Method of beneficiating phosphate ores containing dolomite

Abstract

A method of beneficiating a phosphate ore containing silica and an alkaline earth metal carbonate impurity, particularly dolomite or calcite. The steps include testing the ore for excessive levels of carbonate impurities, the use of conventional flotation steps to remove silica, grinding the ore to a particle size in which at least 90% of the ore particles are less than 0.355 mm and thereafter reagentizing the ground phosphate containing ore with water, a carbonate collector, a phosphate depressant and a pH regulator to obtain a flotation feed having a solids level of about 20-30% and a pH of about 5.6-6.0. The flotation feed is then subjected to a reverse flotation in a flotation cell to remove carbonate impurities as the cell overflow and to collect a phosphate concentration as the cell underflow.

Description

BACKGROUND OF THE INVENTION

Phosphate ores occur in important deposits in various parts of the world, including central Florida. Each deposit has characteristic impurities which must first be removed to increase the phosphate content of the material so that it can be used in fertilizers to enrich farmlands and thereby increase crop yields. The phosphate content of fertilizers are generally expressed as "BPL" content [bone phosphate of lime, or Ca.sub.3 (PO.sub.4).sub.2 ].

The phosphate ore deposits found in central Florida generally contain siliceous mineral (quartz) impurities, and the lower zones of some of these deposits also contain carbonate mineral impurities including dolomite [Ca,Mg]CO.sub.3. Such phosphate ores have been improved in phosphate content by various "beneficiating" processes to remove a major portion of the impurities, and thereby increase the phosphorus content [expressed in terms of phosphorus pentoxide (P.sub.2 O.sub.5) by the chemist].

Froth flotation and skin flotation beneficiation are conventionally used to remove siliceous gangue materials from the phosphate-containing ores. In such a process, the ore materials are classified into various particle sizes. The coarser fractions may be suitable for direct sale, or may be further beneficiated by sizing and by froth and skin flotation techniques. The very fine materials, which primarily contain clay slimes and clay-sized particles are usually discarded. The intermediate fraction, which typically has a particle size range from about 0.10 mm up to about 1.0 mm represents the bulk of the material which has the greatest need for beneficiation.

U.S. Pat. No. 2,293,640 issued to A. Crago describes a "double float" froth flotation which is commercially used for beneficiating such fractions of phosphate ores in which siliceous minerals (quartz) are the predominant gangue. The intermediate size fraction is conditioned with fatty acid reagents and the phosphate mineral is floated to separate it from the bulk of the silica tail impurities. The float portion is deoiled with sulfuric acid, rinsed, and refloated with amine reagents to float away the remaining silica tail impurities.

Removal of dolomite and similar carbonate mineral impurities from phosphate ores such as apatite, fluorapatite and francolite by the above double flotation method has generally been ineffective because the flotation characteristics of the carbonate minerals (dolomite) are very similar to those of these phosphate-containing minerals.

As used herein, "francolite" is intended to refer to sedimentary apatites, found in phosphate-containing mineral ores in Florida, including carbonate fluorapatite. These ores usually carry quartz (silica), and some contain dolomite [Ca,Mg]CO.sub.3 impurities. In the Florida phosphate deposits, "francolite" with dolomite impurities is typically found in the lower zone of the Hawthorn formation in which the carbonates of calcium and magnesium have not been leached out.

Phosphate ores containing primarily quartz impurities with lesser amounts of dolomite impurities are often found in an upper zone in a phosphate deposit above the lower zone. In the past, the practice has been to recover only the upper zone phosphate ores and leave the lower zone ores because the methods available to remove dolomite added too much cost to the product, and the added recovery was not considered worth the effort. More recently, however, the market value of phosphate fertilizers has increased sufficiently to warrant the added recovery costs of mining the lower zone deposits simultaneously with the upper zone phosphate ore deposits.

Methods for beneficiating phosphate ores containing carbonate and siliceous gangue materials are described in U.S. Pat. Nos. 3,259,242; 3,462,016; 3,462,017; 3,807,556; 4,144,969 and 4,189,103. Each of these patents deals with the difficulties associated with the separation of carbonate mineral impurities such as dolomite from the phosphate ore.

U.S. Pat. Nos. 4,144,969 and 4,189,103 which are assigned to a common assignee herewith, describe a phosphate ore beneficiating process in which the deslimed ore is first subjected to a "double float" froth flotation as described in U.S. Pat. No. 2,293,640 to remove siliceous gangue. The float product containing apatite with dolomite impurities is then conditioned at about 70% solids with an apatite-collecting cationic reagent and a liquid hydrocarbon, and then subjected to a froth flotation. Most of the apatite is recovered in the froth concentrate and the alkaline earth metal carbonate impurities (dolomite) are rejected in the underflow tailings.

Dolomite is removed as a float or froth concentrate from phosphate-containing ores in the processes described in U.S. Pat. Nos. 3,462,016; 3,462,017 and 3,806,556. Siliceous gangue is removed in the first stage of a two-stage anionic flotation. The siliceous gangue is the underflow, while the phosphate minerals with carbonate impurities are separated as the "float" in the first stage. The phosphate minerals are then selectively depressed for removal as an underflow concentrate, and the carbonate impurities are floated in the second stage. Fatty acid collector reagents such as oleic acid, stearic acid, and other carboxylic acids including tall oils are used for both the first and second stage anionic flotation. In the second stage, the carbonate particles are floated, and the apatite particles (phosphate) sink.

The Johnston U.S. Pat. No. 3,807,556 adds a soluble sulphate salt in the interstage conditioning of the above processes to reduce the loss of soluble phosphate in the second stage flotation. It is believed that the Johnston patent tacitly recognizes the sensitivity of the fatty acid collector reagents in the above flotation to variations of pH frequently experienced in actual plant operations. See Johnston U.S. Pat. No. 3,807,556, column 3, lines 3-16.

The general concept of carbonate flotation, however, is very desirable to obtain a greater yield of phosphate from phosphate ores containing both apatite and carbonate. In order to have a commercially practical process for carbonate flotation, the problems described above in the Johnston patent must first be solved.

A process for more effective carbonate separation has application to certain central Florida deposits and the western phosphates found in Idaho, Montana, Utah and Wyoming. Applicants have developed such a process which has particular utility for the dolomite-containing phosphate ores of central Florida.

The copending application of Robert E. Snow, U.S. Ser. No. 269,448 filed on even date herewith, is directed to a flotation method for beneficiating a phosphate ore concentrate to remove dolomite [Ca,Mg]CO.sub.3 by a reverse flotation with an anionic flotation agent comprising a sulfonated fatty acid.

As used herein, the term "mesh" refers to standard Tyler mesh, and if an ore fraction is said to have a particle size smaller than a certain mesh, such statement means that substantially all of the fraction will pass through a screen having that Tyler mesh size, and likewise, if an ore fraction is said to have a particle size greater than a certain mesh, then substantially none of the material will pass through a screen having that Tyler mesh size. As used herein, the symbol "M" also refers to Tyler mesh size.

