a polysaccharide and a polymeric material comprising the
polymerization residue of acrylamide residue(s), a hydroxyl
containing polymer unit, and an anionic group containing polymer
unit. The anionic group containing polymer unit may comprise the
polymerization residue of vinyl sulfonate, 2-acrylamido-2-methyl
propane sulfonic acid, styrene sulfonic acid, and
2-sulfoethylmethacrylate, inter alia.
[0017] Further, sulfonate moieties have been used as collectors.
For example, U.S. Pat. No. 3,164,549 discloses recovery of
phosphate fraction from phosphate ore by employing fuel oil and
sulfonic acid or it salt. U.S. Pat. No. 5,171,427 discloses
dialkylated aryl sulfonic acids or salts thereof or their mixture
used as collectors in the flotation of minerals, particularly oxide
minerals.
[0018] From the foregoing, it will be seen that sulfonate moieties
have been used as depressants for gangue minerals, especially for
siliceous gangue and in processes in which beneficiary such as
phosphate is floated.
[0019] The prerequisite for flotation separation is the liberation
of particles. For flotation of mineral ores, therefore, comminuting
(grinding the solids up by such techniques as dry-grinding,
wet-grinding, and the like) is required to liberate minerals.
Extensive grinding or comminution can result in better liberation
of particles for the separation of beneficiary and gangue in a
froth flotation process. However, such grinding or comminution can
result in a relatively large proportion of ultrafine particles
(less than 10 .mu.m). The presence of ultrafine particles
represents a challenge for froth flotation such as slime coating,
which can lead to lower recovery of beneficiary. In slime coating,
particles of ultrafines coat larger particles of ore. This issue is
especially serious for the flotation of non-sulfide mineral ores
such as industrial mineral ores, phosphate ores, potash ores, and
metallic oxide ores: Ultrafine particles of gangue or gangue-rich
material may coat particles of beneficiary or beneficiary-rich
material--in such a case, beneficiary-rich material may be
separated with the gangue in a froth flotation process. Such an
eventuality can undesirably result in lower recovery of the
beneficiary. Similarly, for example, ultrafines of beneficiary may
coat particles of gangue--the particles of gangue may thus be
separated with beneficiary. Such an eventuality can undesirably
result in a lower purity of beneficiary. In order to avoid such
problems, desliming processes are commonly implemented before and
in preparation for froth flotation, to remove ultrafine particles.
However, ultrafines often nevertheless enter the froth flotation
process and cause slime coating and other issues that have
deleterious effects on separation of beneficiary and gangue.
Therefore dispersants are often employed in froth flotation
processes to mitigate the detrimental effect of ultrafines in froth
flotation by dispersing ultrafines of beneficiary and gangue and/or
reducing the availability of ultrafines to coat the larger
particles in desliming processes and/or conditioning processes or
otherwise mitigate loss of beneficiary and/or reduction of the
purity of beneficiary.
[0020] In view of the above issues, it would be an advantage to
provide for froth flotation improved methods and/or compositions
that can be implemented in existing froth flotation installations
for separation of beneficiary from ores. It would be an advantage
to provide improved methods and/or compositions that can be used
effectively to concentrate beneficiaries from materials that
contain ultrafine particles. It would be an advantage to provide
one or more dispersants to effectively disperse both beneficiary
and gangue particles in the grinding process, desliming processes,
conditioning processes, or any combination thereof of ores and/or
slurries of comminuted ores for froth flotation separation.
SUMMARY
[0021] Disclosed herein is a sparge composition comprising,
consisting of, or consisting essentially of (i) a medium; (ii) a
phosphate ore comprising a phosphate beneficiary and a gangue;
(iii) a collector; and (iv) a modifier comprising one or more
sulfonated polymers. In embodiments, the gangue comprises, consists
of, or consists essentially of silica, a silicate, carbonate, or
any combination thereof. In embodiments, the medium comprises,
consists of, or consists essentially of water. In embodiments, the
phosphate beneficiary comprises an apatite. In some such
embodiments, the apatite comprises, consists of, or consists
essentially of francolite. In embodiments the collector comprises,
consists of, or consists essentially of a sulfonated fatty acid. In
embodiments, the sulfonated fatty acid is selected from sulfonated
oleic acid, sulfonated linoleic acid, sulfonated palmitic acid,
sulfonated stearic acid, and any combination thereof. In some such
embodiments, the collector comprises, consists of, or consists
essentially of a sulfonated oleic acid. In embodiments, the sparge
composition has a pH of 4 to 7. In embodiments, the sparge
composition further comprises phosphoric acid. In embodiments, the
sparge composition further comprises a pH adjustment agent. In some
such embodiments, the pH adjustment agent comprises, consists of,
or consists essentially of sulfuric acid. In embodiments, the
modifier has a weight average molecular weight of from about 300
g/mole to about 100,000 g/mole. In some such embodiments, the
modifier comprises, consists of, or consists essentially of a
polymer comprising a first residue of acrylic acid and/or a salt
thereof, and a further residue of 2-acrylamido-2-methylpropane
sulfonic acid or a salt thereof (ATBS), sulfomethylated acrylamide,
or a further residue of both ATBS and sulfomethylated
acrylamide.
[0022] Also disclosed herein is a method of froth flotation, the
method comprising, consisting of, or consisting essentially of
forming a sparge composition, the sparge composition comprising,
consisting of, or consisting essentially of (i) a medium, (ii) a
phosphate ore, the phosphate ore comprising a phosphate beneficiary
and a gangue, (iii) a collector, and (iv) a modifier comprising one
or more sulfonated polymers; and sparging the sparge composition to
yield a sparged composition comprising a froth and a sparged
slurry, the sparged slurry comprising a concentrate of the
phosphate beneficiary, and the froth comprising tailings of the
gangue. In embodiments, the gangue comprises, consists of, or
consists essentially of a silicate, silica, carbonate, or any
combination thereof. In embodiments, the medium comprises, consists
of, or consists essentially of water. In embodiments, the collector
comprises, consists of, or consists essentially of a sulfonated
fatty acid. In some such embodiments, the sulfonated fatty acid
comprises, consists of, or consists essentially of sulfonated oleic
acid. In embodiments, the sparge composition comprises phosphoric
acid, sulfuric acid, or a combination thereof. In embodiments, the
modifier comprises, consists of, or consists essentially of a
sulfonated natural polymer, a sulfonated synthetic polymer, or a
combination thereof. In some such embodiments, the modifier
comprises, consists of, or consists essentially of a sulfonated
synthetic polymer having a weight average molecular weight of from
about 300 g/mole to about 100,000 g/mole. In some such embodiments,
the sulfonated synthetic polymer comprises the residue of
sulfonated vinyl alcohol, sulfonated acrylamide, sulfomethylated
acrylamide, 2-acrylamido-2-methylpropane sulfonic acid and/or a
salt thereof (ATBS), styrene sulfonic acid and/or a salt thereof,
or any combination thereof. In some such embodiments, the
sulfonated synthetic polymer further comprises the residue of
acrylic acid and/or a salt thereof, methacrylic acid and/or a salt
thereof, acrylamide, vinyl alcohol, maleic acid and/or a salt
thereof, maleic acid esters, or any combination thereof. In some
such embodiments, the sulfonated synthetic polymer comprises a
first residue comprising a polymerized residue of acrylic acid
and/or a salt thereof; and a second residue comprising a
polymerized residue of ATBS, a sulfomethylated acrylamide, or a
combination thereof. In some such embodiments, the sulfonated
synthetic polymer has a weight average molecular weight of about
300 g/mole to about 100,000 g/mole. In embodiments, the method
further includes separating at least a portion of the concentrate
of the phosphate beneficiary from the sparged slurry.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 shows a plot of the percentage grade of phosphate
recovered versus % phosphate recovery for a variety of froth
flotation tests with different depressants in tap water.
[0024] FIG. 2 shows a plot of the percentage grade of phosphate
recovered versus % phosphate recovery for a further variety of
froth flotation tests varying quantities of depressants.
[0025] FIG. 3 shows a plot of the percentage grade of phosphate
recovered versus % phosphate recovery for a variety of froth
flotation tests in a synthetic water source.
[0026] FIG. 4 shows a plot of percentage grade of phosphate
recovered versus % phosphate recovery for several froth flotation
tests at pH 4.2-4.6.
[0027] FIG. 5 shows a plot of percentage grade of phosphate
recovered versus % phosphate recovery for several froth flotation
tests at pH 6.5-7.
DETAILED DESCRIPTION
[0028] Although the present disclosure provides references to
preferred embodiments, persons skilled in the art will recognize
that changes may be made in form and detail without departing from
the spirit and scope of the invention. Reference to various
embodiments does not limit the scope of the claims attached hereto.
