Reclaiming value from phosphate mine waste rock: An integrated flowsheet for sustainable recovery

IF 9 1区工程技术 Q1 ENGINEERING, CHEMICAL

Separation and Purification Technology Pub Date : 2025-09-29 DOI:10.1016/j.seppur.2025.135421

Hicham Amar, Yassine Taha, Abdellatif Elghali, Yassine Ait-Khouia, Manar Derhy, Rachid Hakkou, Mostafa Benzaazoua

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引用次数: 0

Abstract

Phosphate mining operations generate substantial quantities of waste rock as a byproduct of ore extraction, referred to as phosphate mine waste rock (PMWR) and stored in large stockpiles. PMWR retains significant residual phosphate yet is challenging to process due to lithological heterogeneity and a wide particle size distribution, necessitating the development of an optimized processing strategy. This study investigates a beneficiation route integrating size classification, sensor-based sorting (SBS) coupled with comminution, and reverse flotation for PMWR upgrading. Classification and sorting partitioned the material into a fine fraction (FF, <10 mm), dominated by sandy phosphate, and a coarse fraction (CF, >10 mm), composed of indured phosphate (IndP). Chemical and mineralogical analyses revealed enrichment in carbonate-fluorapatite (CFA) within the FF (63.5 %) compared to the IndP fraction (50.8 %), with more than 80 % of CFA grains free in both fractions. Reverse flotation with phosphoric acid ester and alkyl ether amine collectors, as well as phosphoric acid as depressant and pH modifier, exhibited effective gangue elimination and satisfactory selectivity, yielding an 11 % increase in CFA grade with 88.7 % recovery for the FF, and an 18 % increase with 89.4 % recovery for the IndP. Based on these outcomes, a novel process flowsheet is proposed to support resource efficiency and reduce the environmental footprint of PMWR. Valorization of residual phosphate through this approach constitutes a critical step toward advancing circular economy principles in sustainable phosphate mining.

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磷矿废石的价值回收：可持续回收的综合流程

磷矿开采作业产生大量的废石作为矿石开采的副产品，称为磷矿废石（PMWR），并储存在大量库存中。PMWR保留了大量的残余磷酸盐，但由于其岩性不均一性和广泛的粒度分布，加工具有挑战性，因此需要开发优化的加工策略。研究了一种集粒度分级、传感器分选—粉碎—反浮选为一体的PMWR改造选矿路线。分级分选将物料分为以砂质磷酸盐为主的细粒（FF, <10 mm）和以诱导磷酸盐为主的粗粒（CF, >10 mm）。化学和矿物学分析显示，与IndP组分（50.8 %）相比，FF组分中碳酸盐-氟磷灰石（CFA）富集（63.5 %），两个组分中游离CFA颗粒均超过80% %。采用磷酸酯和烷基醚胺捕收剂，以及磷酸作为抑制剂和pH调节剂进行反浮选，可以有效地消除脉石，并具有良好的选择性，使CFA品位提高11 %，FF回收率提高88.7 %，IndP回收率提高18 %，89.4% %。在此基础上，提出了一种新的工艺流程，以支持PMWR的资源效率和减少环境足迹。通过这种方法对残余磷酸盐进行定价是在可持续磷矿开采中推进循环经济原则的关键一步。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Separation and Purification Technology 工程技术-工程：化工

CiteScore

14.00

自引率

12.80%

发文量

2347

审稿时长

43 days

期刊介绍： Separation and Purification Technology is a premier journal committed to sharing innovative methods for separation and purification in chemical and environmental engineering, encompassing both homogeneous solutions and heterogeneous mixtures. Our scope includes the separation and/or purification of liquids, vapors, and gases, as well as carbon capture and separation techniques. However, it's important to note that methods solely intended for analytical purposes are not within the scope of the journal. Additionally, disciplines such as soil science, polymer science, and metallurgy fall outside the purview of Separation and Purification Technology. Join us in advancing the field of separation and purification methods for sustainable solutions in chemical and environmental engineering.