SUMMARY OF THE INVENTION

The subject invention is directed to an overall process for upgrading a phosphate-containing mineral ore matrix as mined from the earth, and includes the reverse flotation process claimed in the copending application of Robert E. Snow. Such an ore matrix typically includes apatite (phosphate minerals), clay and clay-sized slimes, siliceous (quartz) gangue and alkaline earth metal carbonate impurities. The method of the subject invention includes the steps of:

(a) washing and sizing a phosphate-containing ore which contains alkaline earth metal carbonate impurities to substantially deslime and to remove particles larger than from about 4-7 mm, and particles finer than about 0.1 mm, thereby forming a deslimed ore;

(b) splitting the deslimed ore to form a pebble fraction having a particle size of about 1-4 mm and a primary ore fraction having a particle size of about 0.1 mm to about 1 mm;

(c) subjecting the portion of the pebble fraction which is high in alkaline earth metal carbonate impurities, and which contains about 45-62% BPL to a gravity separation wherein a portion of the less dense alkaline earth metal carbonate mineral impurities are separated from the pebble fraction, thereby producing a low carbonate sink fraction;

(d) comminuting the low carbonate sink fraction and any portion of the pebble fraction containing more than about 62% BPL and containing about 1-1.75% alkaline earth metal carbonate impurities to a particle size of less than about 0.4 mm, thereby forming a flotation feed;

(e) slurrying the flotation feed with water to 20-30% solids, and reagentizing said flotation feed with a phosphate depressant, a carbonate collector, and a pH regulator to pH 5.5-6.0;

(f) subjecting the reagentized flotation feed to froth flotation to cause the remaining alkaline earth metal carbonate mineral impurities to float, and the phosphate-containing materials to sink to thereby remove said alkaline earth carbonate mineral impurities as an overflow tail to waste, and to collect as an underflow a phosphate concentrate containing substantially less alkaline earth metal carbonate impurities;

(g) subjecting that portion of the underflow phosphate concentrate (which contains excess silica) to cyclone separation to obtain a fine particle size fraction (less than 0.043 mm) and a fraction having a particle size larger than 0.043 mm;

(h) subjecting the fraction larger than 0.043 mm to an amine float to remove silica therefrom;

(i) collecting the cell underflow phosphate-rich concentrate;

(j) further separating the primary ore fraction into a first fraction of about 0.5 to 1 mm particle size, a second fraction of about 0.3 to 0.6 mm particle size, and a third fraction of about 0.1 to 0.3 mm particle size;

(k) subjecting each of said first, second and third fractions to fatty acid flotation with fatty acids, fuel oil and ammonia to remove silica impurities and obtain first, second and third phosphate-rich concentrates;

(l) thereafter combining said first and second phosphate-rich concentrates to form a combined concentrate;

(m) grinding that portion of the combined concentrate containing excess alkaline earth metal carbonate impurities until about 90% of the particles are less than about 0.4 mm;

(n) slurrying the ground combined concentrates containing excess alkaline earth metal carbonate impurities with water to 20-30% solids, and reagentizing said concentrate with a phosphate depressant, a carbonate collector and a pH regulator to pH 5.5-6.0;

(o) subjecting said reagentized combined concentrate to flotation to separate the excess alkaline earth metal carbonate impurities as the cell overflow, and to collect the phosphate-rich materials as the flotation cell underflow;

(p) slurrying that portion of the third phosphate-rich concentrate containing an excess of alkaline earth metal carbonate impurities with water to 20-30% solids and reagentizing that portion with a phosphate depressant, a carbonate collector, and a pH regulator to pH 5.5-6.0;

(q) subjecting the reagentized third phosphate-rich concentrate to flotation to separate the excess alkaline earth metal carbonate impurities as the cell overflow and collect phosphate-rich materials as the flotation cell underflow.

DETAILED DESCRIPTION OF THE INVENTION

Phosphate ores which are beneficiated by the method of the subject invention are found in sedimentary deposits in central Florida. Typically, the overburden is first removed, and the phosphate-rich ores are mined using draglines. These ores are generally referred to as apatite and carbonate-fluorapatite-containing ores. A more specific description for the phosphate values in these ores is "francolite". The invention is particularly adapted to separating alkaline earth metal carbonate impurities, particularly dolomite [Ca,Mg]CO.sub.3 from francolite.

The invention is further illustrated by the drawings, wherein FIG. 1 is a flow diagram of a preferred embodiment of the present invention. The invention is not limited to the preferred embodiment, but is encompassed by the broad scope of the appended claims.

Ore matrix 10 is first washed, deslimed and sized by conventional techniques at 11. Early removal of the clay slimes is desirable to avoid excessive consumption of flotation reagents by the slimes. The amount and quality of phosphate found in the typical clay slimes is not sufficient to warrant recovery.

The deslimed ore matrix usually contains large rocks or agglomerates ("mud-balls") which must be reduced in size or removed from the ore matrix 10. The slurried ore matrix is washed and sized as shown to remove such larger particles 12. Hammermills, impactors or similar devices are used to reduce the size of those larger particles which are not easily reduced in size by log washers used in the washing and sizing operation 11.

The pebble portion of the ore matrix 10 which is about +16 mesh is collected, and the larger particles 12 which are about -3/-5 mesh are generally discarded. The collected -16 mesh "debris" is then deslimed to produce a deslimed debris 13 having a particle size smaller than about 16 mesh and larger than about 150 mesh. The -150 mesh material 14 is sent to waste.

The deslimed debris 13 is then split into a first fraction 15 which is -16 to +150 mesh and a pebble fraction 16 (-3/-5+16 mesh). The first fraction 15 is further sized as at 17 into a skin float feed fraction 18 (-16+28 mesh), a fine feed fraction 19 (-42+150 mesh), and a coarse feed fraction 20 (-28+42 mesh). The skin float feed fraction 18 is then subjected to attrition scrubbing and desliming at 21, followed by reagentizing in a conditioner 22, where the slurry is dewatered to 68-72% solids. Ammonia, fatty acid and fuel oil are added to the skin flotation feed fraction 18 in the conditioner 22, and the conditioned skin flotation feed fraction 18 is subjected to a conventional skin flotation 23 employing Humphrey spirals available from Jensco, Inc., Eaton Park, Fla. In the conventional skin flotation, the conditioned phosphate skin flotation feed fraction 18 is skin floated in the spirals, and tail 24 drops out of each flight. Other equipment may be used instead of Humphrey spirals to accomplish the above skin flotation. Such equipment is well-known for this use, and includes moving belts, washing tables and combinations of all of these. Tail 24 from the skin flotation 23 is subjected to a scavenger float 25. Tail 26 from the scavenger float 25 is discarded. Concentrate 27 from the scavenger float 25 is blended with concentrate 28 from the skin flotation 23 to form a combined concentrate 29.

The combined concentrate 29 is then dewatered at 30, and collected to test bin 31. If the combined concentrate 29 contains less than 1% by weight MgO, it can be sold as product 32 without further processing.

If the dewatered combined concentrate 29 contains more than 1% by weight MgO as at 33, it is subjected to "liberation" grinding at 34 in ball mills or rod mills to release the francolite from the concentrate 29. The concentrate 29 is ground until at least 90% of the ore is about -42 mesh, or less than about 0.356 mm in particle size.