Additionally, any examples set forth in this specification are not
intended to be limiting and merely set forth some of the many
possible embodiments for the appended claims.
Definitions
[0029] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art. In case of conflict, the present
document, including definitions, will control.
[0030] As used herein, the terms "comprise(s)," "include(s),"
"having," "has," "can," "contain(s)," and variants thereof are
intended to be open-ended transitional phrases, terms, or words
that do not preclude the possibility of additional acts or
structures. The singular forms "a," "and" and "the" include plural
references unless the context clearly dictates otherwise. The
present disclosure also contemplates other embodiments
"comprising," "consisting of" and "consisting essentially of," the
embodiments or elements presented herein, whether explicitly set
forth or not.
[0031] As used herein, the term "optional" or "optionally" means
that the subsequently described event or circumstance may but need
not occur, and that the description includes instances where the
event or circumstance occurs and instances in which it does
not.
[0032] As used herein, the term "about" modifying, for example, the
quantity of an ingredient in a composition, concentration, volume,
process temperature, process time, yield, flow rate, pressure, and
like values, and ranges thereof, employed in describing the
embodiments of the disclosure, refers to variation in the numerical
quantity that can occur, for example, through typical measuring and
handling procedures used for making compounds, compositions,
concentrates or use formulations; through inadvertent error in
these procedures; through differences in the manufacture, source,
or purity of starting materials or ingredients used to carry out
the methods, and like proximate considerations. The term "about"
also encompasses amounts that differ due to aging of a formulation
with a particular initial concentration or mixture, and amounts
that differ due to mixing or processing a formulation with a
particular initial concentration or mixture. Where modified by the
term "about" the claims appended hereto include equivalents to
these quantities. Further, where "about" is employed to describe a
range of values, for example "about 1 to 5" or "about 1 to about
5", the recitation means "1 to 5" and "about 1 to about 5" and "1
to about 5" and "about 1 to 5" unless specifically limited by
context.
[0033] As used herein, "ore" means any solid terranean material of
economic value that is obtained by excavation such as quarrying,
open-cast mining, or pit mining: "ore" is construed herein to
include not only rock, minerals, and mineral aggregates containing
one or more metals in elemental and/or chemically compounded forms,
but also coal and other solid terranean substances.
[0034] As used herein, "carbonate" or "a carbonate", unless
specified to the contrary, means inorganic carbonate such as
material containing CO.sub.3.sup.2-, HCO.sub.3.sup.- ions and
counterions.
[0035] As used herein, "phosphate", unless specified to the
contrary, refers to inorganic phosphate such as material containing
PO.sub.4.sup.3-, H.sub.2PO.sub.4.sup.2-, and H.sub.2PO.sub.4.sup.-
ions and counterions.
[0036] As used herein, "medium" means a material that is liquid at
20.degree. C. and 1 atmosphere pressure. In any of the embodiments
herein, the medium can comprise, consist of, or consist essentially
of water.
[0037] As used herein, "phosphoric acid" refers to orthophosphoric
acid, commonly given the formula H.sub.3PO.sub.4.
[0038] As used herein, "phosphate ore" means an ore in the form of
a particulate comprising inorganic phosphate.
[0039] As used herein, "particulate" or "particulate material"
means a plurality of particles. As used herein, "particle" means a
discreet, solid object to which can be ascribed physicochemical
properties such as volume or mass, wherein a particle has a largest
maximum dimension in any direction of about 0.001 .mu.m to about 5
mm.
[0040] As used herein, "ultrafine particles" or "ultrafines" means
particles having a particle size of less than 10 .mu.m when
measured according to throw-action sieve analysis carried out
wet.
[0041] As used herein, "comminuted" means reduced in size. In
embodiments, comminuted means powdered, pulverized, ground, or
otherwise divided by mechanical means.
[0042] As used herein, "sparge composition" means a composition
comprising a particulate material; a sulfonated polymer, and/or
other collector; and a liquid medium. Such a composition has a
liquid surface and comprises a slurry of the particulate material
in the medium. Such a composition, after being sparged, comprises
froth at the liquid surface and a sparged slurry. In direct froth
flotation, the froth comprises a concentrate, and the sparged
slurry comprises tailings. In reverse froth flotation, the froth
comprises tailings and the sparged slurry comprises a concentrate.
In embodiments, the collector is a sulfonated fatty acid.
[0043] As used herein, "concentrate" means a material in which a
beneficiary has been concentrated by a froth flotation process. The
concentrate has a higher concentration of the beneficiary (as a
ratio by weight of beneficiary to beneficiary plus gangue) than the
particulate material of the sparge composition before sparging.
[0044] As used herein, "tailings" means a material in which a
gangue has been concentrated by a froth flotation process. The
tailings have a higher concentration of the gangue (as a ratio by
weight of gangue to beneficiary plus gangue) than the particulate
of the sparge composition before sparging.
[0045] As used herein, "sparged slurry" means the liquid body of a
sparge composition that has been sparged, wherein a froth has
formed at the air-liquid interface. As used herein, the sparged
slurry excludes or substantially excludes froth.
[0046] As used herein "slurry of particles" means a composition
comprising a liquid medium and particulate material, wherein the
particulate material is dispersed and/or suspended in the medium,
and wherein the composition excludes or substantially excludes a
collector. In embodiments, the liquid medium consists essentially
of water.
[0047] As used herein, "sparge", "sparged", or "sparging" refers to
the introduction of a gas into a sparge composition for the purpose
of creating a plurality of bubbles that migrate upwards within the
liquid. In embodiments, the gas is air.
[0048] As used herein, a "collector" means a material that
selectively adheres to targeted particles in a sparge composition,
and increases adhesion or association of the targeted particles to
bubbles of a gas during sparging. "Targeted particles" are
gangue-rich particles (in reverse froth flotation) or
beneficiary-rich particles (in direct froth flotation).
[0049] As used herein, a "depressant" means a material that
selectively reduces the adhesion or association of untargeted
particles in a sparge composition to bubbles of a gas during
sparging. Untargeted particles are gangue-rich particles in direct
froth flotation or beneficiary-rich particles in a reverse froth
flotation. A depressant acts to decrease the migration of
untargeted particles to the surface of a sparged composition.
[0050] As used herein, a "frother" or "frothing agent" means a
composition of matter that reduces the surface tension of water and
enables the formation of a froth at air-liquid interface of a
sparge composition during sparging.
[0051] As used herein, "dispersant" means a material that disperses
particles of an ore in a liquid medium such as water, assists in
the dispersion of particles of an ore in the medium, stabilizes a
dispersion of particles of an ore in the medium, or any combination
thereof. In embodiments, a dispersant is a material that disperses
ultrafine particles of the ore.
[0052] As used herein, a "modifier" means a material that is, acts
as, or is effective as a dispersant, a depressant, or both a
dispersant and depressant. In embodiments, the modifiers of the
invention are, act as, or are effective as both dispersants and
depressants.
[0053] As used herein, "ATBS" means 2-acrylamido-2-methylpropane
sulfonic acid and/or salts thereof, except where otherwise
specified as follows: as used herein, "ATBS sulfonic acid" means
2-acrylamido-2-methylpropane sulfonic acid; as used herein an "ATBS
salt" means a salt of 2-acrylamido-2-methylpropane sulfonic
acid.
[0054] As used herein, "flotation" of a material means a process in
froth flotation in which during the aeration of a slurry of a
comminuted ore in a liquid medium, the material migrates to the
surface of the slurry and to a froth layer that forms on the
surface of the slurry.
[0055] As used herein, "depression" of a material refers to a
process in froth flotation in which during the sparging of a slurry
of a comminuted ore in a liquid medium, the material remains
substantially within the sparged slurry and does not tend to
migrate into the froth layer.
[0056] As used herein, "sulfonated monomer" means a polymerizable
compound comprising at least one sulfonate or sulfate group
(--SO.sub.3H, --SO.sub.3R, --SO.sub.3--, --O--SO.sub.3H,
--O--SO.sub.3R, or --O--SO.sub.3--, where R is alkyl, aryl,
alkaryl, or another organic group).
[0057] As used herein, "sulfonated monomer residue" and like terms
mean a polymerized residue of a monomer, wherein the residue
comprises at least one sulfonate or sulfate moiety.
[0058] As used herein, "sulfonate moiety", "sulfonate", "sulfonate
group", "sulfonated" and like terms means a moiety comprising at
least one sulfonate or sulfate group (--SO.sub.3H, --SO.sub.3R,
--SO.sub.3.sup.---, --O--SO.sub.3H, --O--SO.sub.3R, or
--O--SO.sub.3.sup.-, where R is alkyl, aryl, alkaryl, or another
organic group).
