阅读说明：本技术 用于对磷酸盐矿石进行反向泡沫浮选的改进组合物和方法 (Improved composition and process for reverse froth flotation of phosphate ores ) 是由 J·刘 S·R·史利南 K·奥布赖恩 D·N·T·哈伊 于 2018-05-25 设计创作，主要内容包括：描述了用于反向泡沫浮选分离的改进鼓泡组合物和其用途以及反向泡沫浮选的改进方法。描述了包括捕收剂和选矿剂的鼓泡组合物,所述捕收剂包括磺化脂肪酸和/或其盐并且所述选矿剂包括羟基脂肪酸组合物。所述鼓泡组合物适于用于反向泡沫浮选以从包括磷酸盐和白云石、方解石、硅酸盐和/或其它脉石的矿石中分离磷酸盐精选矿。所公开的组合物和方法表现出磷酸盐与这种矿石的改进分离。(An improved bubbling composition for reverse froth flotation separation and its use and an improved process for reverse froth flotation are described. A bubbling composition is described comprising a collector and a beneficiation agent, the collector comprising a sulfonated fatty acid and/or a salt thereof and the beneficiation agent comprising a hydroxy fatty acid composition. The bubbling composition is suitable for use in reverse froth flotation to separate phosphate concentrates from ores including phosphates and dolomite, calcite, silicates, and/or other gangue. The disclosed compositions and methods exhibit improved separation of phosphate from such ores.)

1. A bubbling composition, comprising:

(i) a medium comprising water;

(ii) phosphate ores including phosphate beneficiates (phosphate beneficiaries) and gangue;

(iii) a collector comprising one or more sulfonated fatty acids, one or more sulfonated fatty acid salts, or any combination thereof; and

(iv) a beneficiation agent comprising one or more hydroxy fatty acids, one or more hydroxy fatty acid salts, or any combination thereof.

2. The bubbling composition according to claim 1, wherein said phosphate concentrate comprises Ca²⁺And PO₄ ^3-。

3. The bubbling composition according to claim 1 or claim 2, wherein said beneficiation agent comprises ricinoleic acid, ricinoleate, 12-hydroxystearic acid, 12-hydroxystearate, 9, 10-dihydroxyoctadecanoic acid, 9, 10-dihydroxyoctadecanoate, 9,10, 18-trihydroxyoctadecanoic acid, 9,10, 18-trihydroxyoctadecanoate, hydroxyeicosenoic acid (lesquerolic acid), hydroxyeicosenoate, 15-hydroxyhexadecanoic acid, 15-hydroxyhexadecanoate, isoricinoleic acid, isoricinoleate, hydroxyoctadecadienoic acid (densipolic acid), hydroxyoctadecadienate, 14-hydroxy-eicosa-cis-11-cis-17-dienoic acid, 14-hydroxy-eicosa-cis-17-dienoic acid, 2-hydroxyoleic acid, 2-hydroxyoleate, 2-hydroxylinoleic acid, 2-hydroxylinoleate, 18-hydroxystearic acid, 18-hydroxystearate, 15-hydroxylinoleic acid, 15-hydroxylinoleate, or any combination thereof.

4. The bubbling composition according to any one of claims 1-3, wherein said hydroxy fatty acid composition comprises ricinoleic acid, ricinoleate, or a combination thereof.

5. The bubbling composition according to any one of claims 1-4, wherein said gangue comprises calcite, dolomite, silicates, or any combination thereof.

6. The bubbling composition according to any one of claims 1-5, wherein said collector comprises sulfonated oleic acid, sulfonated oleate, sulfonated linoleic acid, sulfonated linoleate, sulfonated linolenic acid, sulfonated linolenate, sulfonated ricinoleate, sulfonated palmitoleate, sulfonated 11-eicosenoic acid, sulfonated 11-eicosenate, sulfonated erucic acid, sulfonated erucate, sulfonated nervonic acid, sulfonated nervonate, or any combination thereof.

7. The bubbling composition according to any one of claims 1 to 6, wherein said collector comprises sulfonated oleic acid, sulfonated oleate salt, or a combination thereof.

8. The bubbling composition according to any one of claims 1 through 7, wherein said phosphate ore comprises apatite.

9. The bubbling composition according to claim 8, wherein said apatite is selected from the group consisting of fluorapatite, hydroxyapatite, chlorapatite, or any combination thereof.

10. The bubbling composition according to any one of claims 1 to 9, further comprising one or more emulsifying surfactants, one or more additional collectors, one or more inhibitors, one or more activators, one or more frothers, or any combination thereof.

11. The bubbling composition according to any one of claims 1 to 10, further comprising a pH adjusting agent.

12. The bubbling composition according to any one of claims 1 to 11, wherein the pH of said bubbling composition is from about 4 to about 7.

13. A method of froth flotation, comprising:

bubbling the bubbling composition according to any one of claims 1 to 12 to form a bubbling slurry comprising a froth and an underflow, wherein the underflow comprises a concentrate comprising the phosphate concentrate and the froth comprises tailings comprising the gangue; and

separating at least a portion of the concentrate from at least a portion of the tailings.

14. Use of a bubbling composition according to any one of claims 1 to 12 for refining phosphate ores.

15. The use according to claim 14, wherein the phosphate ore is used for the production of phosphoric acid.

Background

The present invention relates to novel materials, compositions and methods for improving the effectiveness of froth flotation beneficiation processes. Many minerals and other materials are obtained from mining and other resource recovery operations as intimate mixtures that are difficult to separate into their constituents. For example, the mined ore is often a multi-mineral ore and contains at least one desired component, a concentrate, and one or more other less valuable and/or desirable materials, gangue.

In the beneficiation process, two or more materials that coexist in a mixture are separated from each other to obtain a concentrate that takes a more concentrated form than that present in the mixture. One form of beneficiation is froth flotation separation.

In froth flotation separation of mineral ores, the ore is finely ground (crushed) to form crushed ore in particulate form. The crushed ore is slurried in a liquid medium, typically water, to make a slurry as the sparging component. Other components that aid in the separation of the concentrate from the gangue, such as collectors, modifiers, depressants, frothers (frothers), and/or activators, may be included in the bubbling composition.

In a process known as bubbling, a gas (typically air) is bubbled through the bubbling composition and a foam is formed at the surface of the bubbling composition. During sparging, some materials from the ore, such as targeted particles, float up (i.e., float) with the gas bubbles and concentrate in the froth, while others concentrate in the liquid (underflow) body.

The collector functions to aid in flotation of the targeted particles in the sparging composition. The inhibitor acts to prevent or prevent untargeted particles in the flotation bubble composition.

Bubbling a bubbling composition with a gas, the bubbles of the bubbling composition rising from the slurry with the hydrophobic particles and forming a froth layer above the underflow. A foam layer may then be deposited on the launder. The less hydrophobic material remains in the slurry and froth flotation separation is completed.

Two common forms of flotation separation are direct flotation and reverse flotation. In the direct flotation process, the froth comprises concentrate or concentrate, while in the reverse flotation process, the froth comprises gangue or tailings. The aim of flotation in both forms of froth flotation is to separate and recover as much concentrate as possible from the particulate material at as high a concentrate concentration as possible. In froth flotation, the bubbling composition is bubbled to form a froth layer and an underflow. In direct froth flotation, the froth layer comprises concentrate (concentrate) and the underflow comprises tailings (gangue concentrate). In reverse froth flotation, the froth layer comprises tailings and the underflow comprises concentrate. In direct froth flotation, the froth may include more concentrate than gangue and the tailings may include more gangue than concentrate. In reverse froth flotation, the froth may include more gangue than concentrate and the tailings may include more concentrate than gangue.

Froth flotation separation can be used to separate solids (e.g., constituents of mineral ores) from solids and liquids or semi-solids from solids (e.g., to separate bitumen from oil sands).

A prerequisite for flotation separation is the release of particles. Thus, in order to float mineral ores, comminution (grinding of solids by techniques such as dry grinding, wet grinding, etc.) is required to liberate the mineral. Extensive grinding or comminution may provide better release of the particles for separation of concentrates and gangue in the froth flotation process.