Water and reagents are added at 35 to the dewatered combined concentrate 29 at dolomite float cell 36. Sufficient water is added to bring the slurry to about 15-25% solids. Included in the reagents added at this point are a phosphate depressant, a carbonate collector and a pH regulator to adjust the pH to about 4.5-6.9, or more preferably, about 5.5-6.0. Sulfuric acid (H.sub.2 SO.sub.4) is presently used as the pH regulator, but other pH regulators, including phosphoric acid, and acidic waters from the other processes may be used, including gypsum pond waters which contain fluosilicic acid. A conventional phosphate depressant such as sodium tripolyphosphate is added to depress the phosphate in the slurried concentrate 29, and to inhibit the attachment of the flotation agent to the phosphate particles.

As also described in the copending application of Robert E. Snow, a water soluble sodium salt of a sulfonated oleic acid is added at this point as an anionic flotation agent for dolomite. The anionic flotation agent attaches to the dolomite impurities and they are floated away to waste 37 as the flotation cell overflow to separate the dolomite from phosphate concentrate 38, which is the cell underflow from the dolomite float 36. The phosphate concentrate 38 is then dewatered at 39 and delivered to concentrated product stockpile at 40.

The coarse feed fraction 20 is subjected to attrition scrubbing and desliming at 41 and then reagentized with reagents 42 in the conditioner 43. The slurry is adjusted by dewatering or adding water as necessary to 68-72% solids, and ammonia, fatty acid and fuel oil are added, and the conditioned coarse feed fraction 20 is then subjected to a coarse float at 44.

Cell underflow tall 45 from the coarse float 44 is sized at 35 mesh, as by screen 46, and the -35M "unders" 47 are sent to waste. The +35M "overs" 48 are sent back to the conditioner 22 and combined with the first fraction 15 (-16+150 mesh) to be conditioned and subjected to the skin flotation 23.

Concentrate 49 from the coarse float 44 is adjusted to 68-72% solids and acid scrubber at 50 with sulfuric acid 51. Concentrate 49 is then washed at 52 and subjected to a conventional amine float 53 with the usual amine, kerosene and pH reagents 54.

The amine float 53 produces a cell overflow silica tail 55 which goes to waste, and a cell underflow phosphate concentrate 56. The phosphate concentrate 56 is dewatered at 30 and tested at 31. If it contains more than about 1% MgO, it is mixed with the combined concentrate 29 from the skin flotation 23 and the scavenger float 25, treated as described above, and with those fractions, it is subjected to the dolomite float at 36 as described above to remove alkaline earth metal carbonate impurities (dolomite).

The fine feed fraction 19 (-42+150M) is adjusted to 68-72% solids and reagentized at conditioner 57 with reagents 58, which are the same as reagents 42, to prepare the fine feed fraction 19 for fine float 59. The conditioned fine feed fraction 19 is then subjected to fine float 59. Silica tail 60 is sent to waste. The float concentrate 61 is sent to acid scrub 62, where it is scrubbed with sulfuric acid 51, and the solids level is again adjusted to 68-72%. The scrubbed float concentrate 61 is then washed at 63, reagentized at 54, and then subjected to an amine float 64 to remove the cell overflow silica tail 65 to waste.

Cell underflow phosphate concentrate 66 is tested, and if it contains less than 1% MgO, it is collected as product 67. If the cell underflow phosphate concentrate 66 contains more than 1% MgO, it is subjected to a dolomite float 68 as described above at dolomite float 36 using all the same conditioning reagents 35 including the sulfonated oleic acid anionic flotation agent as described above. The over flow tails 69 which comprise primarily the dolomite impurities, are sent to waste. The cell underflow phosphate concentrate 70 is dewatered at 71, and sent to the concentrated product stockpile 40.

The pebble fraction 16 (-3/-5+16M) is sent to test bin 72. If pebble fraction 16 contains more than 62% BPL (bone phosphate of lime) and less than 1% MgO, it is collected as product 73. If pebble fraction 16 contains less than about 45-50% BPL, it is sent to discard 74. If the pebble fraction 16 contains more than about 45-50% BPL, but below 62% BPL, and more than 1% MgO as at 75, it is subjected to heavy media separation 76. Float 77 is sent to waste, and sink product 78 is tested. If sink product 78 contains less than 1% MgO and more than 62% BPL, it is collected as product 79. If sink product 78 contains more than 1% MgO, it is taken to rod mill 81 and ground to at least 90% -42 mesh particle size.

If the pebble fraction 16 (-3/-5+16M) has greater than 62% BPL, greater than 1% MgO, but less than 2.0% MgO as at 80, it is sent directly to the rod mill 81 where it is ground to at least 90% -42 mesh particle size. The rod mill 81 is optionally provided with a screen or classifier 82 which can be used for sizing particles at 35 or 42M. The oversize particles 83 are recycled back to the rod mill 81. The undersize particles 84 which do pass through the screen are sent on to dolomite float 85. The same reagents 86 as described above are added here to condition the sized mill discharge 87 for the dolomite float 85.

The cell overflow tails 88 from the dolomite float 85 containing the dolomite impurities are sent to waste, while the cell underflow phosphate concentrate 89 is dewatered at 90 to become product 91. Product 91 can be sent to attack tank storage bin 92 if it is going to be used to make wet process phosphoric acid.

If the condition of the cell underflow phosphate concentrate 89 requires it, it can be subjected to cyclone separation, as at 93 to separate a +325 mesh fraction 94 and a -325 mesh fraction 95. The -325 mesh fraction 95 is thickened and filtered as at 96, and the resulting product 97 is sent to the attack tank 92.

The +325 mesh fraction 94 from the cyclone separation 93 is reagentized with amine, kerosene and pH reagents 98 as described above, and is then subjected to a conventional amine float 99 as described above to remove silica tail 100 to waste as the cell overflow. Cell underflow phosphate concentrate 101 is dewatered at 102 and the dewatered product 103 is sent to the attack tank 92.

There are many variations of the above process which will adapt the process for most efficient use for recovery of the phosphate values from a particular phosphate ore deposit. Such variations will be readily apparent to the man skilled in the art. The most significant feature of the subject process is the "reverse" flotation of dolomite, in which the dolomite is floated away and the phosphate-rich apatite minerals are the cell underflow product. The effectiveness of the reverse flotation of dolomite depends to a large extent on the use of a sulfonated fatty acid anionic flotation agent which is stable under the acid pH conditions experienced in phosphate ore beneficiation. A particularly effective sulfonated fatty acid which is used in the process of the subject invention is the sodium salt of sulfonated oleic acid in an aqueous solution. A typical analysis for this composition is:

______________________________________Active ingredients 41.0%Fatty acid 7.0%Inorganic sulfates 2.6%Water 45.0%______________________________________ The active composition is a true sulfonate (C-S linkage), making it a stable compound. Based on the description in U.S. Pat. No. 2,743,288, the structural formula is believed to be: ##STR1## As stated in the above patent, the carbon chain length may vary to some extent. A satisfactory compound is available from Cities Service Company, Industrial Chemicals Division, P.O. Box 50360, Atlanta, Ga. 30302; and is sold under the trademark SUL-FON-ATE OA-5. Although the subject compound is a sulfonated oleic acid, it is contemplated that other sulfonated fatty acids (C.sub.12 -C.sub.22), both saturated and unsaturated, and their stable salts, can also be used in combination with conventional phosphate depressants, and will function effectively as anionic flotation agents which selectively attach to alkaline earth metal carbonate impurities in phosphate-containing ores to float away alkaline earth metal carbonate impurities.