[0059] As used herein, the term "sulfonated fatty acid" means a
compound that is a product of a sulfonating one or more fatty acids
and/or a salt thereof. The sulfonated fatty acid has at least one
--COOH or CO.sub.2.sup.-, and at least one --SO.sub.3H or
SO.sub.3.sup.-.
[0060] As used herein, "sulfonated polymer" means a polymer
comprising at least one sulfonate or sulfate group (--SO.sub.3H,
--SO.sub.3R, --SO.sub.3.sup.-, --O--SO.sub.3H, --O--SO.sub.3R, or
--O--SO.sub.3.sup.-, where R is alkyl, aryl, alkaryl, or another
organic group).
[0061] As used herein, "phosphate beneficiary" means a beneficiary
comprising phosphate.
DISCUSSION
[0062] Preferred methods and materials are described below,
although methods and materials similar or equivalent to those
described herein can be used in practice or testing of the present
invention. All publications, patent applications, patents and other
references mentioned herein are incorporated by reference in their
entirety. The materials, methods, and examples disclosed herein are
illustrative only and not intended to be limiting.
[0063] Applicants have found that sulfonated polymers having a
weight average molecular weight of about 100,000 g/mole or less
unexpectedly improve the floating of gangue minerals in the reverse
flotation of mineral ores such as phosphate ores, and have found
that sulfonated polymers act as dispersants for both beneficiary
and gangue particles for mineral ores. Therefore, sulfonated
polymers can be used as dispersants in both direct and reverse
froth flotation and can be applied before flotation in a grinding
process, a desliming process, a conditioning process, or any
combination thereof. In embodiments, the sulfonated polymers
decrease slime coating in the froth flotation.
[0064] The polymers comprise one or more sulfonate and/or sulfate
groups. Disclosed are methods and compositions for froth flotation
that include modifiers that comprise, consist of, or consist
essentially of one or more sulfonated polymers. The modifiers,
compositions comprising the modifiers, and methods can be
implemented in existing froth flotation installations for
separation of beneficiary and gangue of a comminuted ore. The
comminuted ore comprises particles of ore. In embodiments, the
particles of ore comprise, consist of, or consist essentially of
ultrafine particles. Used in a reverse froth flotation process in a
medium for the separation of beneficiary and gangue from a mineral
ore, the modifiers of Applicant's invention unexpectedly provide
improved separation and selectivity toward concentrate or tailings,
improved recovery of beneficiary (as measured by weight of
beneficiary recovered as a proportion of total beneficiary in the
mineral ore), higher grade (as measured by weight of beneficiary in
the concentrate), improved depressing action of depressant on the
beneficiary (as measured by reduction of depressant dosage),
improved dispersion of particles of ore, improved dispersion of
ultrafines of ore, reduced slime coating of particles of ore, or
any combination thereof.
First Embodiments
[0065] Therefore, in first embodiments, there is provided a sparge
composition for froth flotation, the sparge composition comprising,
consisting of, or consisting essentially of a medium, a mineral
ore, a collector, and a modifier comprising one or more sulfonated
polymers. In embodiments, the sparge composition for froth
flotation is a sparge composition for reverse froth flotation. In
embodiments, the medium comprises, consists of, or consists
essentially of water. In embodiments, the medium is water. In
embodiments, the mineral ore comprises, consists of, or consists
essentially of a beneficiary and a gangue. In embodiments, the
mineral ore comprises, consists of, or consists essentially of a
phosphate ore, the phosphate ore comprising a phosphate beneficiary
and a gangue. In embodiments, the gangue comprises, consists of, or
consists essentially of a silicate, silica, carbonate, or any
combination thereof. In embodiments, the gangue comprises calcite,
dolomite, clay, or any combination thereof.
[0066] In embodiments the mineral ore comprises, consists of, or
consists essentially of a fertilizer ore, an industrial mineral
ore, a fuel mineral ore, or any combination thereof. In
embodiments, the mineral ore comprises, consists of, or consists
essentially of a fertilizer ore selected from phosphate ore, potash
ore, and a combination thereof. In embodiments, the mineral ore
comprises, consists of, or consists essentially of an industrial
mineral ore selected from limestone, clay, sand, gravel, diatomite,
kaolin, bentonite, silica, barite, gypsum, talc, zircon, fluorite,
and any combination thereof. In embodiments, the mineral ore
comprises, consists of, or consists essentially of a fuel mineral
ore selected from coal, bituminous oil sands, and a combination
thereof. In embodiments, the mineral ore comprises, consists of, or
consists essentially of an apatite. In some such embodiments, the
mineral ore comprises, consists of, or consists essentially of
hydroxylapatite, fluorapatite, chlorapatite, or any combination
thereof. In some embodiments, the mineral ore comprises, consists
of, or consists essentially of francolite.
[0067] In embodiments, the mineral ore comprises phosphate ore and
the gangue comprises calcite, dolomite, silica and/or silicate, or
any combination thereof.
[0068] In embodiments, the mineral ore comprises francolite and the
gangue comprises silica, silicate, carbonate, or any combination
thereof.
[0069] In embodiments, the sparge composition further comprises
phosphoric acid. In some such embodiments, the weight ratio of the
phosphoric acid to the mineral ore is from about 0.5 kg to about 20
kg of phosphoric acid per ton of the particles of the mineral ore,
in embodiments from about 0.5 kg to about 8 kg, in embodiments from
about 1 kg to about 8 kg, in embodiments from about 1.5 kg to about
8 kg, in embodiments from about 1.5 kg to about 7 kg, in
embodiments from about 1.5 kg to about 6 kg, in embodiments from
about 1.5 kg to about 5 kg, in embodiments from about 1.5 kg to
about 4 kg, or in embodiments from about 1.5 kg to about 3 kg of
phosphoric acid per ton of mineral ore.
[0070] In embodiments the sparge composition further comprises a pH
adjustment agent. In embodiments, the pH adjustment agent is an
acid. In embodiments, the pH adjustment agent is a base. In
embodiments, the acid is selected from hydrochloric acid, sulfuric
acid, p-toluene sulfonic acid, and any combination thereof. In
embodiments, the pH adjustment agent comprises, consists of, or
consists essentially of sulfuric acid.
[0071] In embodiments, the sparge composition has a pH from 1-3, in
embodiments 3-6, in embodiments 6-10, in embodiments 11-14, in
embodiments 4.5 to 5.5, in embodiments, 4.7 to 5.3, in embodiments
5.0 to 5.2, or in embodiments 4-7.
[0072] In embodiments, the sparge composition further comprises a
second collector. In some embodiments, the second collector
comprises, consists of, or consists essentially of a functionalized
silicone.
[0073] In embodiments, the sparge composition further comprises a
second collector selected from those disclosed in pages 5-40 of
Bulatovic, S. M. Ed., Handbook of Flotation Reagents Vol. 1.
Elsevier. In some such embodiments, the second collector is
selected from primary, secondary, and tertiary amines and/or their
ammonium salts, ether amines, fatty amines, amine condensates,
amphoteric amine carboxylic compounds, and any combination
thereof.
[0074] In some embodiments, the collector is selected from
sulfonated oleic acid, sulfonated linoleic acid, sulfonated
palmitic acid, sulfonated stearic acid, and any combination
thereof. In embodiments, the collector comprises, consists of, or
consists essentially of sulfonated oleic acid.
[0075] In embodiments, the sparge composition comprises, consists
of, or consists essentially of: water; a particulate comprising a
phosphate ore, the phosphate ore comprising silica, a silicate, a
carbonate, or any combination thereof, sulfonated oleic acid; a
modifier comprising one or more sulfonated polymers; and phosphoric
acid, wherein the pH of the sparge composition is from about 4 to
about 7.
[0076] In embodiments, the one or more sulfonated polymers are
selected from a sulfonated natural polymer, a sulfonated synthetic
polymer, and a combination thereof.