Phosphate ores typically include phosphate minerals and gangue impurities, such as carbonAcid salts and silicates. One phosphate mineral is apatite, which comprises PO₄ ^3-And Ca²⁺. The apatite comprises hydroxyapatite (hydroxyapatite), fluoroapatite, chloroapatite, and phosphorus anions^-、Cl^-、OH^-And/or CO₃ ^2-And other anionic minerals. Impurities in phosphate ores are carbonates, such as dolomite and/or calcite, silicates and clays. Phosphate ores are typically beneficiated and then used in any subsequent (downstream) processes such as phosphoric acid production. Even after beneficiation, the impurities present in phosphate ores can cause considerable problems in such downstream operations. For example, the presence of carbonates in phosphate ore concentrates may result in high sulfur consumption and higher viscosity in the production of phosphoric acid from phosphate concentrates. Thus, efficient removal of carbonates from phosphate ores is critical for the production of phosphoric acid downstream from the phosphates of the ore. One of the common processes for removing carbonate is reverse froth flotation, in which carbonate minerals are concentrated in the froth as tailings, while phosphate minerals are concentrated in the underflow.

Since the 80's of the 20 th century, phosphate ores have been beneficiated by froth flotation using sulfonated fatty acids as collectors. An advantage of sulfonated fatty acids is that sulfonated fatty acids act as collectors over a wide range of pH, temperature and water hardness. Further, sulfonated fatty acids exhibit higher selectivity for carbonate and/or silicate containing targeting particles than non-sulfonated fatty acids. However, one disadvantage of sulfonated fatty acids when used in froth flotation is that sulfonated fatty acids can cause excessive froth with a concomitant reduction in the grade and/or recovery (yield) of the concentrate, and excessive froth can cause downstream froth treatment problems.

Although the aim of froth flotation is to separate and recover as much concentrate as possible in the highest possible concentration, in such a process there is a trade-off between the purity of the concentrate and the yield of the concentrate. Adjustments to froth flotation conditions and/or materials at the expense of yield may result in improved purity, or vice versa.

In view of the above, it would be advantageous to provide improved methods and/or compositions for froth flotation that can be implemented in existing froth flotation facilities to separate concentrates from ores. It would be advantageous to provide an improved process and materials thereof for obtaining higher yields and higher purities of concentrates. It would be advantageous to provide an improved method and/or composition for froth flotation that does not cause excessive froth during the froth flotation process, does not reduce the grade and/or recovery (yield) of the concentrate, and does not cause froth treatment problems.

Disclosure of Invention

Disclosed herein are bubbling compositions for reverse froth flotation of phosphate ores. In an embodiment, a bubbling composition is disclosed, comprising: (i) a medium; (ii) crushing phosphate ore; (iii) a collector comprising a sulfonated fatty acid composition comprising one or more sulfonated fatty acids, one or more sulfonated fatty acid salts, or any combination thereof; and (iv) a beneficiation agent comprising a hydroxy fatty acid composition comprising one or more hydroxy fatty acids, one or more hydroxy fatty acid salts, or a combination thereof, wherein the crushed phosphate ore comprises a phosphate concentrate and a gangue. In embodiments, the medium comprises, consists of, or consists essentially of water. In an embodiment, the weight of the sulfonated fatty acid composition divided by the weight of the hydroxy fatty acid composition is from about 0.01 to about 99. In some embodiments, the pH of the bubbling composition is from about 4 to about 7. In some embodiments, the one or more sulfonated fatty acids, the one or more sulfonated fatty acid salts, or the combination thereof comprises, consists of, or consists essentially of: a sulfonated fatty acid, a sulfonated fatty acid salt, or a combination thereof. In some embodiments, the one or more hydroxy fatty acids, the one or more hydroxy fatty acid salts, or the combination thereof comprise, consist of, or consist essentially of: a hydroxy fatty acid, a hydroxy fatty acid salt, or a combination thereof.

In an embodiment, the hydroxy fatty acid composition comprises a C6 to C30 hydroxy fatty acid, a C6 to C30 hydroxy fatty acid salt, or a combination thereof.

In an embodiment, the hydroxy fatty acid composition comprises a hydroxy fatty acid having one to three hydroxyl groups, a hydroxy fatty acid salt having one to three hydroxyl groups, or a combination thereof.

In embodiments, the hydroxy fatty acid composition comprises ricinoleic acid, ricinoleate, 12-hydroxystearic acid, 12-hydroxystearate, 9, 10-dihydroxyoctadecanoic acid, 9, 10-dihydroxyoctadecanoate, 9,10, 18-trihydroxyoctadecanoic acid, 9,10, 18-trihydroxyoctadecanoate, hydroxyeicosenoic acid (lesquerolic acid), hydroxyeicosenoate, 15-hydroxyhexadecanoic acid, 15-hydroxyhexadecanoate, isoricinoleic acid, isoricinoleate, hydroxyoctadecadienoic acid (densipolic acid), hydroxyoctadecadienoate, 14-hydroxy-eicosa-cis-11-cis-17-dienoic acid, 14-hydroxy-eicosa-cis-17-dienoic acid, 2-hydroxyoleic acid, 2-hydroxyoleate, 2-hydroxylinoleic acid, 2-hydroxylinoleate, 18-hydroxystearic acid, 18-hydroxystearate, 15-hydroxylinoleic acid, 15-hydroxylinoleate, or any combination thereof.

In an embodiment, the hydroxy fatty acid composition comprises ricinoleic acid, ricinoleate salt, or a combination thereof.

In an embodiment, the hydroxy fatty acid composition comprises a hydroxy fatty acid obtained from hydrolysis of castor oil, a hydroxy fatty acid salt obtained from hydrolysis of castor oil, or a combination thereof.

In embodiments, the hydroxy fatty acid composition comprises an unsaturated hydroxy fatty acid having one or two double bonds, an unsaturated hydroxy fatty acid salt having one or two double bonds, or a combination thereof. In some such embodiments, the hydroxy fatty acid composition consists essentially of sodium ricinoleate, potassium ricinoleate, or a combination thereof.

In an embodiment, the hydroxy fatty acid composition comprises a saturated hydroxy fatty acid, a saturated hydroxy fatty acid salt, or a combination thereof.

In an embodiment, the gangue comprises carbonates.

In an embodiment, the gangue comprises calcite, dolomite, or a combination thereof.

In an embodiment, the sulfonated fatty acid composition comprises sulfonated oleic acid, sulfonated oleate, sulfonated linoleic acid, sulfonated linoleate, sulfonated linolenic acid, sulfonated linolenate, sulfonated ricinoleate, sulfonated palmitoleate, sulfonated 11-eicosenoic acid, sulfonated 11-eicosenoate, sulfonated erucic acid, sulfonated erucate, sulfonated nervonic acid, or any combination thereof.

In an embodiment, the crushed phosphate ore comprises crushed apatite.

In embodiments, the sparging composition further comprises one or more emulsifying surfactants, one or more additional collectors, one or more inhibitors, one or more activators, one or more frothers, or any combination thereof.

In an embodiment, the bubbling composition includes sodium tripolyphosphate or ammonium polyphosphate, or a combination thereof.

In an embodiment, the bubbling composition includes a pH adjuster.

Provided herein is a method of reverse froth flotation comprising bubbling any one of the bubbling compositions disclosed herein. In an embodiment, the method further comprises: grinding a phosphate mineral ore to provide a ground phosphate ore. In some such embodiments, the method further includes combining the ground phosphate ore with at least a portion of the media to form a medium ore slurry. In some such embodiments, the method further comprises adjusting the particle size distribution of particles of the phosphate ore in the medium ore slurry by passing the medium ore slurry through a mesh screen, hydro-swirling the medium ore slurry, de-sliming the medium ore slurry, or any combination thereof. In some such embodiments, the method further includes combining the medium ore slurry with a collector, a beneficiation agent, and optionally a second portion of the media to form the sparging composition.

Provided herein is a use of any of the bubbling compositions disclosed herein for refining phosphate ore. In some embodiments of the use, the phosphate ore is used to produce phosphoric acid.

Drawings

Figure 1 shows a plot of phosphate recovery versus phosphate grade when froth flotation was performed on a bubbling composition including various soaps and salts.

Figure 2 shows a plot of phosphate recovery versus phosphate grade when froth flotation is performed on a bubbling composition comprising a sulfonated potassium oleate salt, sodium ricinoleate, and various combinations thereof.

Figure 3 shows a plot of phosphate recovery versus phosphate grade when froth flotation is performed on a bubbling composition comprising sulfonated potassium oleate salts, sulfonated castor soap, and combinations thereof.

Figure 4 shows a plot of phosphate recovery versus phosphate grade when froth flotation is performed on a sparging composition comprising a sulfonated potassium oleate salt, potassium 12-hydroxystearate, and combinations thereof.

Figure 5 shows a plot of phosphate recovery versus phosphate grade when froth flotation was performed on a sparging composition comprising a sulfonated potassium oleate salt and ricinoleate salt obtained from the hydrolysis of castor oil.