Alkyl benzyl sulfonate has been tried as an anionic flotation agent for dolomite in the method of the subject invention without success. It is believed important that the fatty acid portion of the flotation agent molecule have a linear carbon chain, and that one of the carbons in the linear carbon chain be attached directly to the sulfur of the sulfonate group to provide the required stability in a widely fluctuating, usually acid pH medium.

The presently preferred depressant for the phosphate values in the crude phosphate-containing ores is sodium tripolyphosphate. Other conventional depressants for phosphate can be used, including sodium hexametaphosphate, sodium pyrophosphate, fluosilicic acid (without H.sub.2 SO.sub.4) and orthophosphoric acid (clarified phosphoric acid).

Sulfonated linear fatty acids have been used before in the phosphate chemical industry, but they have been used as defoaming agents, not as an anionic flotation agent for floating alkaline earth metal carbonate impurities such as dolomite away from apatites such as francolite, carbonate fluorapatite and other phosphate-containing ores such as collophane.

U.S. Pat. No. 2,743,288 issued Apr. 24, 1956, describes a method for making sulfonated carboxylic acids. See: Column 3, lines 2-18 and particularly, column 3, lines 71-75 and column 4, lines 1-75 of U.S. Pat. No. 2,743,288. As pointed out in the subject patent, in the true sulfonated carboxylic acid having a carbon-sulfur bond the sulfonic acid group exhibits unusually high resistance to hydrolysis and heat.

An important feature of this invention is the surprising superior performance of the water soluble salts of sulfonated, long chain carboxylic acids as anionic flotation agents as compared to conventional, non-sulfonated fatty acid and tall oil anionic flotation agents disclosed in the prior art.

The following examples illustrate the operation of the process of the subject invention to upgrade the value of phosphorite ores. Particular phosphorite ore samples are used in each example to demonstrate the improvements obtained by the combination of process steps and the novel dolomite flotation.

EXAMPLE 1

A phosphate ore matrix mined from a central Florida ore deposit was beneficiated by the method of the subject invention. Conventional washing, desliming and primary sizing steps were performed on the ore matrix to obtain a pebble fraction of -5,-3+16M particle size, which was then subjected to rodmilling to prepare it for a dolomite flotation as described herein. The pebble portion of this ore was ground in the rod mill until all the sample passed through 35M (Tyler) screen, and a wet-dry screen analysis after rodmilling as set forth below.

__________________________________________________________________________Wet-Dry Screen AnalysisSample 1Size, Wt., Cum. % Dist.Tyler Mesh Grams % Wt. % Wt. % BPL % MgO MgO__________________________________________________________________________+35 2.2 1.1 1.1-35+48 38.7 19.3 20.4-48+65 36.8 18.4 38.8-65+100 29.7 14.8 53.6 (62.69)* (0.95)* 46.3-100+150 19.2 9.6 63.2-150+200 14.8 7.4 70.6-200 59.0 29.4 100.0 61.44 2.65 53.7Composite Feed 200.4 100.0 62.32 1.45 100.0__________________________________________________________________________ *Numbers in parentheses are calculated. The sized discharge from the rod mill was then slurried to about 15-25% solids with water, and the pH of the slurry was adjusted to 5.6-6.0 with sulfuric acid. Sodium tripolyphosphate was added at a ratio of about 2.0 lbs/ton of ground ore. Philflo brand oil from Phillips Petroleum Company, Bartlesville, Oklahoma, was also added at a ratio of about 2.5 lbs/ton of ground ore, and a sodium salt of sulfonated oleic acid, SUL-FON-ATE OA-5 from Cities Service Company, Industrial Chemicals Division, Atlanta, Ga., was added at the ratio of 2.5 lbs/ton of ground ore. The reagentized slurry was then subjected to flotation in a conventional float cell.

As previously described, the sulfonated oleic acid salt acts as an anionic flotation agent and attaches primarily to the dolomite impurities which were floated away as dolomite tail in the cell overflow. Most of the phosphate-containing portion of the flotation feed is depressed by the sodium tripolyphosphate, which inhibits the attachment of the sulfonated oleic acid salt to the phosphate particles. The phosphate concentrate left the flotation cell as the cell underflow.

The cell underflow phosphate concentrate was then sized at 325M (Tyler). The -325M fine phosphate concentrate was collected as product. The +325M phosphate concentrate contained a higher percentage of insolubles (about 10% by weight) so it was subjected to a conventional amine flotation to remove silica insolubles.

The rinsed and dewatered +325M phosphate concentrate was adjusted to approximately 20% solids with water. Custamine 3010 brand of aliphatic amine condensate from Custom Chemicals, Inc., Division of Westvaco, Mulberry, Fla., was added at a ratio of about 0.75 lbs/ton of phosphate concentrate, along with kerosene at a ratio of about 0.1 lbs/ton of phosphate concentrate. The resultant pH of the slurry was about 7.1-7.2, and the reagentized slurry was separated by flotation.

The amine flotation overflow silica tail was sent to waste, and the underflow phosphate concentrate was collected and dewatered and combined with the previously collected -325 phosphate concentrate to form a phosphate concentrate product having increased phosphate values, and a significantly decreased level of alkaline earth metal carbonate (dolomite) impurities.

The material balances reported in Table I show the yields and product distributions obtained at the various stages of the process. "% BPL" is the percent phosphate calculated as bone phosphate of lime. The concentration of MgO and CaO indicate the amount of dolomite and calcite in that fraction, respectively. "Insolubles" are primarily silica. To obtain the ratios of CaO, MgO and I&A (Fe.sub.2 O.sub.3 and Al.sub.2 O.sub.3) to P.sub.2 O.sub.5, the BPL values given are first divided by 2.18 to obtain the P.sub.2 O.sub.5 values. The reference numerals in the table refer to the flow diagram shown in FIG. 1 of the drawings, and refer to the step of the process from which the ore fraction was obtained.