[0077] In embodiments the weight average molecular weight of the
sulfonated synthetic polymer is from about 300 to about 5,000,000,
in embodiments about 300 to about 1,000,000, in embodiments about
300 to about 500,000, in embodiments about 300 to about 100,000, in
embodiments about 300 to about 50,000, in embodiments about 300 to
about 35,000, in embodiments about 300 to about 30,000, in
embodiments about 300 to about 25,000, in embodiments from about
500 to about 5,000,000, in embodiments about 500 to about
1,000,000, in embodiments about 500 to about 500,000, in
embodiments about 500 to about 100,000, in embodiments about 500 to
about 50,000, in embodiments about 500 to about 25,000, in
embodiments from about 700 to about 5,000,000, in embodiments about
700 to about 1,000,000, in embodiments about 700 to about 500,000,
in embodiments about 700 to about 100,000, in embodiments about 700
to about 50,000, in embodiments about 700 to about 25,000, in
embodiments from about 1,000 to about 5,000,000, in embodiments
about 1,000 to about 1,000,000, in embodiments about 1,000 to about
500,000, in embodiments about 1,000 to about 100,000, in
embodiments about 1,000 to about 50,000, in embodiments about 1,000
to about 40,000, in embodiments about 1,000 to about 35,000, in
embodiments about 1,000 to about 30,000, in embodiments about 1,000
to about 25,000, in embodiments about 500 to about 20,000, in
embodiments about 500 to about 15,000, in embodiments about 500 to
about 10,000, in embodiments about 500 to about 7,000, in
embodiments about 500 to about 5,000, in embodiments about 500 to
about 3,000, in embodiments about 500 to about 1,000, in
embodiments about 1,000 to about 25,000, in embodiments about 700
to about 20,000, in embodiments about 700 to about 15,000, in
embodiments about 700 to about 10,000, in embodiments about 700 to
about 7,000, in embodiments about 700 to about 5,000, in
embodiments about 700 to about 3,000, in embodiments about 700 to
about 1,000, in embodiments about 1,000 to about 25,000, in
embodiments about 1,000 to about 20,000, in embodiments about 1,000
to about 15,000, in embodiments about 1,000 to about 10,000, in
embodiments about 1,000 to about 7,000, in embodiments about 1,000
to about 5,000, in embodiments about 1,000 to about 3,000, or in
embodiments about 1,000 to about 2,000.
[0078] In embodiments, the weight ratio of the one or more
sulfonated polymers to the particulate comprising the mineral ore
is from about 1 g to about 1000 g of the one or more sulfonated
polymers per ton of the mineral ore, in embodiments from about 5 g
to about 500 g, in embodiments, from about 10 g to about 500 g, in
embodiments from about 20 g to about 300 g, in embodiments from
about 50 g to about 300 g, in embodiments from about 50 g to about
200 g, in embodiments from about 10 g to about 100 g, in
embodiments from about 10 g to about 70 g, in embodiments from
about 30 g to about 70 g of the one or more sulfonated polymers per
ton of ore.
[0079] In embodiments, 1% to 99% by weight of the particulate
comprises particles having a particle size from about 38 microns to
about 250 microns, in embodiments 50% to 80% by weight of the
comminuted ore has a particle size from about 38 microns to about
250 microns, in embodiments 60% to about 70% has a particle size
from about 38 microns to about 250 microns, in embodiments 65% to
75% has a particle size from about 38 microns to about 250 microns,
or in embodiments about 68% to about 72% has a particle size from
about 38 microns to about 250 microns as measured by throw-action
sieve analysis carried out wet. The procedure for this test is
outlined in American Society for Testing and Materials (ASTM) C
136[2].
Second Embodiments
[0080] In second embodiments, the modifier of the composition of
the first embodiments comprises, consists of, or consists
essentially of a sulfonated lignin. Lignin is a class of complex
organic polymers. Without limitation thereto and solely for the
purposes of illustration, lignin may be represented by the
structure (I).
##STR00001##
[0081] In embodiments, the sulfonated lignin has a weight average
molecular weight range of from about 1,000 to about 140,000.
[0082] In embodiments, the sulfonated lignin comprises, consists
of, or consists essentially of a byproduct of production of wood
pulp using sulfite pumping. In some embodiments, the sulfonated
lignin is the reaction product of lignin with one or more sulfites,
one or more bisulfites, or a combination thereof.
[0083] In embodiments, the sulfonated lignin has comprises a
modification of structure (I) wherein one or more of the
--CH.sub.2OH groups is replaced with --CH.sub.2SO.sub.3H,
--CH.sub.2SO.sub.3.sup.-, or a combination thereof.
[0084] In embodiments, the sulfonated lignin has a structure
comprising structure (II), structure (III), or both structure (II)
and structure (III):
##STR00002##
wherein R.sub.1 is hydrogen or one of a wide variety of organic
structures found in the structure of lignin; R.sub.2 is one of a
wide variety of organic structures found in the structure of
lignin; and R.sub.3 is hydrogen or one of a wide variety of organic
structures found in the structure of lignin.
Third Embodiments
[0085] In third embodiments, the modifier of the composition of the
first embodiments comprises, consists of, or consists essentially
of a sulfonated starch. In embodiments, the sulfonated starch
comprises amylopectin wherein one or more of the --OH groups is
replaced with a sulfonate group (--SO.sub.3H and/or
--SO.sub.3.sup.-), amylose wherein one or more of the --OH groups
is replaced by a sulfonate group (--SO.sub.3H and/or
--SO.sub.3.sup.-), or a combination thereof.
Fourth Embodiments
[0086] In fourth embodiments, the modifier of the composition of
the first embodiments comprises, consists of, or consists
essentially of a sulfonated cellulose, wherein one or more of the
--OH groups in cellulose molecules is replaced by a sulfonate group
(--SO.sub.3H and/or --SO.sub.3.sup.-).
Fifth Embodiments
[0087] In fifth embodiments, the modifier of the composition of the
first embodiments comprises, consists of, or consists essentially
of a sulfonated lignin, a sulfonated starch, a sulfonated
cellulose, a sulfonated guar gum, a sulfonated xanthan gum, or any
combination thereof.
Sixth Embodiments
[0088] In sixth embodiments, the modifier of the composition of any
of the first embodiments comprises one or more sulfonated synthetic
polymers. In sixth embodiments, the modifier of the sparge
composition of any of the first embodiments comprises one or more
sulfonated synthetic polymers, wherein at least one of the one or
more sulfonated synthetic polymers comprises a residue of a
sulfonated monomer, wherein the sulfonated monomer is selected from
sulfonated vinyl alcohol, sulfonated acrylamide, sulfomethylated
acrylamide, 2-acrylamido-2-methylpropane sulfonic acid and/or a
salt thereof (ATBS), styrene sulfonic acid and/or a salt thereof,
and any combination thereof.
[0089] In embodiments, the at least one of the one or more
sulfonated synthetic polymers comprises a monomer residue having
the structure (IV)
##STR00003##
a monomer residue having the structure (V)
##STR00004##
or a combination thereof, wherein R.sub.5 is a divalent organic
group. In embodiments, the divalent organic group is selected from
alky, aryl, or alkaryl. In some such embodiments, R.sub.5 is
(CH.sub.2)n wherein n is 1-6. In some such embodiments, R.sub.5 is
(CH.sub.2)n wherein n is 1-3.
[0090] In embodiments, the at least one of the one or more
sulfonated synthetic polymers comprises a monomer residue having
the structure (VI)
##STR00005##
wherein the counterion is selected from NH.sub.4.sup.+, Na.sup.+,
K.sup.+, primary organic ammonium, secondary organic ammonium,
tertiary organic ammonium, and quaternary organic ammonium; the
monomer residue having the structure (VII)
##STR00006##
the monomer residue having the structure (VIII)
##STR00007##
wherein n is 1, 2, or 3 and the counterion is selected from
NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium; the monomer residue having the
structure (IX)
##STR00008##
wherein n is 1, 2, or 3; the monomer residue having the structure
(X)
##STR00009##
the monomer residue having the structure (XI)
##STR00010##
wherein the counterion is selected from NH.sub.4.sup.+, Na.sup.+,
K.sup.+, primary organic ammonium, secondary organic ammonium,
tertiary organic ammonium, and quaternary organic ammonium; the
monomer residue having the structure (XII)
##STR00011##
the monomer residue having the structure (XIII)
##STR00012##
wherein the counterion is selected from NH.sub.4.sup.+, Na.sup.+,
K.sup.+, primary organic ammonium, secondary organic ammonium,
tertiary organic ammonium, and quaternary organic ammonium; the
monomer residue having the structure (XIV)
##STR00013##
wherein R.sub.4 is alkyl; the monomer residue having the structure
(XV)
##STR00014##
wherein R.sub.4 is alkyl and wherein the sulfonate counterion is
selected from NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic
ammonium, secondary organic ammonium, tertiary organic ammonium,
and quaternary organic ammonium; the monomer residue having the
structure (XVI)
##STR00015##
the monomer residue having the structure (XVII)
##STR00016##
wherein the sulfonate counterion is selected from NH.sub.4.sup.+,
Na.sup.+, K.sup.+, primary organic ammonium, secondary organic
ammonium, tertiary organic ammonium, and quaternary organic
ammonium; or any combination thereof.