Figure 6 shows a plot of phosphate recovery versus phosphate rating when froth flotation is performed on a sparging composition comprising a sulfonated sylvite salt and a sparging composition comprising a sulfonated sylvite and a castor oil/sodium corn oil soap formulation.

Figure 7 shows a plot of phosphate recovery versus phosphate rating when froth flotation was performed on a sparging composition comprising a sulfonated potassium oleate salt, a sparging composition comprising sodium ricinoleate, and a sparging composition comprising a sulfonated potassium oleate salt and sodium ricinoleate salt.

Figure 8 shows a plot of phosphate recovery versus phosphate rating when froth flotation was performed on a sparging composition comprising a sulfonated potassium oleate salt, a sparging composition comprising sodium ricinoleate, and a sparging composition comprising a sulfonated potassium oleate salt and sodium ricinoleate salt.

Detailed Description

Although the present disclosure provides reference to preferred embodiments, workers 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. References to various embodiments do not limit the scope of the claims appended 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.

Definition of

Unless defined otherwise, 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.

As used herein, the terms "comprising (comprises), (s))," (including (s)), "(having)", "may (can)", "(containing (content) (s))" and variants thereof are intended to be open transition phrases, terms or words that do not exclude the possibility of additional behavior or structure. The singular forms "a", "an" and "the" include plural referents unless the context clearly dictates otherwise. The present disclosure also contemplates other embodiments that "comprise," "consist of," and "consist essentially of" the embodiments or elements presented herein, whether or not explicitly stated.

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 where it does not.

As used herein, the term "about" used to describe modifications of embodiments of the disclosure, such as amounts, concentrations, volumes, process temperatures, process times, yields, flow rates, pressures, and the like, and ranges thereof, of ingredients in a composition refers to quantitative changes that may occur, for example, as a result of: due to typical measurement and handling procedures used to prepare compounds, compositions, concentrates or use formulations; due to inadvertent errors in these procedures; due to differences in the manufacture, source or purity of the starting materials or ingredients used to carry out the method, and similar close considerations. The term "about" also encompasses amounts that differ due to aging of a formulation or mixture having a particular initial concentration and amounts that differ due to mixing or processing of a formulation or mixture having a particular initial concentration. The appended claims, when modified by the term "about," include equivalents to these amounts. Further, unless the context specifically limits, where "about" is used to describe a range of values, e.g., "about 1 to 5" or "about 1 to about 5," the detailed description refers to "1 to 5" and "about 1 to about 5" and "about 1 to 5.

As used herein, "ore" refers to any solid material of economic value obtained by excavation from an underground source, as well as refined or processed products of such solids. Excavation includes, but is not limited to, quarrying, strip mining, or pit mining. Ores include, but are not limited to, rocks, minerals, mineral aggregates, metal compounds including both metals in their basic form and compounds containing metal atoms, and any grade of coal (peat, lignite, sub-bituminous, or anthracite). The ore comprises a concentrate.

As used herein, "phosphate ore" refers to an ore that includes phosphate groups and/or phosphate moieties. In embodiments, the phosphate ore comprises, consists of, or consists essentially of: ca²⁺、PO₄ ^3-、F^-、OH^-、CO₃ ^2-Silica and/or silicate or any combination thereof. In embodiments, the phosphate ore includes phosphate concentrates and gangue, which includes carbonates, silicates, or combinations thereof.

As used herein,' A "Phosphate concentrate "refers to a concentrate that includes phosphate groups and/or phosphate moieties. In an embodiment, the phosphate concentrate comprises Ca²⁺And PO₄ ^3-Consisting of, or consisting essentially of.

As used herein, "comminuting" refers to mechanically reducing the size of a solid mass. Non-limiting examples of comminution include milling and grinding.

As used herein, a "fatty acid" is a carboxylic acid having an aliphatic chain of at least six carbon atoms.

As used herein, "sparging composition" refers to a mixture of materials that includes crushed ore, a liquid medium, and a collector. In embodiments, the liquid medium comprises, consists essentially of, or consists of water. In an embodiment, the bubbling composition further comprises a foam.

As used herein, "bubbling slurry" refers to a bubbling composition that has been bubbled, wherein the bubbling slurry includes underflow and foam.

As used herein, "bubbling composition" refers to a bubbling composition that has been bubbled, wherein the bubbling composition comprises an underflow and a foam.

As used herein, "concentrate" refers to the portion of the mineral material in the bubbling composition that has been concentrated by the froth flotation process for the concentrate. Prior to sparging, the concentrate has a higher concentrate concentration (as a weight ratio of concentrate to concentrate plus gangue) than the ore in the sparging composition.

As used herein, "tailings" refers to the portion of the mineral material in the bubbling composition that has had the gangue concentrated by the froth flotation process. Prior to sparging, the tailings have a higher gangue concentration (as a weight ratio of gangue to concentrate plus gangue) than the ore in the sparging composition.

As used herein, "underflow" refers to a bubbling slurry that excludes or substantially excludes froth.

As used herein, "foam" refers to a plurality of bubbles present in a bubbling composition during bubbling, after bubbling, or both during and after bubbling. The bubbles are formed by bubbling the bubbling composition with a gas. In an embodiment, the gas is air.

As used herein, "collector" refers to a material or mixture of materials that increases the adhesion or association of a targeting particle with a gas bubble.

As used herein, "inhibitor" refers to a material or mixture of materials that reduces the adhesion or association of untargeted particles with gas bubbles.

As used herein, "frothing agent" or "frothing agent" refers to a material or mixture of materials that promotes foam formation and/or inhibits a reduction in the number of bubbles within the foam during, after, or both during and after bubbling.

As used herein, "dispersant" refers to a material or mixture of materials that increases the dispersion of particles in a liquid medium, stabilizes the dispersion of particles of an ore in a liquid medium, or both.

As used herein, the term "salt" refers to the conjugate base of a carboxylic acid and/or sulfonic acid moiety. Further, the term "salt" refers not only to a full salt, but also to a half salt, and the like, as specified or determined by the context herein. In embodiments, the salt comprises Na⁺、K⁺、NH₄ ⁺And any combination thereof.

As used herein, "beneficiation agent" refers to a material or mixture of materials that improves the yield of beneficiation at a given concentrate grade when reverse froth flotation is performed on a sparging composition comprising a collector and beneficiation, and optionally improves the froth characteristics as compared to an otherwise identical sparging composition in the absence of beneficiation agent.

As used herein, "flotation" or "froth flotation" refers to the process by which a bubbling composition bubbles to form a froth layer and an underflow.

As used herein, "hydroxy fatty acid composition" refers to a composition comprising one or more hydroxy fatty acids, one or more hydroxy fatty acid salts, or any combination thereof.

As used herein, "hydroxy fatty acid" refers to a fatty acid having at least one hydroxyl group.

As used herein, "sulfonationFatty acid composition "refers to a composition consisting of or consisting essentially of: a compound or mixture of compounds that are products of sulfonating one or more fatty acids and/or salts thereof; or a compound or mixture of compounds that is a product of neutralizing or partially neutralizing a compound or mixture of compounds that is a product of sulfonating one or more fatty acids with a base; further wherein each compound present in the sulfonated fatty acid composition comprises at least one-COOH group or salt thereof and at least one-SO₃H group or a salt thereof.

As used herein, "sulfonated fatty acid" refers to a composition consisting of or consisting essentially of a compound or mixture of compounds that is the product of sulfonating a fatty acid, further wherein each compound in the compound or mixture of compounds comprises at least one-COOH group and at least one-SO group₃And (4) an H group.

As used herein, "fatty acid monosulfonate" refers to a compound that is the product of sulfonating a fatty acid and/or salt thereof, the compound including one-SO₃Moiety H or a salt thereof.

As used herein, "fatty acid disulfonate" refers to a compound that is the product of sulfonating a fatty acid and/or salt thereof, said compound comprising two-SOs₃Moiety H or a salt thereof.

As used herein, "phosphate" refers to a material that includes a phosphoric acid moiety or a salt thereof. As used herein, "phosphate anion" refers to PO as specified or determined in the context of the present disclosure₄ ^3-、HPO₄ ^2-、H₂PO₄ ^-Or any combination thereof.

As used herein, the terms "rosin soap", "rosin soap" and the like refer to a material or mixture of materials resulting from the saponification of rosin. In the examples, the rosin is derived from plants such as pine and other conifers. The rosin comprises abietic acid. For example, "rosin sodium soap" refers to a material derived from the saponification of rosin with a sodium base such as sodium hydroxide and includes sodium rosinate.