TABLE I__________________________________________________________________________Processing Material Balance I&A + % % % % % % CaO/ MgO/ I&A/ % Distribution MgO/% Wt. Ref. Fraction BPL Insol Fe.sub.2 O.sub.3 Al.sub.2 O.sub.3 CaO MgO P.sub.2 O.sub.5 P.sub.2 O.sub.5 P.sub.2 O.sub.5 BPL MgO P.sub.2__________________________________________________________________________ O.sub.5100 16, -3+16M 62.32 9.25 0.82 0.90 44.39 1.44 1.556 0.050 0.060 100 100 0.110 78, Pebble 84 Rod mill -35MDolomite Flotation17 85, Cell Overflow 50.94 4.89 0.99 0.92 42.69 5.37 1.831 0.230 0.082 13.90 63.99 0.312 88 Dolomite Tail83 85, Cell Underflow 64.65 10.14 0.78 0.89 44.74 0.63 1.512 0.021 0.056 86.10 36.01 0.077 89 Phosphate ConcSizing at 325M8.3 93, -325M Phos Conc 67.73 4.79 1.07 1.27 46.53 0.79 1.501 0.025 0.075 9.02 4.37 0.100 95, 9774.7 93, +325M Phos Conc 64.31 10.73 0.75 0.85 44.54 0.61 1.513 0.021 0.054 77.09 31.64 0.075 94Silica Flotation64.90 98, Cell Underflow 71.09 1.79 0.82 0.94 49.18 0.67 1.512 0.021 0.054 74.03 30.20 0.075 99, Phosphate Conc 1019.8 98, Cell Overflow 19.41 69.97 0.32 0.29 13.78 0.21 1.551 0.024 0.069 3.05 1.43 0.093 99, Silica Tail 10073.2 97, Combined -325M 70.71 2.13 0.85 0.98 48.88 0.68 1.511 0.021 0.057 83.05 34.57 0.078 101 Phos Conc Plus Cell Underflow Phos Conc__________________________________________________________________________ The above processing material balance shows the significant positive effect in upgrading the phosphate ore matrix obtained by the combined steps of grinding, dolomite flotation using a sulfonated fatty acid salt, further sizing and a conventional amine flotation. In this example, the percent bone phosphate of lime was increased from 62.32% up to 71.09%. The percent dolomite (measured as MgO) decreased from 1.44% to 0.67%. This decrease is most important, because MgO levels higher than about 1% substantially decrease the marketability of the refined phosphate product. The percentage bone phosphate of lime (BPL) distribution shows that 83.05% of the phosphate values were recovered.

EXAMPLE 2

All of the steps of Example 1 were repeated on another pebble sample of a phosphorite ore from a central Florida ore deposit. After grinding in a rod mill until substantially all of the sample passed through a 48 mesh (Tyler) screen, the pebble sample gave the following wet-dry screen analysis.

__________________________________________________________________________Wet-Dry Screen AnalysisSample 2Size, Wt., Cum. % Dist.Tyler Mesh Grams % Wt. % Wt. % BPL % MgO MgO__________________________________________________________________________+48 .5 .2 0.2-48+65 5.0 2.4 2.6-65+100 29.1 14.0 16.6 (61.90)* (1.45)* 18.0-100+150 34.8 16.7 33.3-150+200 27.0 12.9 46.2-200 112.1 53.8 100.0 50.30 5.67 82.0Composite Feed 208.5 100.0 55.66 3.72 100.0__________________________________________________________________________ *Parentheses indicate calculated values. The processing material balance for sample 2 is set forth in Table II. TABLE II__________________________________________________________________________Processing Material Balance I&A + % % % % % % CaO/ MgO/ I&A/ % Distribution MgO/% Wt. Ref. Fraction BPL Insol Fe.sub.2 O.sub.3 Al.sub.2 O.sub.3 CaO MgO P.sub.2 O.sub.5 P.sub.2 O.sub.5 P.sub.2 O.sub.5 BPL MgO P.sub.2__________________________________________________________________________ O.sub.5100 16, -3+16M 55.66 7.52 1.34 0.57 43.11 3.71 1.692 0.146 0.075 100 100 0.221 78, Pebble 84 Rod mill -48MDolomite Flotation40.4 85, Cell Overflow 44.23 1.27 1.19 0.54 40.34 7.85 1.993 0.388 0.085 32.10 85.65 0.473 88 Dolomite Tail59.6 85, Cell Underflow 63.41 11.75 1.45 0.59 44.98 0.90 1.550 0.031 0.070 67.90 14.35 0.101 89 Phosphate ConcSizing at 325M8.1 93, -325M Phos Conc 63.02 7.33 1.92 0.78 45.93 1.32 1.593 0.046 0.094 9.17 2.83 0.140 95, 9751.5 93, +325M Phos Conc 63.47 12.45 1.38 0.56 44.83 0.83 1.543 0.029 0.067 58.73 11.52 0.096 94Silica Flotation45.2 98, Cell Underflow 68.66 5.25 1.45 0.60 48.49 0.90 1.543 0.029 0.065 55.76 10.96 0.094 99, Phosphate Conc 1016.3 98, Cell Overflow 26.26 64.12 0.86 0.29 18.58 0.33 1.550 0.029 0.096 2.97 0.56 0.124 99, Silica Tail 10053.3 97, Combined -325M 67.80 5.57 1.52 0.63 48.10 0.96 1.550 0.031 0.069 64.93 13.79 0.100 101 Phos Conc Plus Cell Underflow Phos Conc__________________________________________________________________________ The above processing material balance shows a most significant increase in BPL value from 55.66% up to 67.80%. However, therecovery of phosphate values was somewhat less than in Example 1 (53.3% as compared to 73.2%). Since sample 2 pebble initially contained substantially more dolomite (3.71% MgO, as compared to 1.44% MgO), it was necessary that the dolomite flotation remove significantly more of the alkaline earth metal carbonate impurities. The combined steps of first grinding, dolomite flotation, sizing and an amine flotation to remove insolubles (silica) produced a significantly upgraded phosphate concentrate product containing more than 65% BPL, less than 6% insolubles (silica), and less than 1% MgO (as a measure of dolomite). This example shows the improved removal of dolomite made possible by the finer grind (-48 M).

EXAMPLE 3

All the steps of Example 1 were again repeated on another pebble sample of a phosphorite ore from a central Florida ore deposit. After the pebble sample passed through a 35 mesh (Tyler) screen, the ground pebble sample gave the following wet-dry screen analysis.

The ground sample 3 pebble having the wet-dry screen analysis given below was treated as in Example 1, except that the amounts of the reverse flotation reagents were changed. Only 1.5 lbs of carbonate collector (SUL-FON-ATE OA-5) per ton of ground ore and 1.5 lbs of Philflo oil per ton of ground ore were used. The amount of phosphate depressant used remained the same as Example 1.

__________________________________________________________________________Wet-Dry Screen AnalysisSample 3Size, Wt., Cum. % Dist.Tyler Mesh Grams % Wt. % Wt. % BPL % MgO MgO__________________________________________________________________________+35 Trace Trace Trace-35+48 25.5 9.9 9.9-48+65 46.5 18.1 28.0-65+100 41.7 16.2 44.2 (63.70)* (1.20)* 48.9-100+150 29.6 11.5 55.7-150+200 23.7 9.2 64.9-200 90.3 35.1 100.0 59.78 2.33 51.1Composite Feed 257.3 100.0 1.60 100.0__________________________________________________________________________ *Parentheses indicate calculated values. The processing material balance for sample 3 is set forth in Table III.

As can be seen in Table III, the process is effective in reducing the dolomite impurities below the 1% MgO level even when less carbonate collector and less froth modifier (Philflo oil) is used. The cell underflow concentrate from the dolomite flotation contained 65.19% BPL, and 0.70% MgO. As previously described, the 9.55% Insolubles (silica) can be reduced by conventional silica flotation. The resulting product is completely satisfactory as a feed stock to a chemical plant which makes ammonium phosphate fertilizer.