[0091] In some such embodiments, the at least one of the one or
more sulfonated synthetic polymers further comprises the residue of
acrylamide, the residue of acrylic acid, the residue of an acrylic
acid salt, the residue of methacrylic acid, the residue of a
methacrylic acid salt, the residue of maleic acid, the residue of a
salt of maleic acid, the residue of a monoester of maleic acid, the
residue of salt of a monoester of maleic acid, the residue of a
diester of maleic acid, the residue having the structure
(XVIII)
##STR00017##
or any combination thereof. In embodiments, the cation of the
acrylic acid salt, the residue of the methacrylic acid salt, the
residue of the salt of maleic acid, or the residue of the salt of
the monoester of maleic acid is selected from NH.sub.4.sup.+,
Na.sup.+, K.sup.+, primary organic ammonium, secondary organic
ammonium, tertiary organic ammonium, and quaternary organic
ammonium.
[0092] In embodiments, the modifier of the sparge composition of
any of the first embodiments comprises, consists of, or consists
essentially of a copolymer of acrylic acid and/or a salt of acrylic
acid with ATBS. In embodiments, the cation of the salt of the
acrylic acid is selected from NH.sub.4.sup.+, Na.sup.+, K.sup.+,
primary organic ammonium, secondary organic ammonium, tertiary
organic ammonium, and quaternary organic ammonium. In embodiments,
the ATBS is an ATBS salt, wherein the cation is selected from
NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium.
[0093] In embodiments, the modifier of the sparge composition of
any of the first embodiments comprises, consists of, or consists
essentially of a terpolymer of acrylic acid and/or a salt of
acrylic acid, ATBS, and acrylamide. In embodiments, the cation of
the salt of the acrylic acid is selected from NH.sub.4.sup.+,
Na.sup.+, K.sup.+, primary organic ammonium, secondary organic
ammonium, tertiary organic ammonium, and quaternary organic
ammonium. In embodiments, the ATBS is an ATBS salt, wherein the
cation is selected from NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary
organic ammonium, secondary organic ammonium, tertiary organic
ammonium, and quaternary organic ammonium.
Seventh Embodiments
[0094] In seventh embodiments, there is provided a method
comprising sparging the sparge composition of any one of the first
to sixth embodiments to yield a froth comprising tailings of gangue
and a sparged slurry comprising a concentrate of phosphate
beneficiary; and separating at least a portion of the concentrate
from the sparged slurry. In embodiments, the sparging the sparge
composition yields a sparged composition, the sparged composition
comprising, consisting of, or consisting essentially of an upper
froth layer and a lower slurry layer. In some such embodiments, the
lower slurry layer comprises water and a slurry of the concentrate
and the upper froth layer comprises the tailings. In some such
embodiments, the method comprises separating the upper froth layer
from the lower slurry layer. Therefore the separating the at least
the portion of concentrate from the tailings is accomplished by
means known in the art. In embodiments, the separating comprises,
consists of, or consists essentially of tapping off at least a
portion of the upper froth layer, skimming off at least a portion
of the upper froth layer, depositing at least a portion of the
upper froth layer onto a launder, decanting at least a portion of
the upper froth layer, or any combination thereof.
Eighth Embodiments
[0095] In eighth embodiments, there is provided a method of froth
flotation, the method comprising, consisting of, or consisting
essentially of forming a sparge composition, the sparge composition
comprising (i) a medium, (ii) a particulate comprising a mineral
ore, the mineral ore comprising a beneficiary and a gangue, (iii) a
collector, and (iv) a modifier comprising one or more sulfonated
polymers; and sparging the sparge composition to yield a sparged
composition, the sparged composition comprising, consisting of, or
consisting essentially of a froth and a sparged slurry. In
embodiments, the mineral ore comprises, consists of, or consists
essentially of a phosphate ore, the phosphate ore comprising a
gangue and a phosphate beneficiary, wherein the sparged slurry
comprises a concentrate of the phosphate beneficiary. In
embodiments, the method further comprises separating at least a
portion of the concentrate of the phosphate beneficiary from the
sparged composition. In some eighth embodiments, the froth
comprises tailings of the gangue and the sparged slurry comprises
the concentrate of the phosphate beneficiary, and the method
comprises separating at least a portion of the concentrate of the
phosphate beneficiary from the sparged slurry. In other eighth
embodiments, the froth comprises a concentrate of the beneficiary
and the sparged slurry comprises tailings of gangue, and the method
comprises separating at least a portion of the concentrate from the
sparged froth. In any of the eighth embodiments, the medium
comprises, consists of, or consists essentially of water.
[0096] In embodiments, the gangue comprises, consists of, or
consists essentially of a silicate, silica, carbonate, or any
combination thereof. In embodiments, the gangue comprises, consists
of, or consists essentially of calcite, dolomite, clay, or any
combination thereof. In embodiments, the ore comprises, consists
of, or consists essentially of a phosphate ore. In some such
embodiments, the gangue comprises or consists essentially of
silicate, silica, carbonate, or any combination thereof.
[0097] In embodiments the mineral ore comprises, consists of, or
consists essentially of a fertilizer ore, a fuel mineral ore, or
any combination thereof. In embodiments, the mineral ore comprises,
consists of, or consists essentially of a fertilizer ore selected
from phosphate ore, potash ore, and a combination thereof. In
embodiments, the mineral ore comprises, consists of, or consists
essentially of an industrial mineral ore selected from limestone,
clay, sand, gravel, diatomite, kaolin, bentonite, silica, barite,
gypsum, talc, zircon, fluorite, and any combination thereof. In
embodiments, the mineral ore comprises, consists of, or consists
essentially of a fuel mineral ore selected from coal, bituminous
oil sands, and a combination thereof.
[0098] In embodiments, the mineral ore comprises phosphate ore and
the gangue comprises calcite, dolomite, silica, a silicate, or any
combination thereof.
[0099] In embodiments, the sparge composition of the method of the
eighth embodiments further comprises phosphoric acid. In some such
embodiments, the weight ratio of the phosphoric acid to the
particulate comprising the mineral ore in the sparge composition of
the method of the eighth embodiments is from about 0.5 kg to about
20 kg of phosphoric acid per ton of the particles of the mineral
ore, in embodiments from about 0.5 kg to about 8 kg, in embodiments
from about 1 kg to about 8 kg, in embodiments from about 1.5 kg to
about 8 kg, in embodiments from about 1.5 kg to about 7 kg, in
embodiments from about 1.5 kg to about 6 kg, in embodiments from
about 1.5 kg to about 5 kg, in embodiments from about 1.5 kg to
about 4 kg, or in embodiments from about 1.5 kg to about 3 kg of
phosphoric acid per ton of the particulate comprising the mineral
ore.
[0100] In embodiments the sparge composition further comprises a pH
adjustment agent. In embodiments, the pH adjustment agent is an
acid. In embodiments, the pH adjustment agent is a base. In
embodiments, the acid is selected from hydrochloric acid, sulfuric
acid, p-toluene sulfonic acid, and any combination thereof. In
embodiments, the pH adjustment agent comprises, consists of, or
consists essentially of sulfuric acid.
[0101] In embodiments the sparge composition further comprises a pH
adjustment agent. In embodiments, the pH adjustment agent is an
acid. In embodiments, the pH adjustment agent is a base. In
embodiments, the acid is selected from hydrochloric acid, sulfuric
acid, p-toluene sulfonic acid, and any combination thereof. In
embodiments, the pH adjustment agent comprises, consists of, or
consists essentially of sulfuric acid.
[0102] In embodiments, the sparge composition has a pH from 1-3, in
embodiments 3-6, in embodiments 4-7, in embodiments 6-10, in
embodiments 11-14, in embodiments 4.5 to 5.5, in embodiments, 4.7
to 5.3, or in embodiments 5.0 to 5.2.
[0103] In embodiments, the collector is selected from tall oils,
sulfonated fatty acids, sulfonated tall oils, and any combination
thereof. In some such embodiments, the collector comprises,
consists of, or consists of a sulfonated fatty acid. In some such
embodiments, the collector is selected from sulfonated oleic acid,
sulfonated linoleic acid, sulfonated palmitic acid, sulfonated
stearic acid, and any combination thereof. In embodiments, the
collector comprises, consists of, or consists essentially of
sulfonated oleic acid.
[0104] In embodiments, the sparge composition comprises, consists
of, or consists essentially of: water; a particulate comprising a
phosphate ore, the phosphate ore comprising a phosphate beneficiary
and a gangue selected from calcite, dolomite, silica and/or
silicate, and any combination thereof; sulfonated oleic acid; a
modifier comprising one or more sulfonated polymers; and phosphoric
acid, wherein the pH of the sparge composition is from about 4 to
about 7.
[0105] In embodiments, the one or more sulfonated polymers is
selected from a sulfonated natural polymer, a sulfonated synthetic
polymer, and a combination thereof.