As used herein, "refining" and the like refer to processing to remove gangue and/or unwanted components from materials such as ores.

As used herein, "grade%" or "grade" refers to the percentage by weight of concentrate that is beneficiated. Thus, grade is a measure of the purity of the concentrate relative to the concentrate.

As used herein, "% recovery," "percent recovery," and the like refer to the weight of concentrate recovered from a concentrate as a percentage of the total concentrate recovered from the concentrate and tailings. Thus, recovery is a measure of the amount of concentrate recovered in the concentrate rather than in the tailings.

As used herein, "Kg/t" refers to kilograms per metric ton.

Discussion of the related Art

Preferred methods and materials are described below, but methods and materials similar or equivalent to those described herein can also be used in the 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.

It has been found that inclusion of a beneficiation reagent comprising at least one hydroxy fatty acid and/or salt thereof in a bubbling composition comprising a comminuted phosphate ore and a sulfonated fatty acid composition unpredictably increases the purity and/or yield of phosphate concentrates when the bubbling composition is subjected to reverse froth flotation.

Bubbling composition

Thus, in an embodiment, there is provided a bubbling composition for reverse froth flotation comprising, consisting of, or consisting essentially of: a liquid medium; phosphate ore comprising, consisting of or consisting essentially of phosphate concentrate and gangue; a collector comprising, consisting of, or consisting essentially of a sulfonated fatty acid composition; and a beneficiation agent comprising, consisting of, or consisting essentially of a hydroxy fatty acid composition. In embodiments, the phosphate ore comprises, consists of, or consists essentially of crushed phosphate ore.

In the examples, the particle size of the crushed ore was less than 4000 microns as measured by ASTM C136 90% (#4 us standard mesh); in an embodiment, about 90% is less than 1500 microns; in an embodiment, 90% is less than 1000 microns; in an embodiment, 90% is less than 500 microns; or in embodiments, 90% is less than 250 microns as measured by ASTM C136.

In embodiments, 1% to 99% by weight of the crushed ore has a particle size as measured by ASTM C136 of from about 38 microns to about 250 microns; in an embodiment, 50% to 80% by weight of the crushed ore has a particle size of about 38 microns to about 250 microns; in embodiments, 60% to about 70% of the particle sizes are about 38 microns to about 250 microns; in embodiments, 65% to 70% of the particle sizes are from about 38 microns to about 250 microns; alternatively, in embodiments, about 68% of the particle sizes are from about 38 microns to about 250 microns, as measured by ASTM C136.

In embodiments, the liquid medium comprises, consists of, or consists essentially of water.

Phosphate ores include, consist of or consist essentially of phosphate concentrates and gangue. In embodiments, the gangue comprises carbonate anions, silicate anions, silica, or any combination thereof. In an embodiment, the gangue includes carbonate anions. In embodiments, the gangue comprises calcite, dolomite, silicates, silica, or any combination thereof.

In embodiments, the phosphate ore comprises, consists of, or consists essentially of: apatite, phosphite, or combinations thereof. In an embodiment, the apatite comprises, consists of, or consists essentially of: hydroxyapatite, fluorapatite, chlorapatite, or any combination thereof.

In an embodiment, the bubbling composition further comprises a pH adjuster. In embodiments, the pH adjusting agent comprises, consists of, or consists essentially of an acid. In embodiments, the pH adjusting agent comprises, consists of, or consists essentially of a base. In embodiments, the pH adjusting agent comprises, consists of, or consists essentially of a buffer. In embodiments, the acid is selected from hydrochloric acid, sulfuric acid, p-toluenesulfonic acid, or any combination thereof. In embodiments, the pH adjusting agent comprises, consists of, or consists essentially of sulfuric acid.

In embodiments, the pH of the bubbling composition is from about 1 to about 3, in embodiments from about 3 to about 6, in embodiments from about 3 to about 7, in embodiments from about 3 to about 8, in embodiments from about 6 to about 10, in embodiments from about 11 to about 14, in embodiments from about 4 to about 7, in embodiments from about 4 to about 5, in embodiments from about 6 to about 7, in embodiments from about 4.0 to about 5.5, or in embodiments from about 5.0 to about 5.2.

In an embodiment, the pH of the bubbling composition is from 4.3 to 6.8.

In embodiments, the beneficiation agent comprises, consists of, or consists essentially of a hydroxy fatty acid composition; and the collector comprises, consists of, or consists essentially of a sulfonated fatty acid composition, wherein the weight of the sulfonated fatty acid composition divided by the weight of the hydroxy fatty acid composition is from about 0.01 to about 99, or in embodiments from about 0.05 to about 1.2, or in embodiments from about 0.05 to about 1.1, or in embodiments from about 0.1 to about 1, or in embodiments from about 0.20 to about 1.0, or in embodiments from about 0.30 to about 1.0, in embodiments from about 0.40 to about 1.0, or in embodiments about 0.66.

In some such embodiments, the sum of the weight of the sulfonated fatty acid composition plus the weight of the hydroxy fatty acid composition is from about 0.001% to about 5% of the weight of the phosphate ore, or in embodiments from about 0.001% to about 1% of the weight of the phosphate ore, or in embodiments from about 0.01% to about 1% of the weight of the phosphate ore, or in embodiments from about 0.05% to about 0.7% of the weight of the phosphate ore, or in embodiments from about 0.1% to about 0.3% of the weight of the phosphate ore.

In some such embodiments, the hydroxy fatty acid composition comprises, consists of, or consists essentially of ricinoleate, and the sulfonated fatty acid composition comprises, consists of, or consists essentially of a sulfonated oleate. In some such embodiments, the ricinoleate salt comprises, consists of, or consists essentially of: sodium ricinoleate, potassium ricinoleate, or a combination thereof; and the sulfonated oleate comprises, consists of, or consists essentially of: a sulfonated potassium oleate salt, a sulfonated sodium oleate salt, or a combination thereof. In embodiments, the sulfonated fatty acid composition consists of, or consists essentially of, a sulfonated potassium oleate salt, a sulfonated sodium oleate salt, or a combination thereof; and the hydroxy fatty acid composition consists or consists essentially of sodium ricinoleate, potassium ricinoleate, or a combination thereof.

In embodiments, the concentration by weight of the hydroxy fatty acid composition in the bubbling composition is from about 0.001% to about 5%, in embodiments from about 0.01% to about 0.5%, in embodiments from about 0.02% to about 0.15%, or in embodiments from about 0.03% to about 0.12%.

In embodiments, the concentration of the sulfonated fatty acid composition in the bubbling composition is from about 0.001% to about 5%, or in embodiments from about 0.01% to about 0.5%, or in embodiments from about 0.01% to about 0.15% by weight.

In embodiments, the amount of phosphate ore in the bubbling composition is from about 1% to about 80%, in embodiments from about 10% to about 40%, or in embodiments from about 20% to about 30%, by weight of the bubbling composition.

Beneficiation agent for bubbling composition

The bubbling composition includes one or more beneficiation reagents. The beneficiation agent comprises, consists of, or consists essentially of a hydroxy fatty acid composition. The hydroxy fatty acid composition consists essentially of one or more hydroxy fatty acids, one or more hydroxy fatty acid salts, or a combination thereof. In some embodiments, the hydroxy fatty acid composition comprises, consists of, or consists essentially of two or more hydroxy fatty acids and/or salts thereof. In other embodiments, the hydroxy fatty acid composition comprises, consists of, or consists essentially of: a hydroxy fatty acid, a hydroxy fatty acid salt, or a combination thereof.

In embodiments, the hydroxy fatty acid salt comprises, consists of, or consists essentially of: sodium salt of hydroxy fatty acid, potassium salt of hydroxy fatty acid, or ammonium salt of hydroxy fatty acid. In embodiments, the hydroxy fatty acid ammonium salt is composed of, or consists essentially of, inorganic ammonium (NH)₄ ⁺) Salt, organic primary ammonium salt, organic secondary ammonium salt, organic tertiary ammonium salt or organic quaternary ammonium salt.

In embodiments, the hydroxy fatty acid is any fatty acid having at least one hydroxyl group.