TABLE III__________________________________________________________________________Processing Material Balance I&A + % % % % % % CaO/ MgO/ I&A/ % Distribution MgO/% Wt. Ref. Fraction BPL Insol Fe.sub.2 O.sub.3 Al.sub.2 O.sub.3 CaO MgO P.sub.2 O.sub.5 P.sub.2 O.sub.5 P.sub.2 O.sub.5 BPL MgO P.sub.2__________________________________________________________________________ O.sub.5100 16, -3+16M 62.32 8.95 1.09 1.01 44.54 1.62 1.562 0.057 0.074 100 100 0.131 78, Pebble 84 Rod mill -35MDolomite Flotation25.4 85, Cell Overflow 53.90 7.17 1.34 1.45 41.88 4.34 1.698 0.176 0.113 21.97 67.77 0.289 88 Dolomite Tail74.6 85, Cell Underflow 65.19 9.55 1.01 0.86 45.45 0.70 1.524 0.023 0.063 78.04 32.23 0.086 89 Phosphate ConcSizing at 325M6.4 93, -325M Phos Conc 62.54 10.11 1.57 1.69 42.31 1.07 1.478 0.037 0.114 6.42 4.47 0.151 95, 9768.2 93, +325M Phos Conc 65.44 9.50 0.96 0.78 45.75 0.66 1.528 0.022 0.058 71.61 27.76 0.080 94Silica Flotation59.4 98, Cell Underflow 71.43 1.29 1.01 0.84 49.96 0.72 1.529 0.022 0.057 68.08 26.40 0.079 99, 1018.8 98, Cell Overflow 24.99 64.94 0.65 0.37 17.33 0.25 1.515 0.022 0.089 3.53 1.36 0.111 99, Silica Tail 10065.8 97, Combined -325M 70.56 2.16 1.06 0.93 49.22 0.76 1.524 0.024 0.062 74.50 30.87 0.086 101 Phos Conc Plus Cell Underflow Phos Conc__________________________________________________________________________ The above Table III shows a substantial upgrading of pebble sample 3 by the combined steps of first grinding the sample, next subjecting it to an anionic flotation employing a sodium salt of sulfonated oleic acid to remove dolomite [Ca,Mg]CO.sub.3 as the cell overflow and the major portion of the phosphate values as the cell underflow. Sizing at 325 mesh (Tyler) in a cyclone produces a -325M phosphate-rich product (62.54% BPL) and the +325M phosphate concentrate (65.44% BPL) is reagentized and subjected to an amine flotation to significantly reduce the insolubles (silica) content of the phosphate concentrate (from 9.50% to 1.29%). The sizing at 325 mesh represents an important step, because the -325M fraction already is very close to acceptable levels of BPL and MgO. When this material is blended with the amine flotation cell underflow, the blended product has completely acceptable levels of BPL and MgO, namely 70.56% BPL and 0.76% MgO. This product was obtained from a pebble which was borderline on phosphate values (62.32 % BPL) and not satisfactory on dolomite (measured at 1.62% MgO). The yield of product was 65.8% by weight of the total pebble sample 3.

EXAMPLE 4

Another sample of a phosphorite ore from central Florida was washed, deslimed, and subjected to primary sizing to obtain a -3+16 mesh pebble. The pebble contained more than 40% BPL but less than 62% BPL (namely about 61.12% BPL). This sample was first subjected to heavy media separation with the results shown in Table IV.

TABLE IV__________________________________________________________________________Processing Material Balance % Distribution% Wt. Ref. Fraction % BPL % Insol % MgO BPL MgO__________________________________________________________________________Heavy Media Separation21.4 77 -3+16M Float @ G = 1.85 42.30 8.39 8.04 14.8 50.378.6 78 -3+16M Sink @ G = 1.85 66.25 5.83 2.16 85.2 49.7100.0 77, -3+16M Composite (61.12) (6.38) (3.42) 100.0 100.0 78Dolomite Flotation21.0 88 Cell Overflow 47.25 2.92 8.17 15.0 79.6 Dolomite Tail79.0 89 Cell Underflow 71.31 6.61 0.56 85.0 20.4 Phosphate Concentrate__________________________________________________________________________ The float product comprised 21.4% of the total solids and contained 42.30% BPL. In this example, the sink product comprised 78.6% of the total solids and contained 66.25% BPL, so it was significantly upgraded by the heavy media separation. However, it still contained an excess of dolomite (measured as 2.16% MgO) and insolubles (5.83% by weight--primarily silica). This sink product was subjected to grinding and dolomite flotation as described in Example 1 and the results are also reported in Table IV. After the sink product had been ground in a rod mill until substantially all of the sample will pass through a 48 mesh (Tyler) screen, it had the following wet-dry screen analysis. __________________________________________________________________________Wet-Dry Screen AnalysisSample 4Size, Wt., Cum. % Dist.Tyler Mesh Grams % Wt. % Wt. % BPL % MgO MgO__________________________________________________________________________+48 1.1 .5 .5-48+65 35.9 17.4 17.9-65+100 42.5 20.6 38.5 (70.06)* (0.89)* 26.4-100+150 27.1 13.1 51.6-150+200 18.9 9.2 60.8-200 81.0 39.2 100.0 61.33 4.05 73.6Composite Feed 206.5 100.0 66.25 (2.13)* 100.0__________________________________________________________________________ *Parentheses indicate calculated values.

The sample 4, -48M (less than 0.295 mm) fraction was subjected to reverse flotation following the procedure of Example 1 with the following changes: 2 lbs/ton carbonate collector (SUL-FON-ATE OA-5) and 2 lbs/ton froth modifier (white mineral oil) were used.

Table IV shows the effectiveness of the dolomite flotation to remove dolomite (measured as MgO) from the phosphorite ore. The dolomite content measured as MgO was 2.16% MgO in the sink product from the heavy media separation, and was decreased down to 0.56% MgO in the phosphate concentrate obtained after grinding and dolomite flotation. The subject phosphate concentrate can optionally be subjected to amine flotation if it is desired to decrease the amount of insolubles below 6.61%.

EXAMPLE 5

This example is like Example 4 above but with a phosphorite ore sample from central Florida which contained considerably less dolomite (measured as 2.10% MgO). As in Example 4, the ore sample was first subjected to primary sizing to obtain a -5,-3+16 mesh pebble which was then subjected to heavy media separation with the results reported in Table V.

The reverse flotation procedure of Example 1 was again followed to remove dolomite from the -48M (-0.295 mm) fraction of sample 5 ore which was recovered as the sink product from the heavy media separation. The amounts of the flotation reagents were the same as in Example 1, but the particle size was finer (-48M instead of -35M).

TABLE V__________________________________________________________________________Processing Material Balance % Distribution% Wt. Ref. Fraction % BPL % Insol % MgO BPL MgO__________________________________________________________________________Heavy Media Separation14.8 77 -3+16M Float @ G = 1.85 56.70 8.69 3.55 13.3 25.285.2 78 -3+16M Sink @ G = 1.85 64.01 9.17 1.84 86.7 74.8100.0 77, -3+16M Composite (62.93) (9.10) (2.10) 100.0 100.0 78Dolomite Flotation19.1 88 Cell Overflow 51.38 4.47 6.45 15.3 66.8 Dolomite Tail80.9 89 Cell Underflow 67.00 10.28 0.76 84.7 33.2 Phosphate Concentrate__________________________________________________________________________

The sink product of the heavy media separation was ground in a rod mill until substantially all of the material passed through a 48 mesh (Tyler) screen. The ground product had the following wet-dry screen analysis.