[0106] In embodiments the weight average molecular weight of the
one or more sulfonated synthetic polymers is from about 300 to
about 5,000,000, in embodiments about 300 to about 1,000,000, in
embodiments about 300 to about 500,000, in embodiments about 300 to
about 100,000, in embodiments about 300 to about 50,000, in
embodiments about 300 to about 35,000, in embodiments about 300 to
about 30,000, in embodiments about 300 to about 25,000, in
embodiments from about 500 to about 5,000,000, in embodiments about
500 to about 1,000,000, in embodiments about 500 to about 500,000,
in embodiments about 500 to about 100,000, in embodiments about 500
to about 50,000, in embodiments about 500 to about 25,000, in
embodiments from about 700 to about 5,000,000, in embodiments about
700 to about 1,000,000, in embodiments about 700 to about 500,000,
in embodiments about 700 to about 100,000, in embodiments about 700
to about 50,000, in embodiments about 700 to about 25,000, in
embodiments from about 1,000 to about 5,000,000, in embodiments
about 1,000 to about 1,000,000, in embodiments about 1,000 to about
500,000, in embodiments about 1,000 to about 100,000, in
embodiments about 1,000 to about 50,000, in embodiments about 1,000
to about 40,000, in embodiments about 1,000 to about 35,000, in
embodiments about 1,000 to about 30,000, in embodiments about 1,000
to about 25,000, in embodiments about 500 to about 20,000, in
embodiments about 500 to about 15,000, in embodiments about 500 to
about 10,000, in embodiments about 500 to about 7,000, in
embodiments about 500 to about 5,000, in embodiments about 500 to
about 3,000, in embodiments about 500 to about 1,000, in
embodiments about 1,000 to about 25,000, in embodiments about 700
to about 20,000, in embodiments about 700 to about 15,000, in
embodiments about 700 to about 10,000, in embodiments about 700 to
about 7,000, in embodiments about 700 to about 5,000, in
embodiments about 700 to about 3,000, in embodiments about 700 to
about 1,000, in embodiments about 1,000 to about 25,000, in
embodiments about 1,000 to about 20,000, in embodiments about 1,000
to about 15,000, in embodiments about 1,000 to about 10,000, in
embodiments about 1,000 to about 7,000, in embodiments about 1,000
to about 5,000, in embodiments about 1,000 to about 3,000, or in
embodiments about 1,000 to about 2,000.
[0107] In embodiments, the weight ratio of the one or more
sulfonated polymers to the particulate comprising the mineral ore
in the sparge composition of the method of the eighth embodiments
is from about 1 g to about 1000 g of the one or more sulfonated
polymers per ton of the particulate comprising the mineral ore, in
embodiments from about 5 g to about 500 g, in embodiments, from
about 10 g to about 500 g, in embodiments from about 20 g to about
300 g, in embodiments from about 50 g to about 300 g, in
embodiments from about 50 g to about 200 g, in embodiments from
about 10 g to about 100 g, in embodiments from about 10 g to about
70 g, or in embodiments from about 30 g to about 70 g of the one or
more sulfonated polymers per ton of the particulate.
Ninth Embodiments
[0108] In ninth embodiments, the modifier of the composition of the
method of the seventh or eighth embodiments comprises, consists of,
or consists essentially of a sulfonated lignin. In embodiments, the
sulfonated lignin has a weight average molecular weight range of
from about 1,000 to about 140,000.
[0109] In embodiments, the sulfonated lignin comprises, consists
of, or consists essentially of a byproduct of production of wood
pulp using sulfite pumping. In some embodiments, the sulfonated
lignin is the reaction product of lignin with one or more sulfites,
one or more bisulfites, or a combination thereof.
[0110] In embodiments, the sulfonated lignin has comprises a
modification of structure (I) wherein one or more of the
--CH.sub.2OH groups is replaced with --CH.sub.2SO.sub.3H,
--CH.sub.2SO.sub.3.sup.-, or a combination thereof.
[0111] In embodiments, the sulfonated lignin has a structure
comprising structure (II), structure (III), or both structure (II)
and structure (III), wherein R.sub.1 is hydrogen or one of a wide
variety of organic structures found in the structure of lignin;
R.sub.2 is one of a wide variety of organic structures found in the
structure of lignin; and R.sub.3 is hydrogen or one of a wide
variety of organic structures found in the structure of lignin.
Tenth Embodiments
[0112] In tenth embodiments, the modifier of the method of the
seventh or eighth embodiments comprises, consists of, or consists
essentially of a sulfonated starch. In embodiments, the sulfonated
starch comprises amylopectin wherein one or more of the --OH groups
is replaced with a sulfonate group (--SO.sub.3H and/or
--SO.sub.3.sup.-), amylose wherein one or more of the --OH groups
is replaced by a sulfonate group (--SO.sub.3H and/or
--SO.sub.3.sup.-), or a combination thereof.
Eleventh Embodiments
[0113] In eleventh embodiments, the modifier of the method of the
seventh or eighth embodiments comprises, consists of, or consists
essentially of a sulfonated cellulose, wherein one or more of the
--OH groups in cellulose molecules is replaced by a sulfonate group
(--SO.sub.3H and/or --SO.sub.3.sup.-).
Twelfth Embodiments
[0114] In twelfth embodiments, the modifier of the method of the
seventh or eighth embodiments comprises, consists of, or consists
essentially of a sulfonated natural polymer selected from
sulfonated lignin, sulfonated starch, sulfonated cellulose,
sulfonated guar gum, sulfonated xanthate gum, and any combination
thereof.
Thirteenth Embodiments
[0115] In thirteenth embodiments, the modifier of the method of the
seventh or eighth embodiments comprises a sulfonated synthetic
polymer. In thirteenth embodiments, the modifier of the sparge
composition of the methods of the seventh or eighth embodiments
comprises a sulfonated synthetic polymer comprising a residue of a
sulfonated monomer, wherein the sulfonated monomer is selected from
sulfonated vinyl alcohol, sulfonated acrylamide, sulfomethylated
acrylamide, 2-acrylamido-2-methylpropane sulfonic acid and/or a
salt thereof (ATBS), styrene sulfonic acid and/or a salt thereof,
and any combination thereof.
[0116] In embodiments, the sulfonated synthetic polymer comprises a
monomer residue selected from the monomer residue having the
structure (IV), wherein the counterion is selected from
NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium; the monomer residue having the
structure (V), the monomer residue having the structure (VI),
wherein the counterion is selected from NH.sub.4.sup.+, Na.sup.+,
K.sup.+, primary organic ammonium, secondary organic ammonium,
tertiary organic ammonium, and quaternary organic ammonium; the
monomer residue having the structure (VII); the monomer residue
having the structure (VIII), wherein the counterion is selected
from NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium; the monomer residue having the
structure (IX); the monomer residue having the structure (X); the
monomer residue having the structure (XI), wherein the counterion
is selected from NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic
ammonium, secondary organic ammonium, tertiary organic ammonium,
and quaternary organic ammonium; the monomer residue having the
structure (XII); the monomer residue having the structure (XIII),
wherein the counterion is selected from NH.sub.4.sup.+, Na.sup.+,
K.sup.+, primary organic ammonium, secondary organic ammonium,
tertiary organic ammonium, and quaternary organic ammonium; the
monomer residue having the structure (XIV), wherein R.sub.4 is
alkyl; the monomer residue having the structure (XV), wherein
R.sub.4 is alkyl and wherein the counterion is selected from
NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium; the monomer residue having the
structure (XVI); the monomer residue having the structure (XVII),
wherein the counterion is selected from NH.sub.4.sup.+, Na.sup.+,
K.sup.+, primary organic ammonium, secondary organic ammonium,
tertiary organic ammonium, and quaternary organic ammonium; and any
combination thereof.
[0117] In some such thirteenth embodiments, the sulfonated
synthetic polymer further comprises the residue of acrylamide, the
residue of acrylic acid, the residue of an acrylic acid salt, the
residue of methacrylic acid, the residue of a methacrylic acid
salt, the residue of maleic acid, the residue of a salt of maleic
acid, the residue of a monoester of maleic acid, the residue of
salt of a monoester of maleic acid, the residue of a diester of
maleic acid, the residue having the structure (XVI), or any
combination thereof. In embodiments, the cation of the acrylic acid
salt, the residue of the methacrylic acid salt, the residue of the
salt of maleic acid, or the residue of the salt of the monoester of
maleic acid is selected from NH.sub.4.sup.+, Na.sup.+, K.sup.+,
primary organic ammonium, secondary organic ammonium, tertiary
organic ammonium, and quaternary organic ammonium.