In an embodiment, the hydroxy fatty acid comprises a hydrocarbon chain to which at least one hydroxyl group and at least one carboxyl group are attached. In embodiments, one, two or three hydroxyl groups are attached to the hydrocarbon chain. In an embodiment, the hydrocarbon chain is aliphatic. In embodiments, the hydrocarbon chain is branched or straight. In some embodiments, the hydrocarbon chain contains at least one-C ═ C-double bond, in other embodiments, the hydrocarbon chain is saturated. In embodiments, the hydrocarbon chain comprises one-C ═ C-double bond or two-C ═ C-double bonds. In an embodiment, the hydrocarbon chain comprises 5 to 50 carbon atoms, in an embodiment 10 to 30 carbon atoms, in an embodiment 15 to 25 carbon atoms, in an embodiment 15 to 21 carbon atoms, or in an embodiment 16 to 20 carbon atoms. In an embodiment, the hydroxy fatty acid composition comprises two or more hydroxy fatty acids having different numbers of carbon atoms in the hydrocarbon chain from each other.

In embodiments, the hydroxy fatty acid composition comprises, consists of, or consists essentially of: having the structural formula

C_aH_2a+1(CHOH)_b(CH₂)(CH＝CH)_c(CH₂)_dHydroxy fatty acid of COOH and/or the sameA salt, wherein a is an integer from 1 to 10; b is an integer of 1 to 5; c is 0 or 1; and d is an integer of 5 to 10. In some embodiments where c ═ 1, CH ═ CH is cis, and in other such embodiments, CH ═ CH is trans. In some embodiments, C_aH_2a+1The group is a linear n-alkyl group. In other embodiments, C_aH_2a+1The group is a branched alkyl group.

In embodiments, the hydroxy fatty acid composition comprises, consists of, or consists essentially of: having the structural formula

CR₁R₂OH(CH₂)_e(CHOH)_f(CH₂)_gFatty acid of COOH and/or salt thereof, wherein R₁And R₂Independently selected from C1-C5 alkyl and hydrogen; e is an integer from 1 to 10; f is 0 or an integer from 1 to 5; and g is an integer of 1 to 20. In some embodiments, R₁And R₂Are all hydrogen.

In embodiments, the hydroxy fatty acid composition comprises, consists of, or consists essentially of: having the structural formula

C_aH_2a+1(CH＝CH)(CH₂)_h(CHOH)(CH₂)_i(CH＝CH)_k(CH₂)_mHydroxy fatty acid of COOH and/or a salt thereof, wherein a is an integer of 1 to 10; h is an integer from 1 to 10; i is 0 or an integer from 1 to 10; k is 0 or 1, provided that if i is 0, then k is 0; and m is 0 or an integer of 1 to 10. In some such embodiments, each CH ═ CH is cis, in some other such embodiments, each CH ═ CH is trans, and in yet other such embodiments, the hydroxy fatty acid has one cis ═ CH and one trans (CH ═ CH). In some embodiments, C_aH_2a+1Is a linear n-alkyl group.

In an embodiment, the hydroxy fatty acid composition comprises a compound having the formula

C_aH_2a+1(CHOH)_j(CH₂)_q(CH＝CH)(CH₂)_h(CH＝CH)(CH₂)_i(CHOH)_pCOOHWherein a is an integer of 1 to 10; j is 0 or an integer of 1 to 5; q is 0 or an integer from 1 to 10, with the proviso that if j > 0, q is at least 1; h is an integer from 1 to 10; p is 0 or 1, provided that j + p > 0; and i is 0 or an integer from 1 to 7, provided that if i is 0, then p is also 0. In some such embodiments, both CH ═ CH are cis, in other such embodiments both CH ═ CH are trans, and in yet other such embodiments, one CH ═ CH group is cis and the other CH ═ CH group is trans.

In embodiments, the hydroxy fatty acid composition comprises, consists of, or consists essentially of: has an experimental formula

C_nH_(2n+1-x)(OH)_x(CR₃＝CR₄)_yCO₂H

Wherein n is an integer of 5 to 25, x is an integer of 1 to 5, y is 0 or an integer of 1 to 3 and R is₃And R₄Independently selected from alkyl or hydrogen. Against this background, empirical formula C_nH_(2n+1-x)(OH)_x(CH＝CH)_yCO₂H means that the hydroxy fatty acid molecule comprises one-COOH group, 1 to 5-OH groups and at least one alkyl and/or alkylene group; the empirical formula does not indicate the arrangement of these groups in the molecule. E.g. C_nH(_2n+1-x)(OH)_xA split into two or more alkylene groups or two or more alkylene groups and an alkyl group may be via one or more intervening CH ═ CH double bonds. Furthermore, C_nH(_2n+1-x)(OH)_xMay have any arrangement with respect to the (OH) group. In the examples, CR₃＝CR₄Is cis-form.

In embodiments, the hydroxy fatty acid composition comprises, consists of, or consists essentially of: ricinoleic acid, ricinoleate, 12-hydroxystearic acid, 12-hydroxystearate, 9, 10-dihydroxyoctadecanoic acid salt, 9,10, 18-trihydroxyoctadecanoic acid (trihydroxyoctadecanoic acid)), trihydroxyoctadecanoic acid salt, hydroxyoctadecanoic acid saltEicosenoic acid (n-C)₆H₁₃(CHOH)CH₂(CH＝CH)(CH₂)₉COOH), hydroxyeicosenoate, 15-hydroxyhexadecanoic acid, 15-hydroxyhexadecanoate, isoricinoleic acid (cis-normal C)₅H₁₁(CH＝CH)(CH₂)₂(CHOH)(CH₂)₇COOH), isoricinoleate, hydroxyoctadecadienoic acid (cis, cis-normal C)₂H₅(CH＝CH)(CH₂)₂(CHOH)CH₂(CH＝CH)(CH₂)₇COOH), hydroxyoctadecadienoic acid salt, 14-hydroxy-eicosa-cis-11-cis-17-dienoic acid (hydroxyeicosadienoic acid), n-C₂H₅(CH＝CH)(CH₂)₂(CHOH)CH₂(CH＝CH)(CH₂)₉COOH)), hydroxyeicosadienoate, 2-hydroxyoleic acid, 2-hydroxyoleate, 2-hydroxylinoleic acid, 2-hydroxylinoleate, 18-hydroxystearic acid, 18-hydroxystearate, 15-hydroxylinoleic acid, 15-hydroxylinoleate, or any combination thereof.

In embodiments, the hydroxy fatty acid composition comprises, consists of, or consists essentially of: sodium ricinoleate, potassium ricinoleate, sodium 12-hydroxystearate, potassium 12-hydroxystearate, sodium 9, 10-dihydroxyoctadecenoate, potassium 9, 10-dihydroxyoctadecenoate, sodium trihydroxyoctadecenoate, potassium hydroxyeicosenoate, sodium 15-hydroxyhexadecanoate, potassium 15-hydroxyhexadecanoate, sodium isoricinoleate, potassium isoricinoleate, sodium hydroxyoctadecadienoate, potassium hydroxyoctadecadienoate, sodium hydroxyeicosadienoate, potassium hydroxyeicosadienoate, sodium 2-hydroxyoleate, potassium 2-hydroxyoleate, sodium 2-hydroxylinoleate, potassium 2-hydroxylinoleate, sodium 18-hydroxystearate, potassium 18-hydroxystearate, sodium 15-hydroxylinoleate, potassium 15-hydroxylinoleate, or any combination thereof.

In embodiments, the beneficiation agent comprises, consists of, or consists essentially of ricinoleate. In an embodiment, the ricinoleate is a product of castor oil hydrolysis. In the examples, the castor oil hydrolysis is the saponification of castor oil with an alkali. In an embodiment, the base is selected from aqueous sodium hydroxide, aqueous potassium hydroxide or aqueous ammonium hydroxide. In embodiments, the ammonium of the aqueous ammonium hydroxide solution is selected from inorganic ammonium, organic primary ammonium, organic secondary ammonium, organic tertiary ammonium, organic quaternary ammonium, or any combination thereof. In embodiments, the ricinoleate salt comprises, consists of, or consists essentially of sodium or potassium ricinoleate. In some such embodiments, the sodium ricinoleate or potassium ricinoleate is the product of the saponification of castor oil with aqueous sodium hydroxide or potassium hydroxide, respectively.

In an embodiment, the hydroxy fatty acid salt is selected from an ammonium, sodium or potassium salt of a hydroxy fatty acid. In the examples, the ammonium is inorganic ammonium (NH)₄ ⁺) Organic primary ammonium, organic secondary ammonium, organic tertiary ammonium or organic quaternary ammonium.

In embodiments, the hydroxy fatty acid, hydroxy fatty acid salt, or combination thereof is a hydrolysate of a natural oil. In an embodiment, the natural oil is castor oil. In the examples, the hydrolysis is a saponification with alkali. In embodiments, the base comprises, consists of, or consists essentially of: an aqueous sodium hydroxide solution, an aqueous potassium hydroxide solution, an aqueous ammonium hydroxide solution, or any combination thereof.