__________________________________________________________________________Wet-Dry Screen AnalysisSample 5Size, Wt., Cum. % Dist.Tyler Mesh Grams % Wt. % Wt. % BPL % MgO MgO__________________________________________________________________________+48 0.5 0.2 0.2-48+65 29.1 14.4 14.6-65+100 42.0 20.8 35.4 (64.70)* (1.12)* 35.3-100+150 29.2 14.4 49.8-150+200 22.5 11.1 60.9-200 79.1 39.1 100.0 62.94 3.16 64.7Composite Feed 202.4 100.0 64.01 1.91 100.0__________________________________________________________________________ *Parentheses indicate calculated values. Table V shows the effectiveness of the dolomite flotation to effectively remove lesser amounts of dolomite (2.10% measured as MgO) from a phosphorite ore by the combined steps of heavy media separation, grinding and dolomite flotation. As seen in Table V, the recovery of phosphate concentrate as cell underflow from the dolomite flotation was 80.9% by weight, and the phosphate concentrate had an acceptably low level of dolomite (less than 1% MgO). The BPL value of 67% is acceptable, and the 10.28% insolubles (silica) can easily be reduced by an amine flotation.

The subject invention makes possible the efficient recovery of phosphate values from lower zone phosphorite ores containing large amounts of alkaline earth metal carbonate impurities such as dolomite [Ca,Mg]CO.sub.3. The upgraded ores are much more suited for use in wet process phosphoric acid production, because the excess dolomite impurities have been removed which would otherwise adversely affect the quality of the acid for use in ammonium phosphate fertilizer production.

The subject invention provides the most efficient possible recovery of mixed phosphorite ores. The strategic placement of test bins in the process as described above insures that higher grade ores are not treated unnecessarily, and that beneficiated ores are not subjected to excess beneficiation steps. This represents a substantial saving in processing water, reagents and energy. When the phosphorite ore contains more than about 2% MgO (as a measure of dolomite), heavy media separation is used to bring the MgO level down in the range of about 1-2% so that it can be further reduced by the reverse dolomite flotation described herein.

A significant advantage and economy of the invention is the placement of the reverse dolomite float after the grinding step which is already necessary in chemical plants to prepare beneficiated phosphorite ore for wet processing. This same step is required to obtain an effective separation of dolomite in the reverse flotation. The insertion of the dolomite float after the chemical plant grinding step minimizes the cost for the greatly increased recovery of usable phosphate values from upper and lower zone phosphorite ores.

In summary, the subject method of beneficiating a phosphate ore matrix, comprising francolite containing a major portion of the phosphate values in said phosphate ore, said ore also including silica and an alkaline earth metal carbonate impurity, the steps comprising:

(a) washing and sizing the ore matrix to deslime the matrix and to remove particles larger than about 6.7 mm;

(b) splitting the deslimed ore matrix into a pebble fraction in which the particles range in size from about 1 mm to about 6.7 mm; a fine fraction having a particle size from about 0.104 mm to about 0.350 mm; a coarse fraction ranging in size from about 0.350 mm to about 0.589 mm; and a fraction having a particle size in the range of 0.589 to 1 mm;

(c) subjecting that portion of the pebble fraction which contains more than about 45% BPL, less than 62% BPL and more than 1% MgO to a heavy media flotation, and thereafter grinding said pebble portion until at least 90% of sink product will pass through a 42 mesh (Tyler) screen, and thereafter;

(d) reagentizing said sink product with water, to about 20-30% solids based on the solids in said sink product, a pH regulator, a carbonate collector comprising a water soluble salt of a sulfonated linear fatty acid having a straight carbon chain from about eight to twenty-two carbons, and a direct carbon to sulfur bond and a phosphate depressant; and

(e) subjecting said reagentized sink product to a reverse flotation to float away the alkaline earth metal carbonate impurity, and collecting as the flotation cell underflow a phosphate concentrate.

Various embodiments of the invention are believed to be within the scope of the following claims.

Claims

1. The method of beneficiating a phosphate ore matrix comprising francolite containing a major portion of the phosphate values in said phosphate ore, said ore also including silica and an alkaline earth metal carbonate impurity, the steps comprising:

(a) washing and sizing the ore matrix to deslime the matrix and to remove particles larger than about 6.7 mm;

(b) splitting the deslimed ore matrix into a pebble fraction in which the particles range in size from about 1 mm to about 6.7 mm; a fine fraction having a particle size from about 0.104 mm to about 0.350 mm; a coarse fraction ranging in size from about 0.350 mm to about 0.589 mm; and a fraction having a particle size in the range of 0.589 to 1 mm;

(c) subjecting that portion of the pebble fraction which contains more than about 45% BPL, less than 62% BPL and more than 1% MgO to a heavy media flotation, and thereafter grinding said pebble portion until at least 90% of sink product will pass through a 42 mesh (Tyler) screen, and thereafter

(d) reagentizing said sink product with water, to about 20-30% solids based on the solids in said sink product, a pH regulator, a carbonate collector comprising a water soluble salt of a sulfonated linear fatty acid having a straight carbon chain from about eight to twenty-two carbons, and a direct carbon to sulfur bond and a phosphate depressant; and

(e) subjecting said reagentized sink product to a reverse flotation to float away the alkaline earth metal carbonate impurity, and collecting as the flotation cell underflow a phosphate concentrate.

2. The method of claim 1, in which the alkaline earth metal carbonate comprises dolomite [Ca,Mg]CO.sub.3 in the amount of 1-2% measured as MgO, and including the additional steps of:

(f) adjusting the solids level of said phosphate concentrate obtained in step (e) of claim 1 as necessary to about 68-72% solids;

(g) reagentizing said fine fraction with ammonia, fatty acid and fuel oil to form a fine float feed;

(h) rejecting the silica tail flotation cell underflow to waste and collecting the cell overflow phosphate concentrate;

(i) adjusting the phosphate concentrate to 68-72% solids and acid scrubbing said concentrate to remove said fine flotation reagents therefrom;

(j) reagentizing said phosphate concentrate with amine, kerosene at a pH of about 7, and subjecting said reagentized phosphate concentrate to an amine float to remove silica tail as the flotation cell overflow;

(k) collecting a phosphate concentrate as the flotation cell underflow;

(l) adding water to that portion of said phosphate concentrate which contains more than about 1% dolomite measured as MgO to about 20-30% solids;

(m) reagentizing said phosphate concentrate with a carbonate collector comprising a water soluble salt of a sulfonated linear fatty acid having a straight carbon chain from about eight to twenty-two carbons, and a direct carbon to sulfur bond, a pH regulator and a phosphate depressant;

(n) subjecting said reagentized phosphate concentrate to a reverse flotation to float away the alkaline earth metal carbonate impurity as the flotation cell overflow and collecting as the flotation cell underflow a phosphate concentrate having less than 1% MgO as a measure of dolomite.