[0118] In embodiments, the modifier of the sparge composition of
any of the methods of the seventh or eighth embodiments comprises,
consists of, or consists essentially of a copolymer of acrylic acid
and/or a salt of acrylic acid with ATBS. In embodiments, the cation
of the salt of the acrylic acid is selected from NH.sub.4.sup.+,
Na.sup.+, K.sup.+, primary organic ammonium, secondary organic
ammonium, tertiary organic ammonium, and quaternary organic
ammonium. In embodiments, the ATBS is an ATBS salt, wherein the
cation is selected from NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary
organic ammonium, secondary organic ammonium, tertiary organic
ammonium, and quaternary organic ammonium.
[0119] In embodiments, the modifier of the sparge composition of
any of the methods of the seventh or eighth embodiments comprises,
consists of, or consists essentially of a terpolymer of acrylic
acid and/or a salt of acrylic acid, ATBS, and acrylamide. In
embodiments, the cation of the salt of the acrylic acid is selected
from NH.sub.4.sup.+, Na.sup.+, K.sup.+, primary organic ammonium,
secondary organic ammonium, tertiary organic ammonium, and
quaternary organic ammonium. In embodiments, the ATBS is an ATBS
salt, wherein the cation is selected from NH.sub.4.sup.+, Na.sup.+,
K.sup.+, primary organic ammonium, secondary organic ammonium,
tertiary organic ammonium, and quaternary organic ammonium.
[0120] In embodiments, at least one of the one or more sulfonated
polymers of any one of the methods of the seventh or eighth
embodiments comprises a residue of a monomer, wherein the monomer
is selected from sulfonated vinyl alcohol, sulfonated acrylamide,
sulfomethylated acrylamide, 2-acrylamido-2-methylpropane sulfonic
acid and/or a salt thereof (ATBS), styrene sulfonic acid and/or a
salt thereof, and any combination thereof. In some such
embodiments, the at least one of the one or more sulfonated
polymers further comprises a residue of a monomer selected from
acrylic acid, methacrylic acid, acrylamide, vinyl alcohol, maleic
acid, maleic acid esters, and any combination thereof. In some such
embodiments, the at least one of the one or more sulfonated
polymers comprises a residue of a monomer, wherein the monomer is
acrylic acid. In some such embodiments, the at least one of the one
or more sulfonated polymers comprises the residue of ATBS, the
residue of a sulfomethylated acrylamide, or both the residue of
ATBS and the residue of sulfomethylated acrylamide.
[0121] In embodiments, the modifier of any of the methods of the
seventh and eighth embodiments comprises a naphthalene sulfonate
formaldehyde condensate, sulfonated
poly(thiophene-3-[2-(2-methoxyethoxy)ethoxy]-2,5-diyl), or a
combination thereof.
Fourteenth Embodiments
[0122] In fourteenth embodiments, at least one of the one or more
sulfonated polymers of any of the first to thirteenth embodiments
is tagged with a fluorescent tag. In embodiments, the fluorescent
tag is copolymerized into the backbone of the at least one of the
one or more sulfonated polymers or the fluorescent tag is otherwise
covalently bonded to the at least one of the one or more sulfonated
polymers. In embodiments, the fluorescent tag is selected from the
group consisting of hydroxy allyloxy propyl naphthalimide (HAPNQ),
pyrene tetrasulfonic acid (PTSA), naphthalene disulfonic acid, and
4-methoxy-N-(3-dimethylaminopropyl)-naphthalimide vinylbenzyl
chloride quat (VBNQ). In embodiments, the fluorescent tag is about
2% to about 5% by weight of the one or more sulfonated
polymers.
[0123] In embodiments, the modifier of any of the first to
thirteenth embodiments comprises a fluorescent tag material. In
such embodiments, the ratio by weight of the fluorescent tag
material to the one or more sulfonated polymers is from about 2:98
to about 5:95. In some such embodiments, the fluorescent tag
material is selected from the group consisting of hydroxy allyloxy
propyl naphthalimide (HAPNQ), pyrene tetrasulfonic acid (PTSA),
naphthalene disulfonic acid, and VBNQ.
Fifteenth Embodiments
[0124] In fifteenth embodiments, the method of any one of the
seventh to fourteenth embodiments further comprises grinding a raw
mineral ore to form the phosphate ore. In embodiments, the grinding
reduces the largest dimension of the raw mineral ore by a factor of
2 to a factor of 1.times.10.sup.9.
Sixteenth Embodiments
[0125] In sixteenth embodiments, the method of the fifteenth
embodiments further comprises the step of combining the phosphate
ore with at least a portion of the medium to form a medium-ore
slurry.
Seventeenth Embodiments
[0126] In seventeenth embodiments, the method of the sixteenth
embodiments further comprises desliming the phosphate ore.
Eighteenth Embodiments
[0127] In eighteenth embodiments, the method of any one of the
sixteenth or seventeenth embodiments further comprises combining
the phosphate ore with at least a portion of the modifier, the
collector, or the modifier and the collector to form a
modifier/collector-ore slurry, and conditioning the phosphate
ore.
Nineteenth Embodiments
[0128] In nineteenth embodiments, the method of the seventh to
eighteenth embodiments comprises combining the particulate with the
modifier, the collector, and the medium to make the sparge
composition.
Twentieth Embodiments
[0129] In twentieth embodiments, there is provided a use of any of
the sparge compositions of the first to sixth embodiments in the
beneficiation of phosphate ore by reverse froth flotation to
furnish a phosphate beneficiary for use in the manufacture of
orthophosphoric acid.
[0130] The foregoing may be better understood by reference to the
following examples, which are presented for purposes of
illustration and are not intended to limit the scope of the
invention. In particular the examples demonstrate representative
examples of principles innate to the invention and these principles
are not strictly limited to the specific condition recited in these
examples. As a result it should be understood that the invention
encompasses various changes and modifications to the examples
described herein and such changes and modifications can be made
without departing from the spirit and scope of the invention and
without diminishing its intended advantages. It is therefore
intended that such changes and modifications be covered by the
appended claims.
EXAMPLES
[0131] Separation of a phosphate ore into a concentrate and
tailings was conducted using a sulfonate polymer as modifier. The
phosphate ore comprised francolite with calcite, dolomite, and
silicate as gangue.
Example 1: Preparation of Phosphate Ore Samples
[0132] Two samples of a sedimentary phosphate ore were obtained
from the flotation circuit in a phosphate flotation plant as
follows: the feed containing an aqueous slurry of a comminuted
deslimed ore for the conditioning tank of a phosphate flotation
plant was tapped at three different times; on a first occasion to
obtain pulp sample I, on a second occasion to obtain a pulp sample
II, and on a third occasion to obtain pulp sample III. Pulp samples
I, II, and III were each separately dried, and bagged to give ore
samples I and II respectively.
[0133] Each of ore samples I and II was chemically analyzed for
weight percent P.sub.2O.sub.5 equivalent, MgO equivalent, SiO.sub.2
equivalent, and weight loss at 925.degree. C. The particle
distribution of each of ore samples I and II was analyzed. The
results are given in TABLE 1:
TABLE-US-00001 TABLE 1 Particle size distribution (as measured
throw-action sieve analysis carried out wet) and composition (as
measured by X-ray fluorescence) of Ores I, II, and III Particle
size distribution, Composition, % % by weight % weight Ore <38
>38 .mu.m >250 loss at sample .mu.m <250 .mu.m .mu.m
P.sub.2O.sub.5 MgO CaO SiO.sub.2 925.degree. C. Ore 12.8 68.1 19.1
21.64 1.25 53.89 1.34 19.16 Sample I Ore 12.2 67.5 20.3 21.13 1.13
53.68 1.15 19.21 Sample II Ore 20.58 71.58 7.84 22.34 0.54 57.35
0.94 19.56 Sample III
Example 2: Aqueous Polymers
[0134] Six aqueous polymers were synthesized as in Table 2:
TABLE-US-00002 TABLE 2 Aqueous polymers Weight average molecular
Aqueous Actives, weight, Polymer Composition wt % g/mole A
Potassium polyacrylate 29 25,000-30,000 B Sodium poly(sodium
acrylate-co-methyl 30 25,000-30,000 acrylate) C Poly(maleic acid)
40 25,000-30,000 D Ammonium salt of poly(acrylic acid-co-ATBS 34.5
5,000-10,000 sulfonic acid) E Sodium salt of poly(acrylic acid-co-
35 25,000-30,000 sulfomethylated acrylamide) F Sodium salt of
poly(acrylic acid-co- 35 25,000-30,000 sulfomethylated acrylamide),
tagged with less than 2% hydroxyl allyloxy propyl naphthalimide
quaternary salt (HAPNQ)
Example 3: First Set of Sparge Tests with Ore Sample I
[0135] Reverse flotation tests were conducted in a Denver D-12
Laboratory Flotation Machine. Sulfonated oleic acid was used as
collector at a dosage of two kilograms per ton of ore, phosphoric
acid was used as a depressant, one of the polymers listed in TABLE
2 was used as modifier, and sulfuric acid was used as pH adjustment
agent. Each collector, depressant, and pH adjuster was prepared as
a 10% solution in deionized water. For each test, a phosphate ore
slurry was made by dispersing dried phosphate ore Sample I at 25%
solids in tap water. The slurry was then conditioned by the
addition of depressant, modifier and the collector in the amounts
given in TABLE 3. The pH of the conditioned slurry was adjusted to
5.0-5.2 with sulfuric acid. Finally, the slurry was sparged with
air. Calcite and dolomite were floated from the slurry and removed
as tailings, while the phosphate ore concentrate remained in the
slurry as concentrate. Both concentrate and tailings were filtered,
dried, weighed, and analyzed for P.sub.2O.sub.5 content. The
flotation test results are given in TABLE 3 and FIG. 1:
TABLE-US-00003 TABLE 3 First set of sparge tests with Ore Sample I
in tap water Modifier Concentrate Depressant Aqueous Recovery Test
Phosphoric Aqueous Polymer, Grade of of # acid, kg/t Polymer g/t
Yield, % P.sub.2O.sub.5, % P.sub.2O.sub.5, % 1 1 None 47.82 32.40
73.17 2 2 None 52.29 32.32 77.97 3 1 A 150 56.09 31.20 84.02 4 1 B
150 59.37 30.00 84.75 5 1 C 150 46.58 33.07 73.54 6 1 D 150 54.62
32.72 83.31 7 1 E 150 53.63 33.05 82.25 8 1 F 150 53.35 33.30 82.91
kg/t: kilogram per ton of dry ore; g/t: gram per ton of dry ore
[0136] FIG. 1 shows a plot of % grade versus % recovery. As shown
in TABLE 3 and FIG. 1, addition of the sulfonated polymers D, E,
and F significantly improved both phosphate grade and recovery.