In embodiments, the hydroxy fatty acid, hydroxy fatty acid salt, or combination thereof is a hydrolysis product of a triglyceride that is an ester of at least one hydroxy fatty acid. In the examples, the hydrolysis is a saponification with alkali. In embodiments, the base comprises, consists of, or consists essentially of: an aqueous sodium hydroxide solution, an aqueous potassium hydroxide solution, an aqueous ammonium hydroxide solution, or any combination thereof.

In embodiments, the hydroxy fatty acid composition of the bubbling composition includes more than one type of hydroxy fatty acid, more than one type of hydroxy fatty acid salt, more than one salt of one or more hydroxy fatty acids, or any combination thereof.

Collectors for bubbling compositions

In embodiments, the collector comprises, consists of, or consists essentially of a sulfonated fatty acid composition. In embodiments, the sulfonated fatty acid composition comprises, consists of, or consists essentially of: one or more sulfonated fatty acids, one or more sulfonated fatty acid salts, or any combination thereof. In some embodiments, the one or more sulfonated fatty acids, one or more sulfonated fatty acid salts, or a combination thereof comprises, consists of, or consists essentially of: a sulfonated fatty acid, a sulfonated fatty acid salt, or a combination thereof.

In embodiments, the sulfonated fatty acid composition comprises, consists of, or consists essentially of a compound or mixture of compounds that is: a sulfonation product as one or more fatty acids and/or salts thereof; or as a product of neutralization or partial neutralization with a base of a compound or mixture of compounds that are products of sulfonation of the one or more fatty acids; further wherein each compound present in the sulfonated fatty acid composition comprises at least one-COOH group or salt thereof and at least one-SO₃H group or a salt thereof. Each compound in the compound or compound mixture having a-COOH group or-CO₂ ^-Group and at least one-SO₃H groups or SO₃ ^-A group. Thus, the sulfonated fatty acid composition includes one or more fatty acids and/or salts thereof having a sulfonic acid group.

In embodiments, the sulfonated fatty acid composition comprises, consists of, or consists essentially of: sulfonated oleic acid, sulfonated oleate, sulfonated linoleic acid, sulfonated linoleate, sulfonated linolenic acid, sulfonated linolenate, sulfonated ricinoleic acid, sulfonated ricinoleate, sulfonated palmitoleic acid, sulfonated palmitate, sulfonated 11-eicosenoic acid, sulfonated 11-eicosenoate, sulfonated erucic acid, sulfonated erucate, sulfonated nervonic acid, sulfonated nervonate, sulfonated abietic acid, sulfonated abietate, or any combination thereof.

In an embodiment, the sulfonated fatty acid composition comprises one or more sulfonated fatty acid sodium salts, one or more sulfonated fatty acid potassium salts, one or more sulfonated fatty acid ammonium salts, or any combination thereof. In embodiments, the ammonium is selected from inorganic ammonium (NH)₄ ⁺) Organic primary ammonium, organic secondary ammonium, organic tertiary ammonium, organic quaternary ammonium, or any combination thereof. In an embodiment, the sulfonated fatty acid composition is a neutralized or partially neutralized product of sulfonation of a saturated fatty acid with a sulfonating agent. In this context, neutralization or partial neutralization means reaction with a base. In an embodiment, the sulfonating agent is selected from sulfur trioxide, oleum, chlorosulfonic acid, and sulfuric acid.

In embodiments, the sulfonated fatty acid composition comprises, consists of, or consists essentially of a sulfonated potassium oleate salt.

In the examples, the sulfonated fatty acid is a sulfonated product of fatty acids obtained from hydrolysis of triglycerides.

In an embodiment, the sulfonated fatty acid composition is a sulfonation product or sulfonation neutralization product of a fatty acid or fatty acid mixture obtained from hydrolysis of an oil selected from the group consisting of: linseed oil, cottonseed oil, soybean oil, canola oil, castor oil, coconut oil, palm oil, jojoba oil (jojoba oil), olive oil, peanut oil, sunflower oil, animal fat, tall oil (tall oil), and any combination thereof. In the examples, tall oil is a by-product of papermaking.

In embodiments, the sulfonated fatty acid composition comprises, consists of, or consists essentially of: a fatty acid monosulfonate, a fatty acid disulfonate, one or more fatty acid sulfonate dimers, one or more fatty acid sulfonate trimers, or any combination thereof. In some such embodiments, the sulfonated fatty acid composition comprises a salt of a fatty acid monosulfonate, a salt of a fatty acid disulfonate, one or more salts of the one or more fatty acid sulfonate dimers, one or more salts of a fatty acid sulfonate trimer, or any combination thereof.

Fatty acid sulfonates are compounds that are the sulfonation product of fatty acids, wherein the compound has at least one-SO₃H group or a salt thereof. In embodiments, the sulfonated fatty acid composition comprises, consists of, or consists essentially of one or more fatty acid sulfonates. Fatty acidsMonosulfonate is a monosulfonated compound that is the product of sulfonation of fatty acids, the monosulfonated compound including one-SO per molecule of the monosulfonated compound₃H group or one-SO₃ ^-A group. The fatty acid disulfonate is a disulfonated compound comprising two-SO's per molecule of the disulfonated compound as a sulfonation product of a fatty acid₃H group, two-SO₃ ^-Radical or one-SO₃H group and one-SO₃ ^-A group. The fatty acid sulfonate dimer is a compound obtained by chemically combining a fatty acid sulfonate or a salt thereof with a fatty acid, a fatty acid salt, a fatty acid sulfonate or a salt of a fatty acid sulfonate.

The fatty acid sulfonate trimer is a compound obtained by combining: two molecules of fatty acid and/or salt thereof and one molecule of fatty acid sulfonate or salt thereof; one molecule of a fatty acid or a salt thereof and two molecules of a fatty acid and/or a salt thereof; and/or fatty acid sulfonate and/or salts thereof.

In embodiments, during sulfonation of the fatty acid with the sulfonating agent, one or more fatty acid monosulfonates, fatty acid disulfonates, fatty acid sulfonate dimers, fatty acid sulfonate trimers, fatty acid oligomers, and/or any combination thereof are produced. By way of illustration only, in one non-limiting example, the sulfonated fatty acid composition results from the sulfonation of oleic acid and includes the following: unsaturated oleic acid monosulfonate (I), salt of unsaturated oleic acid monosulfonate (I), saturated hydroxyoleic acid monosulfonate (II), salt of saturated hydroxyoleic acid monosulfonate (II), 8, 10-disulfonic acid oleate (III), salt of 9, 10-disulfonic acid oleate (IV), dimer (V), salt of dimer (V), hydroxysulfonated dimer (VI), salt of hydroxysulfonated dimer (VI), sulfonated dimer (VII), salt of sulfonated dimer (VII), saturated dimer (VIII), salt of saturated dimer (VIII), trimer (IX), salt of trimer (IX), saturated trimer (X), salt of saturated trimer (X), diunsaturated dimer (XI), salt of diunsaturated dimer (XI), A C14-C18 dimer (XII), a salt of a C14-C18 dimer (XII), a monounsaturated dimer (XIII), a salt of a C18-C14 dimer (XIV), a salt of a C18-C14 dimer (XIV), or any combination thereof. In such embodiments, the fatty acid salt composition comprises, consists of, or consists essentially of one or more salts of any one or more of (I), (II), (III), (IV), (V), (VI), (VII), (VIII), (IX), (X), (XI), (XII), (XIII), and (XIV).

As exemplified above, sulfonation of other fatty acids besides oleic acid may also produce a mixture of compounds. In such embodiments, the compound mixture is dependent upon the fatty acid or mixture thereof being sulfonated.

Sulfonated fatty acids such as sulfonated oleic acid can be neutralized or partially neutralized with bases such as aqueous sodium hydroxide, aqueous potassium hydroxide or aqueous ammonium hydroxide, as well as other bases such as sodium carbonate and sodium bicarbonate to produce sulfonated fatty acid salts. In the salt, some or all of the sulfonic acid groups and carboxylic acid groups in the sulfonated fatty acid are converted to sulfonate groups and carboxylate groups, respectively. Whether the collector and/or sulfonated fatty acid composition includes one or more fatty acid sulfonates or one or more sulfonated fatty acid salts may depend on the pH of the sparging composition.

