Physical and thermal treatment of phosphate ores — An overview

The annual consumption of phosphate rock approached 150 million tons. The marketable phosphate is usually 30% P2O5 or higher. The run-of-mine material is mostly of lower grade which needs processing or upgrading. The processing techniques of phosphate ores depend mostly on the type of associated gangue minerals present in the mined rock. In some cases, simple, inexpensive techniques are enough to produce the required grade. For example, crushing and screening is used to get rid of the coarse hard siliceous material, and attrition scrubbing and desliming is used to remove the clayey fine fraction. If silica is the main gangue material, single-stage or double-stage flotation is the conventional mineral processing technique used in this case. If the ore is igneous carbonatitic alkaline or ultra basic phosphate deposit, crushing, grinding, scrubbing, and flotation associated with other steps such as magnetic and/or gravity separation is proved to be successful in upgrading this type of ore. The sedimentary phosphate ores having carbonate-apatite as the main phosphate minerals and containing carbonates (calcite and/or dolomite) represent a challenge in the field of phosphate concentration due to similarity in the physico-chemical properties of surfaces of the ore constituents. Also, if considerable amount of organic matter constitutes the main gangue material, upgrading of the ore becomes difficult. New flotation systems (techniques and reagents) are being developed to treat these challenging phosphate ores. Furthermore, calcination is another solution for upgrading these difficult-to-treat types of ores. However, calcination is indicted with some controversial drawbacks. This overview discusses and summarizes the State-of-the-Art and the existing efforts to overcome these problems and to produce a high-grade phosphate product suitable for fertilizers and other phosphate compounds.