Non-sulfonated Polymers A and B improved phosphate recovery but
lowered phosphate grade. Polymer C (without sulfonate group) showed
an improved phosphate grade but lower phosphate recovery.
Furthermore, usage of depressant phosphoric acid can be
significantly reduced while the phosphate (P.sub.2O5) recovery is
increased
Example 4: Second Set of Sparge Tests with Ore Sample I
[0137] In Example 4, Polymers D and E were tested with ore sample I
in tap water. Example 4 was carried out in the same way as Example
3, except that the amounts of the depressant (phosphoric acid) and
modifier (polymer) were varied from test to test, as shown in TABLE
4. The flotation test results are given in TABLE 4 and FIG. 2.
TABLE-US-00004 TABLE 4 Second Set of Sparge Tests with Ore Sample I
in Tap Water Concentrate Depressant Modifier Recovery Test
Phosphoric Aqueous Aqueous Grade of of # acid, kg/t Polymer
Polymer, g/t Yield, % P.sub.2O.sub.5, % P.sub.2O.sub.5, % 9 1.5
None 49.16 32.36 75.75 10 2 None 52.35 32.22 77.87 11 3 None 53.84
32.15 80.96 12 4 None 54.31 32.29 82.76 13 1.5 D 50 53.77 32.7
82.85 14 1.5 D 100 55.09 32.43 84.68 15 1.5 D 150 56.04 32.2 84.74
16 2 D 150 56.69 32.35 86.41 17 3 D 150 57.96 32.24 87.17 18 4 D
150 58.46 32.25 88.22 19 1.5 E 50 53.94 32.82 83.7 20 1.5 E 100
53.74 33.26 83.73 21 1.5 E 150 55.17 32.86 85.54 22 2 E 150 55.79
32.91 86.49 23 3 E 150 57.18 32.55 87.75 24 4 E 150 57.74 32.34
87.83 kg/t: kilogram per ton of dry ore; g/t: gram per ton of dry
ore
[0138] As shown in TABLE 4 and FIG. 2, addition of either
sulfonated polymer D or sulfonated polymer E significantly
increased the phosphate recovery, while the corresponding phosphate
grade was marginally changed or improved.
Example 5: Sparge Tests of Ore Sample II in Synthetic Process
Water
[0139] Flotation tests on sulfonated Polymer F were conducted with
ore sample II in a synthetic water, but otherwise in the same
manner as Examples 3 and 4.
[0140] The synthetic water contained various ions to simulate the
composition of a process water from the flotation plant (320 mg/l
Ca.sup.2+, 87 mg/l Mg.sup.2+, 740 mg/l Na.sup.+, 34 mg/l K.sup.+,
900 mg/l Cl.sup.-, 1400 mg/l SO.sub.4.sup.2-). The flotation test
results are given in TABLE 5 and FIG. 3
TABLE-US-00005 TABLE 5 Sparge Tests with Ore Sample II in Synthetic
Simulated Process Water Depressant Modifier Concentrate Test
Phosphoric Aqueous Aqueous Yield, Grade of Recovery of # acid, kg/t
Polymer Polymer g/t % P.sub.2O.sub.5, % P.sub.2O.sub.5, % 25 2 None
50.75 33.57 80.40 26 3 None 53.41 33.21 82.64 27 4 None 54.65 33.24
84.84 28 6 None 56.69 33.18 88.07 29 2 F 100 55.88 33.16 87.15 30 3
F 100 56.52 33.54 88.23 31 4 F 100 56.82 33.10 88.03 32 6 F 100
57.76 33.26 89.05 33 2 F 200 55.62 33.38 87.83 34 3 F 200 56.31
33.80 88.22 35 4 F 200 56.32 33.57 87.60 36 6 F 200 57.52 33.54
89.60 kg/t: kilogram per ton of dry ore; g/t: gram per ton of dry
ore
[0141] As shown in TABLE 5 and FIG. 3, the addition of sulfonated
polymer F significantly increased the phosphate recovery, while
phosphate grade was marginally changed or improved. The improvement
in phosphate recovery with the addition of polymer F was
particularly significant at lower dosages of phosphoric acid. At 2
kg/t dosage of phosphoric acid, for example, the phosphate recovery
increased from 80.4% to 87.15% with addition of 100 g/t of the
aqueous sulfonated polymer solution. Furthermore, usage of
phosphoric acid as depressant can be significantly reduced while
simultaneously increasing phosphate recovery.
Example 6: Sparge Tests of Ore Sample III in Synthetic Process
Water
[0142] Flotation tests on sulfonated polymer F were conducted with
ore sample III in a synthetic water at pH 4.2-4.6 at two collector
dosages. The collector was sulfonated oleic acid. The flotation
test results are given in TABLE 6 and FIG. 4. The results showed
that polymer F could reduce the required dosage of phosphoric acid
by 50% while maintaining a similar P.sub.2O.sub.5 grade and
recovery of concentrate.
TABLE-US-00006 TABLE 6 Sparge Tests with Ore Sample III in
Synthetic Simulated Process Water at pH 4.2-4.6 Depressant Modifier
Concentrate Test Phosphoric Aqueous Aqueous Grade Recovery # acid,
kg/t Polymer Polymer g/t Collector kg/t Yield, % of P.sub.2O.sub.5,
% of P.sub.2O.sub.5, % 37 4 F 0 1.5 70.76 29.43 94.27 38 4 F 0 2
64.88 31.60 91.92 39 2 F 100 1.5 70.86 29.29 94.28 40 2 F 100 2
64.28 31.78 91.70 kg/t: kilogram per ton of dry ore; g/t: gram per
ton of dry ore
Example 7: Sparge Tests of Ore Sample III in Synthetic Process
Water
[0143] Flotation tests on sulfonated Polymer F were conducted with
ore sample III in a synthetic water at pH 6.5-7, two collector
dosages. The collector was sulfonated oleic acid. The flotation
test results are given in TABLE 7 and FIG. 5. The results showed
that polymer F could reduce the required dosage of phosphoric acid
by 50% while maintaining a similar P.sub.2O.sub.5 grade and
recovery of concentrate.
TABLE-US-00007 TABLE 7 Sparge Tests with Ore Sample III in
Synthetic Simulated Process Water at pH 6.5-7. Depressant Modifier
Concentrate Test Phosphoric Aqueous Aqueous Grade Recovery # acid,
kg/t Polymer Polymer g/t Collector kg/t Yield, % of P.sub.2O.sub.5,
% of P.sub.2O.sub.5, % 41 4 F 0 1.5 65.79 28.73 88.12 42 4 F 0 2
59.89 30.40 83.91 43 2 F 100 1.5 67.33 28.59 88.99 44 2 F 100 2
59.44 30.65 84.01 kg/t: kilogram per ton of dry ore; g/t: gram per
ton of dry ore
* * * * *