Saturated and unsaturated fatty acids can be sulfonated by methods known in the art to produce sulfonated fatty acids and salts thereof that can be used as collectors in the sparging compositions of the invention. For example, sulfonation of both saturated and unsaturated fatty acids is described in U.S. patent 1,926,442. In an embodiment, the sulfonated fatty acid salt composition comprises, consists of, or consists essentially of: one or more salts of sulfonated saturated fatty acids, one or more salts of sulfonated unsaturated fatty acids, a salt of more than one sulfonated saturated fatty acids, a salt of more than one unsaturated fatty acids, or any combination thereof.

Bubbling method

In an embodiment, there is provided a method of bubbling, the method comprising: any of the bubbling compositions disclosed herein are bubbled to produce a bubbling slurry comprising a froth and an underflow, wherein the underflow comprises the concentrate and a first portion of the medium, and the froth comprises the tailings and a second portion of the medium. The concentrate comprises, consists of, or consists essentially of a concentrate. The tailings comprise, consist of, or consist essentially of gangue. In embodiments, the concentrate comprises, consists of, or consists essentially of phosphate. In embodiments, the gangue comprises, consists of, or consists essentially of the following: carbonate, silicate, silica, or any combination thereof.

In embodiments, the method of bubbling a composition comprises, consists of, or consists essentially of: water; ricinoleic acid, ricinoleate, or a combination thereof; sulfonated oleic acid, sulfonated oleate, or combinations thereof; and phosphate ores including apatite, calcite, dolomite, and silicates; and sulfuric acid.

In an embodiment, the method further comprises separating at least a portion of the concentrate from at least a portion of the tailings. In an embodiment, the at least the portion of the concentrate is about 90% to 100% by weight of the concentrate in the underflow, in an embodiment about 95% to 100%, in an embodiment about 98% to 100%, in an embodiment about 99% to 100%, or 100% by weight of the concentrate in the underflow. In an embodiment, the at least the portion of tailings is about 90% to 100% by weight of tailings in the foam, in an embodiment about 95% to 100%, in an embodiment about 98% to 100%, in an embodiment about 99% to 100%, or 100% by weight of tailings in the foam.

In an embodiment, separating said at least said portion of the concentrate from said at least said portion of the tailings comprises, consists of, or consists essentially of: separating at least a portion of the froth from at least a portion of the underflow. In an embodiment, separating said at least said portion of the concentrate from said at least said portion of the tailings comprises, consists of, or consists essentially of: separating at least a portion of the concentrate from at least a portion of the underflow.

In an embodiment, the bubbling method comprises separating at least a portion of the froth from at least a portion of the underflow.

In an embodiment, the sparging method comprises separating at least a portion of the concentrate from at least a portion of the underflow.

Bubbling a bubbling composition produces a bubbling slurry that includes, consists of, or consists essentially of a froth layer and an underflow. During and after bubbling, the gas bubbles migrate through the bubbling composition to the liquid-air interface and form a foam there.

The underflow comprises concentrate and the froth layer comprises tailings. In some such embodiments, the method includes separating at least a portion of the froth layer from at least a portion of the underflow. Separating said at least said portion of the froth layer from said at least said portion of the underflow is achieved by conventional methods known in the art. In embodiments, the separation comprises, consists of, or consists essentially of: drawing off at least a portion of the froth layer, skimming at least a portion of the froth layer, depositing at least a portion of the froth layer onto a launder, decanting at least a portion of the froth layer, or any combination thereof.

In an embodiment, the method further comprises grinding the phosphate mineral ore to provide a ground phosphate ore. In the examples, grinding reduced the maximum size of the original mineral ore by a factor of 2 to 1 x 10⁹And (4) doubling.

In an embodiment, the method further comprises combining at least a portion of the ground phosphate ore with at least a portion of the liquid medium to provide a medium ore slurry. In some such embodiments, the collector is combined with the ground phosphate ore prior to adding the ground phosphate ore to the at least a portion of the liquid medium. In other embodiments, the collector is combined with a medium ore slurry.

In an embodiment, the method further comprises adjusting the particle size distribution in the medium ore slurry by passing the medium ore slurry through a mesh screen, by hydro-swirling the medium ore slurry, de-sliming the medium ore slurry, or any combination thereof.

In some embodiments, the method further comprises combining a medium ore slurry with a beneficiation agent and optionally a second portion of the media to form a sparging composition comprising crushed phosphate ore, the medium ore slurry comprising a collector. In other embodiments, the method further comprises combining the intermediate ore slurry with a collector, a beneficiation agent, and optionally a second portion of the media to form a sparging composition comprising crushed phosphate ore.

In an embodiment, there is provided a use of any of the bubbling compositions described herein to refine phosphate ore using reverse froth flotation and to provide a refined phosphate ore. In some such embodiments, refined phosphate ore is used to produce phosphoric acid. In the phosphoric acid process, phosphate ore and an acid such as sulfuric acid are combined and reacted together to produce phosphoric acid. The greater the proportion of gangue in the phosphate ore, the more serious the scaling problems etc. that may be encountered in the production of phosphoric acid. Froth flotation can therefore be used to produce concentrates comprising a higher percentage of phosphate than in the original phosphate ore. In such froth flotation, the higher the grade and recovery of phosphate, the less problems are encountered in subsequent phosphoric acid manufacture.

In reverse froth flotation of phosphate ores, increasing the dosage of fatty acid collectors tends to concentrate P₂O₅Increasing P in the concentrate at the expense of% recovery₂O₅% (grade%). It has been found that this is also the case with sulfonated fatty acid and/or sulfonated fatty acid salt collectors, i.e. in reverse froth flotation of phosphate ores, increasing the dosage of sulfonated fatty acid and/or sulfonated fatty acid salt increases the grade at the expense of recovery. It has also been found that increasing the dosage of hydroxy fatty acids and/or salts thereof by P₂O₅Improved P recovery at the expense of% recovery₂O₅The grade of (2). However, it has been found that when reverse froth flotation is performed on phosphate ore using a sparging composition comprising both sulfonated fatty acids and/or sulfonated fatty acid salts and hydroxy fatty acids and/or hydroxy fatty acid salts, at a given P₂O₅Higher P is obtained under grade₂O₅Recovery without regard to the collector dose. This result was unexpected and unpredictable in view of the grade and recovery results obtained with sulfonated fatty acids and/or salts thereof and hydroxy fatty acids and/or salts thereof.

Examples of the invention

For the examples described herein, the feed to the conditioning tank of the flotation circuit of the phosphate flotation plant was drawn and two samples of the feed slurry, sample I and sample II, were obtained in two passes. The feed slurry is deslimed and then passed into the flotation circuit of the apparatus. The feed slurry is filtered, dried and bagged. Phosphate ores are precipitated ores that include apatite, calcite, dolomite and silicates. The particle size distribution and composition of the phosphate ore was measured and is shown in table 1.

TABLE 1 particle size distribution (measured according to ASTM C136) and composition of ore samples (measured using X-ray fluorescence)

In the examples described herein, the reverse Flotation test was conducted in a Danver D-12 Laboratory Flotation Machine (Denver D-12 Laboratory Flotation Machine). For each test, a 25% by weight slurry of phosphate ore was prepared by dispersing a sample of previously dried and bagged phosphate ore in synthetic water. Each slurry is then conditioned by the addition of a collector and/or a beneficiation reagent, or a combination thereof, to provide a sparging composition, and the pH of the sparging composition is adjusted to 4.3-6.8 by the addition of sulfuric acid. The slurry was then bubbled with air. Gangue, including calcite and/or dolomite, floats from the slurry and is removed as tailings, and the concentrated phosphate ore remains in the slurry as a concentrate. Both the concentrate and the tailings were filtered, dried, weighed and analyzed for P₂O₅And (4) content.

Example 1

In this example, the collector formulation consists of deionized water, a collector, a beneficiation agent, or a combination thereof. As collector a sulfonated oleate, i.e. a 50% active ingredient by weight potassium oleate sulfonate (herein "SOA"), was used. The SOA comprises a 50% aqueous solution of a sulfonated sylvite salt comprising by weight about 38% sulfonated oleic acid monomers, about 48% sulfonated oleic acid dimers, trimers, and other oligomers, and about 13% unsulfonated oleic acid and other fatty acids.

The beneficiation agent consists of sodium soap of fatty acids (sodium ricinoleate; sodium salt of non-hydroxy C8-C10 fatty acids "C810", or sodium oleate "oleic acid (oleic)"), sodium soap derived from oil (palm oil, castor oil, coconut oil, corn oil or linseed oil) or sodium soap of rosin.

The performance of these formulations was evaluated by flotation tests using ore sample I at pH 5.0-5.2 as shown in table 2 and figure 1.