3. The method of claim 1, including the additional steps of:

(g) adjusting the solids level of the coarse fraction to about 68-72%;

(h) reagentizing said coarse fraction obtained in step (b) of claim 1 with alkali, fatty acid and fuel oil;

(i) subjecting said reagentized coarse fraction to a coarse flotation in a flotation cell;

(j) collecting the coarse flotation cell overflow phosphate concentrate;

(k) acid scrubbing and washing said coarse flotation cell overflow phosphate concentrate;

(l) reagentizing said phosphate concentrate with amine, kerosene and a pH regulator;

(m) subjecting said phosphate concentrate to an amine float to separate therefrom a silica tail flotation cell overflow to waste and to obtain a flotation cell underflow phosphate concentrate;

(n) dewatering said phosphate concentrate and grinding that portion having more than 1% MgO until 90% by weight of the particle pass through a 42 mesh (Tyler) screen;

(o) adding water, a carbonate collector comprising a water soluble salt of a sulfonated linear fatty acid having a straight carbon chain from about eight to twenty-two carbons, and a direct carbon to sulfur bond, a phosphate depressant and a pH regulator to said phosphate concentrate to obtain a phosphate concentrate slurry having 20-30% solids and a pH of about 5.6-6.0;

(p) subjecting said reagentized phosphate concentrate slurry to a reverse flotation to separate a dolomite tail as the flotation cell overflow; and

(g) collecting a phosphate concentrate containing less than 1% MgO as the flotation cell underflow.

4. The method of claim 3, in which the silica tail resulting from said coarse flotation is collected and screened to obtain a silica tail fraction larger than 0.417 mm and thereafter combining said silica tail fraction with the phosphate ore fraction having a particle size in the range of 0.589 to 1 mm and treating said silica tail fraction as recited in steps (h) through (m) of claim 1.

5. The method of claim 1, including the additional steps of:

(g) scrubbing and desliming said phosphate ore fraction having a particle size in the range of 0.589 to 1 mm;

(h) reagentizing said phosphate ore fraction with water, a pH regulator, ammonia, a fatty acid and fuel oil to obtain a flotation feed having about 68-78% solids, and a pH of about 7;

(i) subjecting said flotation feed to a skin flotation to separate a silica tail therefrom as the unders and to collect a phosphate concentrate as the overflow;

(j) dewatering and grinding said phosphate concentrate to obtain a flotation feed having a particle size in which at least 90% of the particles pass through a 42 mesh (Tyler) screen;

(k) reagentizing said dewatered and ground phosphate concentrate with water, a pH regulator, a carbonate collector comprising a water soluble salt of a sulfonated linear fatty acid having a straight carbon chain from about eight to twenty-two carbons, and a direct carbon to sulfur bond and a phosphate depressant to obtain a flotation feed having 20-35% solids and a pH of about 5.6-6.0;

(l) subjecting said flotation feed to a reverse flotation to separate therefrom a dolomite tail as the flotation cell overflow; and

(m) collecting the flotation cell underflow phosphate concentrate.

6. The method of claim 1, in which the carbonate collector is sodium oleyl sulfonate.

7. The method of claim 1, in which the phosphate depressant comprises sodium tripolyphosphate and the carbonate collector comprises the sodium salt of sulfonated oleic acid.

8. The method of claim 1, in which the phosphate depressant is selected from the group consisting of sodium tripolyphosphate, sodium hexametaphosphate, sodium pyrophosphate, fluosilicic acid and orthophosphoric acid.

9. The method of claim 1, in which the carbonate collector comprises a salt of a sulfonated linear fatty acid having the structural formula ##STR2## R=substituted or unsubstituted alkyl or alkenyl in which C=1-12 A=substituted or unsubstituted alkyl or alkenyl

n=5 to 17

X=Na, K, Li, NH.sub.3.

10. In an improved method for recovering phosphate values from a phosphorite ore matrix containing alkaline earth metal carbonate as a significant impurity, the steps comprising:

(a) washing and sizing a phosphate-containing ore which contains alkaline earth metal carbonate impurities to substantially deslime and to remove particles larger than from about 4-7 mm, and particles finer than about 0.1 mm, thereby forming a deslimed ore;

(b) splitting the deslimed ore to form a pebble fraction having a particle size of about 1-4 mm and a primary ore fraction having a particle size of about 0.1 mm to about 1 mm;

(c) subjecting the portion of the pebble fraction which is high in alkaline earth metal carbonate impurities, and which contains about 45-62% BPL to a gravity separation wherein a portion of the less dense alkaline earth metal carbonate mineral impurities are separated from the pebble fraction, thereby producing a low carbonate sink fraction;

(d) comminuting the low carbonate sink fraction and any portion of the pebble fraction containing more than about 62% BPL and containing about 1-1.75% MgO to a particle size of less than about 0.4 mm, thereby forming a flotation feed;

(e) slurrying the flotation feed with water to 20-30% solids, and reagentizing said flotation feed with a phosphate depressant, a carbonate collector comprising a water soluble salt of a sulfonated linear fatty acid having a straight carbon chain from about eight to twenty-two carbons, and a direct carbon to sulfur bond and a pH regulator to pH 5.5-6.0;

(f) subjecting the reagentized flotation feed to froth flotation to cause the remaining alkaline earth metal carbonate mineral impurities to float, and the phosphate-containing materials to sink to thereby remove said alkaline earth carbonate mineral impurities as an overflow tail to waste, and to collect as an underflow a phosphate concentrate containing substantially less alkaline earth metal carbonate impurities;

(g) subjecting that portion of the underflow phosphate concentrate (which contains excess silica) to cyclone separation to obtain a fine particle size fraction less than 0.043 mm (-325 mesh) and a +325 mesh fraction having a particle size larger than 0.043 mm;

(h) subjecting the fraction larger than 0.043 mm to an amine float to remove silica therefrom;

(i) collecting the cell underflow phosphate-rich concentrate;

(j) further separating the primary ore fraction into a first fraction of about 0.5 to 1 mm particle size, a second fraction of about 0.3 to 0.6 mm particle size, and a third fraction of about 0.1 to 0.3 mm particle size;

(k) subjecting each of said first, second and third fractions to fatty acid flotation with fatty acids, fuel oil and ammonia to remove silica impurities and obtain first, second and third phosphate-rich concentrates;

(l) thereafter combining said first and second phosphate-rich concentrates to form a combined concentrate;

(m) grinding that portion of the combined concentrate containing excess alkaline earth metal carbonate impurities until about 90% of the particles are less than 0.4 mm;

(n) slurring the ground combined concentrate containing excess alkaline earth metal carbonate impurities with water to 20-30% solids, and reagentizing said concentrate with a phosphate depressant, a carbonate collector comprising a water soluble salt of a sulfonated linear fatty acid having a straight carbon chain from about eight to twenty-two carbons, and a direct carbon to sulfur bond and a pH regulator to pH 5.5-6.0 and 20-30% solids;

(o) subjecting said reagentized combined concentrate to flotation to separate the excess alkaline earth metal carbonate impurities as the cell overflow, and to collect the phosphate-rich materials as the flotation cell underflow;

(p) slurrying that portion of the third phosphate-rich concentrate containing an excess of alkaline earth metal carbonate impurities with water to 20-30% solids and reagentizing that portion with a phosphate depressant, a carbonate collector comprising a water soluble salt of a sulfonated linear fatty acid having a straight carbon chain from about eight to twenty-two carbons, and a direct carbon to sulfur bond, and a pH regulator to pH 5.5-6.0; and

(q) subjecting the reagentized third phosphate-rich concentrate to flotation to separate the excess alkaline earth metal carbonate impurities as the cell overflow and collect phosphate-rich materials as the flotation cell underflow.