Table 2: flotation results of various soap and sulfonated sylvite collecting agent formulation under pH of 5.0-5.2

C ═ concentrate, T ═ tailings, H ═ feed.

^*The dose is the amount of collector formulation (in kilograms) per metric ton of phosphate ore.

SOA is itself a 50% aqueous solution of a sulfonated potassium oleate salt.

In FIG. 1, P is plotted₂O₅Recovery rate and P₂O₅And (4) grading results. "neat SOA" refers to runs 1 and 2. "formulation" means runs 3-11.

As can be seen from figure 1, both sodium ricinoleate soap (sodium ricinoleate) and castor oil soap give the best recovery-grade combination, as indicated by the distance from the upper right of the figure. The main component of castor oil is ricinoleate, and therefore, the main component of castor oil sodium soap (saponified castor oil) is sodium ricinoleate.

Example 2

Collector formulations were prepared by combining SOA (a 50% aqueous solution of a sulfonated potassium oleate salt) and NaR (a 50% aqueous solution of sodium ricinoleate derived from castor oil) together at various ratios, as shown in table 3. These collector formulations were added to a 25% slurry of phosphate ore at the dosages shown in table 3, and the resulting reverse flotation yield, P, was determined using ore sample I at pH 5.0-5.2₂O₅Rank sum P₂O₅And (4) recovering rate. The flotation performance of each of these formulations is shown in table 3 and fig. 2.

Table 3: flotation result of collector formula of sodium ricinoleate and sulfonated sylvite under pH of 5.0-5.2

C ═ concentrate, T ═ tailings, H ═ feed.

^*The dose is the amount of collector formulation (in kilograms) per metric ton of phosphate ore.

Figure 2 shows the flotation results of the collector formulation of table 3. The weight ratio of the sulfonated oil potassium acid salt to the sodium ricinoleate<A combination of SOA and NaR at 1:1 or about 1:1 gives P₂O₅The best combination of recovery and grade. These combinations were individually superior to both the sulfonated potassium oleate and sodium ricinoleate ("neat", runs 1 and 2). However, at a weight ratio of potassium sulfonated oleate to sodium ricinoleate of greater than 1.3:1, it was observed that grade recovery was not significantly improved but was slightly more collectable than the potassium sulfonated oleate without the presence of the hydroxy fatty acid composition.

Example 3

A collector formulation was prepared by combining SOA (a 50% aqueous solution of sulfonated potassium oleate salt) and "S-castor oil" (an 80% aqueous solution of sulfonated hydrolyzed castor oil sodium salt), where the hydrolyzed castor oil comprises about 20% sulfonated ricinoleic acid sodium salt and about 80% sodium ricinoleate (unsulfonated). A 25% slurry (pH 5.0-5.2) of phosphate ore sample I was dosed with a collector formulation as described in table 4 to provide a sparging composition, where the results of reverse flotation using the sparging composition were reported.

Table 4: flotation result of collector formula of sulfonated castor oil sodium salt and sulfonated potassium oleate salt under pH of 5.0-5.2

C ═ concentrate, T ═ tailings, H ═ feed.

^*The dose is the amount of collector formulation (in kilograms) per metric ton of phosphate ore.

In FIG. 3 is shown P₂O₅Recovery rate and P₂O₅And (4) drawing grades. The figure shows that the combination of SOA (sulfonated potassium oleate salt, 50% aqueous solution) and S-castor oil ("collector formulation") is superior to both SOA and S-castor oil ("neat") alone.

Example 4

Sulfonated oleic acid (SOA, a 50% aqueous solution of sulfonated potassium oleate salt) and potassium 12-hydroxystearate (H-stearic acid) were added separately for flotation at pH 5.0-5.2 using ore sample I at the dosages shown in table 5. The reverse froth flotation results are shown in table 5 and P is shown in fig. 4₂O₅Recovery rate and P₂O₅And (4) drawing grades.

Table 5: flotation results of potassium 12-hydroxystearate and sulfonated potassium oleate at pH 5.0-5.2

C ═ concentrate, T ═ tailings, H ═ feed.

^*The dose is the amount of collector formulation (in kilograms) per metric ton of phosphate ore

The reverse froth flotation results are shown in table 5 and P is shown in fig. 4₂O₅Recovery rate and P₂O₅And (4) drawing grades. The plot shows that the combination of potassium 12-hydroxystearate and sulfonated potassium oleate salt is superior to potassium 12-hydroxystearate alone ("neat H-stearic acid") and sulfonated potassium oleate alone ("neat SOA").

Example 5

A castor oil potassium soap formulation was prepared by the following procedure: 0.1875 parts by weight of castor oil and 0.1875 parts by weight of a 22.5 wt% aqueous solution of potassium hydroxide were mixed together and heated to 100 ℃ while mixing for 12 hours. The resulting castor oil potassium soap formulation was then allowed to cool to room temperature. 0.125 parts by weight of water and 0.5 parts by weight of SOA (sulfonated potassium oleate salt by weight)50% aqueous solution) was added to a castor oil potassium soap formulation to provide a collector formulation ("formulation"). The preparation method is fully mixed. The formulation thus prepared contained 23% ricinoleic acid soap and 25% sulfonated oleic acid. The formulation was used to carry out flotation at pH 5.0-5.2 using ore sample I at a dose of 2kg/t and to reach 32.45% P₂O₅Grade and 92.13% recovery as shown in table 6 and figure 5.

Table 6 flotation results of a collector formulation derived from ricinoleic acid salt of castor oil and sulfonated potassium oleate salt at pH 5.0-5.2

C ═ concentrate, T ═ tailings, H ═ feed.

^*The dose is the amount of collector formulation (in kilograms) per metric ton of phosphate ore.

Example 6

A castor oil/corn oil sodium soap formulation was prepared by the following procedure: 0.0625 parts by weight of castor oil, 0.0625 parts by weight of corn oil, and 0.125 parts by weight of 25% aqueous sodium hydroxide solution were mixed together and heated to 100 c while mixing for 12 hours. The resulting mixture was allowed to cool to room temperature. 0.25 parts by weight of water and 0.5 parts by weight of SOA (50% aqueous solution of sulfonated sylvite by weight) was added to a castor oil/corn oil soap formulation to provide a collector formulation. The collector formulation was mixed thoroughly. The resulting collector formulation contained 6% ricinoleic acid soap and 25% sulfonated oleic acid. The formulation was used for reverse flotation at pH 5.0-5.2 using ore sample I at a dose of 2kg/t and to reach P of the concentrate₂O₅The grade was 31.97% and the recovery was 90.42%, as shown in table 7 and fig. 6.

Table 7 flotation results of a collector formulation derived from ricinoleic acid salt of castor oil and sulfonated potassium oleate salt at pH 5.0-5.2

C ═ concentrate, T ═ tailings, H ═ feed.

^*The dose is the amount of collector formulation (in kilograms) per metric ton of phosphate ore.

Example 7

A collector formulation was prepared by combining 45% SOA (50% aqueous solution of sulfonated potassium oleate salt) and 55% NaR (50% aqueous solution of sodium ricinoleate derived from castor oil). A collector formulation as described in table 8 and figure 7 was dosed to a 25% slurry of pH 4.3-4.7 of phosphate ore sample II to provide a bubbling composition. The reverse flotation results using the sparging composition are reported in table 7 and figure 7. The results show that the combination of NaR and SOA outperformed both NaR alone and SOA alone ("net") at pH 4.3-4.7.

Table 8: flotation result of collecting agent formula of castor oil sodium salt and sulfonated potassium oleate under pH of 4.3-4.7

C ═ concentrate, T ═ tailings, H ═ feed.

^*The dose is the amount of collector formulation (in kilograms) per metric ton of phosphate ore

Example 8

A collector formulation was prepared by combining 45% SOA (50% aqueous solution of sulfonated potassium oleate salt) and 55% NAR (50% aqueous solution of sodium ricinoleate derived from castor oil). A collector formulation as described in table 9 was dosed to a 25% slurry of pH 6.4-6.8 of phosphate ore sample II to provide a bubbling composition. The results are reported in table 9 and fig. 8. The reverse flotation results using the sparging composition are reported. The results show that the combination of NaR and SOA outperformed both NaR alone and SOA alone ("net") at pH 6.4-6.8.

Table 9: flotation result of collector formula of castor oil sodium salt and sulfonated potassium oleate under pH of 6.4-6.8

C ═ concentrate, T ═ tailings, H ═ feed.

^*The dose is the amount of collector formulation (in kilograms) per metric ton of phosphate ore